evinrude_etec_200

BRP US Inc.
Technical Publications
P.O. Box 597
Sturtevant, Wisconsin 53177 United States
www.evinrude.com or www.johnson.com
† AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II

are registered trademarks of Tyco International, Ltd.
† Amphenol is a registered trademark of The Amphenol Corporation.
† BEP is a registered trademark of Actuant Corporation.
† Champion is a registered trademark of Federal-Mogul Corporation.
† Deutsch is a registered trademark of The Deutsch Company.
† Dexron is a registered trademark of The General Motors Corporation.
† Fluke is a registered trademark of The Fluke Corporation
† GE is a registered trademark of The General Electric Company.
† GM is a registered trademark of The General Motors Corporation.
† Locquic and Loctite are registered trademarks of The Henkel Group.
† Lubriplate is a registered trademark of Fiske Brothers Refining Company.
† NMEA is a registered trademark of the National Marine Electronics Association.
† Oetiker is a registered trademark of Hans Oetiker AG Maschinen.
† Packard is a registered trademark of Delphi Automotive Systems.
† Permatex is a registered trademark of Permatex.
† STP is a registered trademark of STP Products Company.
† Snap-on is a registered trademark of Snap-on Technologies, Inc.
The following trademarks are the property of BRP US Inc. or its affiliates:
Evinrude ® Twist Grip™
Johnson ® Nut Lock™
Evinrude ® E-TEC ® Screw Lock™

FasTrak™ Ultra Lock™
S.A.F.E.™ Moly Lube™
SystemCheck™ Triple-Guard ® Grease
I-Command™ DPL™ Lubricant
®
Evinrude ICON™ 2+4 ® Fuel Conditioner
Evinrude ® / Johnson ® XD30™ Outboard Oil Carbon Guard™
Evinrude ® / Johnson ® XD50™ Outboard Oil HPF XR™ Gearcase Lubricant
Evinrude ® / Johnson ® XD100™ Outboard Oil HPF PRO™ Gearcase Lubricant

Gel-Seal II™
Printed in the United States.

© 2011 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
SERVICE MANUAL
CONTENTS
SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE
1 REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
2 ROUTINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 ENGINE COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . 49
4 ENGINE MANAGEMENT MODULE (EMM) . . . . . . . . . . 53
5 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . . 87
7 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
8 OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
9 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
10 EVINRUDE ICON REMOTE CONTROL SYSTEM . . . . 195
11 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
12 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
13 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
GEARCASE – STANDARD ROTATION . . . . . . . . . . . . 296
GEARCASE – COUNTER ROTATION . . . . . . . . . . . . . 319
14 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
TROUBLE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . T-1
DIAGRAMS
IMPORTANT: For complete outboard rigging and control installation information, refer to the Predeliv-
ery and Installation Guide included with the service manual set.
All special tools referenced in this manual can be found in the Special Tools Guide, P/N 5008526.
2
REFERENCE INFORMATION
1
TABLE OF CONTENTS
SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EMISSION-RELATED INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MANUFACTURER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DEALER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OWNER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EPA EMISSION REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3
SAFETY NOTICE
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This pu blication is written fo r qualified, facto ry- DO NOT perform any work unt il yo u have read
trained technicia ns who ar e alrea dy familiar with and understood these instructions completely.
the use of Evinrude/Johnson Special Tools. The
included in formation is not a substitu te for wo rk Torque wre nch tig htening specifications must
experience. It is an organized guide for reference, strictly be adhered to.
repair, and/or maintenance. Should removal of any locking fastener (lock tabs,
The following sym bols and /or signal words locknuts, or p atch screws) be requ ired, a lways
may be used in this document: replace with a new one.
When repla cement p arts are required, use

A DANGER Evinrude/Johnson Genuine Parts or parts with
Indicates a h azardous situation which, i f equivalent characteristics, including type, strength
not avoided, will re sult in death or serious and mate rial. Use of subst andard p arts could
injury. result in injury or product malfunction.
Always wear EYE PROTECTION AND APPRO-

A WARNING PRIATE GLOVES when using power tools.
Indicates a h azardous situation which, i f Unless otherwise specified, engine must be OFF
not avo ided, could result in death or seri- when performing this work.
ous injury
Always be aware of p arts that can move, such as
flywheels, propellers, etc.
A CAUTION Some components may be HOT. Always wait for
Indicates a h azardous situation which, i f engine to cool down before performing work.
not avoided, could result in minor or mod -
If you use procedures or service tools that are not
erate personal injury.
recommended in th is manual, YOU ALONE must
decide if your actions might injure people or dam-
age the outboard.
NOTICE Indicates a n in struction which, if
not followed, could severely damage engine This document ma y be tra nslated into othe r la n-
components or other property. guages. In the event o f an y discrepancy, t he
English version shall prevail.
These safety alert signal words mean:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
IMPORTANT: Identifies information that controls

correct assembly and operation of the product.
1
A DANGER
Contact with a rot ating prope ller is likely to result in seriou s injury or death. Assure the
engine and prop area is clear of people and objects before starting engine or operating boat.
Do not allow anyon e near a pro peller, even when the engine is off. Blade s 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 e ngine indoors or with out adequate ventilation or permi t exhaust fumes to
accumulate in confine d areas. Engin e exhaust contains carbon mo noxide which, i f 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 mo tor cov er an d fly wheel c over are m achinery guards. Use caution when con ducting
tests on running outb oards. DO NOT wear jewelry or loose clo thing. Keep hai r, hands, and
clothing away from rotating parts.
During service, the outboard may drop unexpe ctedly. Avoid personal injury; always suppo rt
the outboard’s weight with a suitable hoist or the tilt support bracket during service.
To prevent acc idental 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 a gainst h azardous fuel sp ray. Befo re st arting a ny fuel s ystem service, carefully
relieve fuel system pressure.
Do not smo ke, or allow open flame s or sparks, or use ele ctrical devi ces such as cellula r
phones in the vicinity of a fuel leak or while fueling.
Keep all electrical connections clean, tight, and insu lated to preve nt shorting or arcing and
causing an explosion.
Always work in a well ventilated area.
Replace any lo cking fastener (locknut or p atch screw) if it s locking feature bec omes weak.
Definite resistance to tightening must be felt when reusing a locking fastener. If replacement
is indicated, use only authorized replacement or equivalent.
ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL

Units of Measurement List of Abbreviations
A Amperes ABYC American Boat & Yacht Council
amp-hr Ampere hour ATDC after top dead center
fl. oz. fluid ounce AT air temperature sensor
ft. lbs. foot pounds BPS barometric pressure sensor
HP horsepower BTDC before top dead center
in. inch CCA cold cranking amps
in. Hg inches of mercury CFR Code of Federal Regulations
in. lbs. inch pounds CPS crankshaft position sensor
kPa kilopascals EMM Engine Management Module
ml milliliter EPA Environmental Protection Agency
mm millimeter ICOMIA International Council of Marine
N·m Newton meter Industry Associations
P/N part number ID Inside dimension
psi pounds per square inch MCA marine cranking amps
RPM revolutions per minute MWS modular wiring system
°C degrees Celsius NMEA National Marine Electronics Assoc.
°F degrees Fahrenheit ROM read only memory
ms milliseconds S.A.F.E. speed adjusting failsafe electronics
µs microseconds SAC start assist circuit
Ω Ohms SAE Society of Automotive Engineers
V Volts SYNC synchronization
VAC Volts Alternating Current TDC top dead center
VDC Volts Direct Current TPS throttle position sensor
USCG United States Coast Guard
WOT wide open throttle
WTS water temperature sensor
6
EMISSION-RELATED INSTALLATION INSTRUCTIONS
EMISSION-RELATED Owner’s Responsibility

INSTALLATION The owner/operator is required to have outboa rd
maintenance performed to maintain emission lev-
1
INSTRUCTIONS els within prescribed certification standards.
The owner/operator is not to, and should not allow

Failing to follow these instructio ns when
anyone to, modify the outboard in any manner
installing a certified engine in a vessel violates
that wo uld a lter th e horsepower or a llow e mis-
federal l aw (40 CFR 1 068.105 (b )), s ubject to
sions levels to exceed their predetermined factory
fines or other penaltie s as described in the
specifications.
Clean Air Act.
Tampering with the fuel system to change horse-
Maintenance, replacement, or rep air of the emis-
power or mo dify emission levels beyond fa ctory
sion control de vices and systems ma y be per-
settings or specifications will void the product war-
formed by any ma rine SI (sp ark ig nition) engine
ranty.
repair establishment or individual.
Manufacturer’s Responsibility EPA Emission Regulations

All new 19 99 and more recent Evinrude/Johnson
Beginning with 1 999 model year o utboards, man-
outboards are certified to the EPA as confo rming
ufacturers o f ma rine outboards must de termine
to the requirements of the regulations for the con-
the exha ust emissio n levels for each outbo ard
trol of air pollutio n from new watercraf t marine
horsepower family and certif y the se o utboards
spark ignition outboards. This certification is con-
with the Unite d States of America Environmental
tingent on certain adjustments being set to factory
Protection Age ncy (EP A). An emissions control
standards. For this reason, the factory procedure
information labe l, showing emission leve ls a nd
for servicing the product must be strictly followe d
outboard specifications, mu st be placed o n each
and, whe never pra ctical, ret urned to the original
outboard at the time of manufacture.
intent of the design. The responsibilities liste d
above are gen eral and in no way a comple te list-
Dealer’s Responsibility ing of the r ules and reg ulations pert aining to th e
When pe rforming service on all 1 999 a nd more EPA re quirements on e xhaust emissions for
recent Evinrude/Johnson outboards that carry an marine products. For more detailed information on
emissions control information la bel, adjustments this subject, you may cont act th e fo llowing loca-
must be kept with in pub lished factory specifications:
tions.
VIA U.S. POSTAL SERVICE:
Replacement or repair of any emission rela ted
Office of Mobile Sources
component must b e exe cuted in a manne r that
Engine Programs and Compliance Division
maintains emission levels within the prescrib ed
Engine Compliance Programs Group (6403J)
certification standards.
401 M St. NW
Dealers are not to mo dify the outbo ard in an y Washington, DC 20460
manner th at wo uld alter the horsepower or allow
VIA EXPRESS or COURIER MAIL:
emission levels to excee d their predete rmined
factory specifications. Office of Mobile Sources
Engine Programs and Compliance Division
Exceptions include manu facturer’s prescrib ed Engine Compliance Programs Group (6403J)
changes, such as altitude ad justments, for exa m- 501 3rd St. NW
ple. Washington, DC 20001
EPA INTERNET WEB SITE:
www.epa.gov
7
MODEL DESIGNATION
MODEL DESIGNATION
STYLE: LENGTH:
J = Johnson = 15” Std.
E = Evinrude L = 20” Long
Y = 22.5” Special
X = 25” X-long MODEL RUN
HORSEPOWER or SUFFIX
Z = 30” XX-long
B E 200 DP X IN E
PREFIX: DESIGN FEATURES: MODEL YR:
B = Bodensee model B = Blue Paint I =1
D = ICON model C = Counter Rotation N=2
D = Evinrude E-TEC® T =3
E = Electric Start w/Remote Steering R=4
F = Direct-Injection O=5
G = Graphite Paint D=6
H = High Output U=7
J = Jet Drive C=8
M = Military E=9
P = Power Trim and Tilt S=0
R = Rope Start w/Tiller Steering Ex: IN = 2012
S = Saltwater Approved
T = Tiller Steering
TE = Tiller Electric
V = White Paint
W = Commercial Model
Model and serial numbers are located on the swivel bracket and on the powerhead.
1 1
1. Model and serial number 000449 1. Serial number 006828
8
MODELS COVERED IN THIS MANUAL
MODELS COVERED IN THIS MANUAL

This manual covers service information on all 200.1 cubic inch (3.3 L) and 210 cubic inch (3.4 L), 90° V 1
Evinrude E-TEC models.
M ode l D is pla c e m e nt Ge a rc a s e H e ight C olor D e s c ription
E2 0 0 H SL IN E 3.3 L, 2 0 0 .1 ci .5 3 8 L2 20" W h ite Sta in le s s Ste e rin g Arm , H.O./Sta n d a rd Stylin g
E2 0 0 H VL IN M 3.3 L, 2 0 0 .1 ci .5 4 2 M2 20" W h ite Sta in le s s Ste e rin g Arm , H.O./Sta n d a rd Stylin g
E2 0 0 D H L IN S 3.3 L, 2 0 0 .1 ci .5 3 8 L2 20" Blu e Ste e l Ste e rin g Arm , H.O./Sta n d a rd Stylin g
E2 0 0 D H XIN E 3.3 L, 2 0 0 .1 ci .5 4 2 M2 25" W h ite Sta in le s s Ste e rin g Arm , H.O./Sta n d a rd Stylin g
E2 0 0 H C XIN E 3.3 L, 2 0 0 .1 ci .5 4 2 M2 C R 25" W h ite Sta in le s s Ste e rin g Arm , H.O./Sta n d a rd Stylin g
E2 2 5 D PL IN S 3 .3 L , 2 00 .1 ci .5 4 2 M2 20" Blu e Ste e l Ste e rin g Arm , Sta n d a rd Stylin g
E2 2 5 D PXIN S 3 .3 L , 2 00 .1 ci .5 4 2 M2 25" W h ite Sta in le s s Ste e rin g Arm , Sta n d a rd Stylin g
E2 2 5 D C XIN S 3.3 L, 2 0 0 .1 ci .5 4 2 M2 C R 25" W h ite Sta in le s s Ste e rin g Arm , Sta n d a rd Stylin g
E2 2 5 D PZIN S 3 .3 L , 2 00 .1 ci .5 4 2 M2 30" W h ite Sta in le s s Ste e rin g Arm , Sta n d a rd Stylin g
E2 2 5 D C ZIN S 3.3 L, 2 0 0 .1 ci .5 4 2 M2 C R 30" W h ite Sta in le s s Ste e rin g Arm , Sta n d a rd Stylin g
E2 2 5 H SL IN M 3 .3 L , 2 00 .1 ci .5 4 2 M2 20" W h ite Sta in le s s Ste e rin g Arm , H .O. Stylin g
E2 2 5 D H L IN S 3 .3 L , 20 0 .1 ci .5 4 2 M2 20" Blu e Ste e l Ste e rin g Arm , H .O. Stylin g
E2 2 5 D H XIN D 3 .3 L , 20 0 .1 ci .5 4 2 M2 25" Blu e Sta in le s s Ste e rin g Arm , H .O. Stylin g
E2 5 0 D PL IN S 3 .3 L , 2 00 .1 ci .5 4 2 M2 20" Blu e Ste e l Ste e rin g Arm , Sta n d a rd Stylin g
E2 5 0 D PXIN S 3 .3 L , 2 00 .1 ci .5 4 2 M2 25" W h ite Sta in le s s Ste e rin g Arm , Sta n d a rd Stylin g
D E2 5 0 PXIN R 3 .3 L , 2 00 .1 ci .5 4 2 M2 25" W h ite I C ON Co n tro l, Sta in le s s Ste e rin g Arm , Std Stylin g
E2 5 0 D C XIN S 3.3 L, 2 0 0 .1 ci .5 4 2 M2 C R 25" W h ite Sta in le s s Ste e rin g Arm , Sta n d a rd Stylin g
D E2 5 0 C XIN R 3.3 L, 2 0 0 .1 ci .5 4 2 M2 C R 25" W h ite I C ON Co n tro l, Sta in le s s Ste e rin g Arm , Std Stylin g
E2 5 0 D PZIN S 3 .3 L , 2 00 .1 ci .5 4 2 M2 30" W h ite Sta in le s s Ste e rin g Arm , Sta n d a rd Stylin g
D E2 5 0 PZIN R 3 .3 L , 2 00 .1 ci .5 4 2 M2 30" W h ite I C ON Co n tro l, Sta in le s s Ste e rin g Arm , Std Stylin g
E2 5 0 D C ZIN S 3.3 L, 2 0 0 .1 ci .5 4 2 M2 C R 30" W h ite Sta in le s s Ste e rin g Arm , Sta n d a rd Stylin g
D E2 5 0 C ZIN R 3.3 L, 2 0 0 .1 ci .5 4 2 M2 C R 30" W h ite I C ON Co n tro l, Sta in le s s Ste e rin g Arm , Std Stylin g
E2 5 0 H SL IN A 3 .4 L , 21 0 ci .5 4 2 M2 20" W h ite Sta in le s s Ste e rin g Arm , H.O. Stylin g
E2 5 0 D H L IN M 3 .4 L , 2 10 ci .5 4 2 M2 20" Blu e Ste e l Ste e rin g Arm , H.O. Stylin g
E2 5 0 D H XIN M 3 .4 L , 21 0 ci .5 4 2 M2 25" Blu e Sta in le s s Ste e rin g Arm , H.O. Stylin g
E3 0 0 D SL IN A 3 .4 L , 21 0 ci .5 4 2 M2 20" W h ite Sta in le s s Ste e rin g Arm , Sta n d a rd Stylin g
E3 0 0 D PXIN M 3 .4 L , 21 0 ci .5 4 2 M2 25" W h ite Sta in le s s Ste e rin g Arm , Sta n d a rd Stylin g
D E3 0 0 PXIN R 3 .4 L , 21 0 ci .5 4 2 M2 25" W h ite I C ON Co n tro l, Sta in le s s Ste e rin g Arm , Std Stylin g
E3 0 0 D PZIN M 3 .4 L , 21 0 ci .5 4 2 M2 30" W h ite Sta in le s s Ste e rin g Arm , Sta n d a rd Stylin g
D E3 0 0 PZIN R 3 .4 L , 21 0 ci .5 4 2 M2 30" W h ite I C ON Co n tro l, Sta in le s s Ste e rin g Arm , Std Stylin g
E3 0 0 D C XIN M 3 .4 L , 21 0 ci .5 4 2 M2 C R 25" W h ite Sta in le s s Ste e rin g Arm , Sta n d a rd Stylin g
D E3 0 0 C XIN R 3 .4 L , 21 0 ci .5 4 2 M2 C R 25" W h ite I C ON Co n tro l, Sta in le s s Ste e rin g Arm , Std Stylin g
E3 0 0 D C ZIN M 3 .4 L , 21 0 ci .5 4 2 M2 C R 30" W h ite Sta in le s s Ste e rin g Arm , Sta n d a rd Stylin g
D E3 0 0 C ZIN R 3 .4 L , 21 0 ci .5 4 2 M2 C R 30" W h ite I C ON Co n tro l, Sta in le s s Ste e rin g Arm , Std Stylin g
9
SERVICE SPECIFICATIONS
HP 200 225 250
Full Throttle
4500–5800 RPM
Operating Range
200 HP 225 HP
250 HP (183.9 kw)
Power (147.1 kw) (165.5 kw)
@ 5150 RPM
@ 5150 RPM @ 5150 RPM
Idle RPM in Gear 500 ± 50
Standard Rotation Models: P/N 436080 or P/N 396277
Test Propeller
Counter Rotation Models: P/N 436081 or P/N 398674
Weight 20 in. (L) Models: 503 lbs. (228 kg)
(may vary depending 25 in. (X) Models: 524 lbs. (238 kg)
on model) 30 in. (Z) Models: 530 lbs. (240 kg)
ENGINE
Evinrude/Johnson XD100 Oil

Lubrication
Refer to Recommended Lubricants on p. 164
Engine Type 90° V 6-Cylinder Loop-Charged
Displacement 200.1 cu. in. (3279 cm3)
Bore 3.854 in (97.89 mm)
Stroke 2.858 in. (72.60 mm)
3.8535 to 3.8545 in. (97.87 to 97.90 mm)
Standard Bore
To bore oversize, add piston oversize dimension to standard bore
Top Crankshaft Journal 1.6199 to 1.6204 in. (41.15 to 41.16 mm)
Center Crankshaft Journals 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Bottom Crankshaft Journal 1.5747 to 1.5752 in. (40.0 to 40.01 mm)
Rod Crankpin 1.4995 to 1.5000 in. (38.09 to 38.106 mm)
Piston Ring End Gap, Both 0.022 to 0.028 in. (0.57 to 0.72 mm)
Fuel/Oil Ratio EMM Controlled
Starting Enrichment EMM Controlled
Preferred Fuel Regular unleaded gasoline
Acceptable Fuel See Fuel Requirements on p. 134 for additional information.
Minimum (High) Fuel Pressure
22 to 28 psi (152 to 193 kPa)
@ IDLE RPM – 500 ± 50
FUEL
Minimum Fuel Lift Pump Pressure

3 psi (21 kPa)
@ IDLE RPM – 500 ± 50
Maximum Fuel Inlet Vacuum 4 in. Hg. (13.5 kPa)
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. 134 for additional information.
10
HP 200 225 250
Minimum Battery
675 CCA (845 MCA); or
1
ELECTRICAL
750 CCA (940 MCA) below 32°F (0°C)

Requirements
(Use a 107 amp-hr battery for extreme applications.)
Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation. Refer to Predeliv-
Alternator
ery and Installation Guide for multiple battery applications.
Tachometer Setting 6 pulse (12 pole)
Charging Isolator Integral, Terminal on Engine Harness
Engine Fuse P/N 967545 – 10 A
Thermostat 143°F (62°C)
COOLING
Maximum Temperature 190°F (88°C)
Water pressure 15 to 17 psi @ 5000 RPM

Type Capacitor Discharge
Firing Order 1-2-3-4-5-6
IGNITION
Ignition Features EMM Controlled

RPM Limit 6050
Crankshaft Position Sensor Air Gap Fixed
Refer to Emission Control Information Label
Spark Plug
Champion † QC8WEP @ 0.028 ± 0.003 in. (0.71 mm)
“M2” Type Gearcase: 13:24 (.542) (1.85:1)
Gear Ratio “L2” Type Gearcase – 200 HP: 14:26 (.538) (1.86:1)
Refer to GEARCASE TYPES on p. 285
Lubricant HPF XR Gearcase Lubricant
GEARCASE
“M2” Type Gearcase: 38.9 fl. oz. (1150 ml)

“M2” Type – Counter Rotation: 35.8 fl. oz. (1060 ml)
Capacity
“L2” Type Gearcase: 32.5 fl. oz. (960 ml)
20 in. (L) Models: 21 29/32 (556.25 mm) ± one-half turn
Shift Rod Height 25 in. (X) Models: 26 29/32 (683.25 mm) ± one-half turn
30 in. (Z) Models: 31 29/32 (810.25 mm) ± one-half turn
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD
Power Trim/Tilt & Power Steering Fluid or
Lubrication
GM Dexron † II Automatic Transmission Fluid
POWER TRIM/TILT
Fluid Capacity 21 fl. oz. (622 ml)
Trim Range 0° to 21°
Tilt Range 22° to 75°
Tilt UP Stall Pressure 1500 psi (10342 kPa)
Tilt IN Stall Pressure 800 psi (5516 kPa)
11
HP 250 H 300
Full Throttle
4500–6000 RPM 5000–6000 RPM
Operating Range
250 HP 300 HP
Power (183.9 kw) (220.6 kw)
@ 5250 RPM @ 5500 RPM
Idle RPM in Gear 500 ± 50
Standard Rotation Models: P/N 436080 or P/N 396277
Test Propeller
Counter Rotation Models: P/N 436081 or P/N 398674
Weight 20 in. (L) Models: 507 lbs. (230 kg)
(may vary depending 25 in. (X) Models: 528 lbs. (239 kg)
on model) 30 in. (Z) Models: 534 lbs. (242 kg)
ENGINE
Evinrude/Johnson XD100 Oil

Lubrication
Refer to Recommended Lubricants on p. 164
Engine Type 90° V 6-Cylinder Loop-Charged
Displacement 210.0 cu. in. (3441 cc)
Bore 3.854 in (97.89 mm)
Stroke 3.000 in. (76.20 mm)
3.8535 to 3.8545 in. (97.87 to 97.90 mm)
Standard Bore
To bore oversize, add piston oversize dimension to standard bore
Top Crankshaft Journal 1.6199 to 1.6204 in. (41.15 to 41.16 mm)
Center Crankshaft Journals 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Bottom Crankshaft Journal 1.5747 to 1.5752 in. (40.0 to 40.01 mm)
Rod Crankpin 1.4995 to 1.5000 in. (38.09 to 38.106 mm)
Piston Ring End Gap, Both 0.022 to 0.028 in. (0.57 to 0.72 mm)
Fuel/Oil Ratio EMM Controlled
Starting Enrichment EMM Controlled
Preferred Fuel Regular unleaded gasoline
Acceptable Fuel See Fuel Requirements on p. 134 for additional information.
Minimum (High) Fuel Pressure
22 to 28 psi (152 to 193 kPa)
@ IDLE RPM – 500 ± 50
FUEL
Minimum Fuel Lift Pump Pressure

3 psi (21 kPa)
@ IDLE RPM – 500 ± 50
Maximum Fuel Inlet Vacuum 4 in. Hg. (13.5 kPa)
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. 134 for additional information.
12
HP 250 H 300
Minimum Battery
675 CCA (845 MCA); or
1
ELECTRICAL
750 CCA (940 MCA) below 32°F (0°C)

Requirements
(Use a 107 amp-hr battery for extreme applications.)
Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation. Refer to Predeliv-
Alternator
ery and Installation Guide for multiple battery applications.
Tachometer Setting 6 pulse (12 pole)
Charging Isolator Integral, Terminal on Engine Harness
Engine Fuses P/N 967545 – 10 A
Thermostat 143°F (62°C)
COOLING
Maximum Temperature 190°F (88°C)
Water pressure 18 to 25 psi @ 5000 RPM

Type Capacitor Discharge
Firing Order 1-2-3-4-5-6
IGNITION
Ignition Features EMM Controlled

RPM Limit 6050
Crankshaft Position Sensor Air Gap Fixed
Refer to Emission Control Information Label
Spark Plug
Champion † QC8WEP @ 0.028 ± 0.003 in. (0.71 mm)
“M2” Type Gearcase: 13:24 (.542) (1.85:1)
Gear Ratio
Lubricant HPF XR Gearcase Lubricant
GEARCASE
“M2” Type Gearcase: 38.9 fl. oz. (1150 ml)

Capacity “M2” Type – Counter Rotation: 35.8 fl. oz. (1060 ml)
20 in. (L) Models: 21 29/32 (556.25 mm) ± one-half turn
Shift Rod Height 25 in. (X) Models: 26 29/32 (683.25 mm) ± one-half turn
30 in. (Z) Models: 31 29/32 (810.25 mm) ± one-half turn
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD
Power Trim/Tilt & Power Steering Fluid or
Lubrication
GM Dexron † II Automatic Transmission Fluid
POWER TRIM/TILT
Fluid Capacity 21 fl. oz. (622 ml)
Trim Range 0° to 21°
Tilt Range 22° to 75°
Tilt UP Stall Pressure 1500 psi (10342 kPa)
Tilt IN Stall Pressure 800 psi (5516 kPa)
13
STANDARD TORQUE SPECIFICATIONS
STANDARD TORQUE PRODUCT REFERENCE

SPECIFICATIONS AND ILLUSTRATIONS
BRP US Inc. reserves the right to make changes
Size In. Lbs. Ft. Lbs. N·m at a ny time, wit hout no tice, in specificatio ns a nd
models and a lso to discon tinue models. The rig ht
No. 6 7–10 0.58–0.83 0.8–1.1 is also reserve d to change any specifications or
No. 8 15–22 1.25–1.83 1.7–2.5 parts, at any time, without incurring any obligation
to equ ip same on mode ls manufactured prior to
No. 10 24–36 2–3 2.7–4.0 date of such ch ange. Specifications used are
No. 12 36–48 3–4 4.0–5.4 based on the late st product information a vailable
at the time of publication.
1/4 in. 60–84 5–7 7-9.5
5/16 in. 120–144 10–12 13.5–16.5 The continuing accuracy of this manual cannot be
guaranteed.
3/8 in. 216–240 18–20 24.5–27
All photographs and illustrations used in this man-
7/16 in. 336–384 28–32 38–43.5
ual may no t de pict a ctual models or equipment,
M3 15–22 1.25–1.83 1.7–2.5 but are intended as representative views for refer-
ence only.
M4 24–35 2–2.9 2.7–4.0
M5 35–60 2.9–5 4.0–6.8 Certain features or systems discussed in this
manual mig ht not be found o n all mod els in all
M6 84–106 7–8.8 9.5–12 marketing areas.
M8 177–204 14.7–17 20–23
All service technicians must be familiar with nauti-
M10 310–336 25.8–28 35–38 cal orient ation. This manual of ten identifies p arts
and procedures using these terms.
IMPORTANT: These values apply only when a
specific torque for a specific fastener is not listed
in the appropriate section. When tightening two
or mo re screws on the same p art, DO NOT
tighten screws completely, one at a time.
A WARNING
Torque wre nch tightening spe cifications
must be s trictly adhe red to. Replace any
locking fastene r (lo cknut or p atch screw)
if its locking feature becomes weak. Defi-
nite res istance to tu rning mus t be felt
when reusing a locking fastener.
If replac ement is spe cified o r required
because the locking fastener has become
Nautical Orientation 006411
weak, use only authorized Evinrude/
Johnson Genuine Parts.
14
.ROUTINE SERVICE
ROUTINE SERVICE
TABLE OF CONTENTS
2
INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LIFTING THE OUTBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OUTBOARD RIGGING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONTROL CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BATTERY CABLE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SYSTEMCHECK HARNESS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
I-COMMAND NETWORK CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ICON NETWORK CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
WATER PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
BATTERY AND BATTERY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OETIKER CLAMP SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TILT LIMIT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TRIM SENDING UNIT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TRIM TAB ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DUAL-OUTBOARD ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ENGINE FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
RUNNING THE OUTBOARD USING A HOSE AND FLUSHING ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SWIVEL BRACKET AND TRAILERING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
THROTTLE AND SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FUEL AND OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
OIL FILTERS AND OIL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
AIR SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
HOSES AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
EXHAUST PRESSURE FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
PRE-SEASON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SUBMERGED ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
15
.ROUTINE SERVICE
INSPECTION AND MAINTENANCE SCHEDULE
INSPECTION AND MAINTENANCE SCHEDULE

Routine inspection and maintenance is necessary to prolong outboard life. The following chart provides
guidelines for inspection and maintenance to be performed by an authorized Dealer.
IMPORTANT: Outboards used in rental, commercial, or other high hour applications require more fre-
quent inspections and maintenance. Adjust schedule for operating and environmental conditions.
Engine Every 300 hours
Care Routine or every three
Description Product Inspection years (1)
Engine Monitor self-test and warning horn, check 
Emergency stop circuit and lanyard, check operation 
Controls, steering and tilting; check operation 
Engine mounting hardware, re-tighten (40 ft. lbs.) 
Fasteners, tighten any loosened components 
Water intake screens, check condition 
Cooling system; check water pump indicator / water pressure 
Anticorrosion anodes, check condition 
Gearcase, check condition 
Propeller, check condition 
Fuel and oil systems, inspect and repair leaks (2) 
Check battery connections and condition 
Access EMM information, resolve any service codes 
Electrical and ignition wires, inspect for wear or chafing 
Fuel filter, replace 
Oil filters, replace 
Gearcase lubricant, replace A 
Spark plugs, inspect or replace (2) 
(2)
Thermostats, inspect and check operation 
(3) C
Grease fittings, lubricate 
Power trim/tilt and fluid level, inspect B 
(3) C
Propeller shaft splines, inspect and lubricate 
(3) D
Starter pinion shaft, inspect and lubricate 
Control cables, inspect and adjust 
Steering cable, inspect and lubricate C 
Water pump, inspect / replace (more often if water pressure loss or overheating occurs) 
(1) Average recreational use. Commercial use, heavy use, or use in salt or polluted water requires more frequent inspection and maintenance.
(2) Emission-related component
(3) Annually in salt water applications
A HPF Pro Gearcase Lubricant

B Power Trim/Tilt Fluid (Three ram hydraulic systems)
C Triple-Guard Grease
D Starter Bendix Lube Only
16
.ROUTINE SERVICE
LIFTING THE OUTBOARD
LIFTING THE OUTBOARD RIGGING

OUTBOARD CONNECTIONS
A WARNING IMPORTANT: For complete outboard riggin g
and remote control installation information, refer to 2
To avoid personal injury, make sure the lift- the Predelivery and In stallation Guide included
ing cap acity of the hoist is at least twice with the service manual set.
the weight of the outboard.
Common Practices – All Models
DO NOT all ow the lif t hook or chain from
the hoist to come in contact with any part Control Cable Identification
of the engine during lifting.
IMPORTANT: Identify con trol ca ble fun ction
before rigging outboard.
Use correct Lifting Fixture to lift outboard:
Identify each control cable:
Model Lifting Fixture
• Put the co ntrol handle into NEUTRAL positio n.
90° V6 P/N 396748 with The throttle cable casing guide will retract com-
1 3/4 in. screws pletely and the shift cable casing guide will go to
the midpoint of its travel.
Place lif ting tool on flywh eel and se at the three
screws completely.
1
1
2 2
1. Shift cable casing guide extended to midpoint DP0811

2. Throttle cable casing guide retracted
Extend the control cables and lubricate them with

002419
1. Lifting fixture
2. 1 3/4 in. screws
Triple-Guard grease.
Fasten appropriate chain hoo k to eye of too l.

Carefully hoist outboard with chain and unbolt out-
board mounting brackets from frame.
30501
17
.ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
Cable Retainer Clip Installation Cable, Hose, and Wire Routing

When installing retainer clips on control arm lin k-
age pins, clips should be locked and must not be A CAUTION
bent or deformed.
To prevent accidental starting while servic-
For proper installation, review the following steps: ing, disconnect the battery c ables at the
• Place washer on pin. battery. T wist and remove al l sp ark plug
• Position retainer clip with straight section on the leads.
bottom and angled section on the top.
• Use long nose pliers to insert straight section of Refer to Control Cable Identification on p. 17.
clip into linkage pin hole.
Remove two scre ws a nd b racket that fasten t he
grommet to lower motor cover.
1. Straight section DP0818

2. Angled section DP0817
1. Grommet retaining bracket 003964

• Push th e clip toward s t he h ole while li fting on
the curved end with the pliers. Route all hoses, co ntrol cable s, and wiring
• Be sure retainer clip fully engages the pin. through a prote ctive sleeve or conduit into the
• Lock the retainer by moving the an gled section boat and through the grommet.
behind the straight section.
The fuel hose may be routed th rough the protec-
tive sleeve or throug h an alt ernate ho le in the
lower motor cover grommet.
1
To route the fuel hose outside the sleeve, trim the
material cove ring the a lternate fu el hose slot in
the grommet.
Locked Retainer Clip DP0817A
1. Angled section behind straight section
1. Alternate fuel hose location 003970
18
.ROUTINE SERVICE
Refer to the following diagram to ensure pro per same path to the starboard side of the powerhead.
positioning of rigging components in grommet. Secure all cables with clamps.
10 6 11 2
9 12
8 4
7
3
5
1 2
1. Fuel supply hose 000095 003974

2. Fuel supply hose--alternate location
3. Oil supply hose
4. Oil tank sending unit harness NOTICE After in stallation, mak e sure there
5. Battery cables
6. Main wire harness (MWS) is eno ugh clearanc e for all cables to av oid
7. Shift cable binding or chafing through all engine steering
8.
9.
Throttle cable
Accessory charge wires
and tilting angles.
10. I-Command harness
11.
12.
Water pressure hose
Speedometer hose
Control Cable Installation
Refer to Control Cable Identification on p. 17.
Remove contro l ca ble t runnion co vers and cable

attachment hardware.
1
1. Alternate fuel hose location 003971
The main wiring harness, battery cables, oil t ank

sending unit harness, an d any ICON or I-Com- 1. Trunnion covers 005037
mand network cables sh ould be routed along the
19
.ROUTINE SERVICE
Shift Cable Installation and Adjustment Throttle Cable Installation and Adjustment
Place t he s hift ca ble on t he sh ift l ever p in and With remote control lever in NEUTRAL, pull firmly
install the washer and retainer clip. Refer to Cable on throttle cable casing to remove slack.
Retainer Clip Installation on p. 18.
Place throttle cable on throttle lever pin and install
IMPORTANT: Do not bend or deform clip. washer and retainer clip. Refer to Cable Retainer
Clip Installation on p. 18.
Make sure the remote control, gearcase, shift link-
age, and shift cable are in NEUTRAL.
1
Hold the shift linkage in NEUTRAL.
Push and pull on th e shift cable and observe the

cable slack. Hold the casing guide in the center of
the slack.
Adjust shift cable trun nion to align with cente r of

the trunn ion b lock. Place cable trun nion in trun-
nion block.
Install trunnion cover and screw. Tighten screw to 1. Throttle cable retainer clip and washer 003967
a torque of 60 to 80 in. lbs. (7 to 9 N·m).
Make sure th at idle stop of t he throttle lever is
against the crankcase.
1 2
1
1. Shift cable retainer clip and washer 005038
2. Shift cable trunnion
1. Throttle lever stop 003968
Adjust the throttle cable trunnion to align with the

trunnion block. Place the cab le trunn ion in the
trunnion block.
IMPORTANT: Move control h andle t o F OR-

WARD and pull back slowly to NEUTRAL. Make
sure the engine throttle lever is against the stop. If
not, remove slack by adjusting cable trunnion.
20
.ROUTINE SERVICE
Install trunnion cover and screw. Tighten screw to SystemCheck Harness

a torque of 60 to 80 in. lbs. (7 to 9 N·m). Connections
Remove harness connector cover.
1
2
1. Trunnion cover and screw, throttle cable 005039
003972
Battery Cable Connections
Install battery cables on starter solenoid and main Before installing electrical connectors, check th at
ground stud. the seal is in place. Clean of f any dirt from con-
nectors. Apply a light coat of Electrical Grease to
the seal only. DO NOT fill connectors with Electri-
cal Grease.
2 1
1
1. Seal 42079A
1. Positive (+) battery connection 003975
2. Ground (–) connection
21
.ROUTINE SERVICE
Connect outboard main wire harness to boat wire If using a mechanical control system, con nect the
harness. Secure connectors in bra cket. Refer to I-Command En gine Interface Cable to the EMM
the diagram inside of the electrical cover. CANbus connector.
1 1
1. Harness connections 003973 1. EMM CANbus connector 004265
NOTICE BE SURE all harness es a nd wires Use an I-Command Ignition and Trim Harness to
are not pinche d, cannot cont act flywheel, and connect the outboard to the key switch and trim/tilt
do not interfere with mov ing throttle or shift control. Sea l unused SystemCheck co nnector
linkages. with 6-Pin Connector Seal, P/N 586076.
Replace harness connector cover. If conne cting to an existing I-Command Classic

network, connect the purple wires bet ween the I-
I-Command Network Connections Command Ig nition and Trim Harn ess an d the I-
Command Engine Interface Cable. T his connec-
If the outbo ard will be used with I-Command, or
tion supplies power to th e network when th e key
other NMEA 2000 compliant CANbus instruments,
switch is on. I-Command Digital networks do not
use the following connections to su pply informa-
use this connection.
tion to the network:
If using an Evinrude ICON control system, the I-
Command Engine Interface Cable, Power Supply
Kit, and Ignition and T rim Ha rness are not 2
required. Conn ect the I-Command ne twork 4
directly to the ICON gateway module. Refer to the
ICON Remot e Control Syste m Inst allation 1
Guide.
3
1. I-Command Ignition connector 006862

2. Trim/Tilt connector
3. SystemCheck connector (with seal)
4. Network power supply connector (Deutsch style
networks)
Route the harnesses around the starboard side of

the powerhead along the same path as the battery
cables.
22
.ROUTINE SERVICE
For an I-Command oil level display, an accessory IMPORTANT: Do not force conn ectors or lock-
CANbus oil level sende r must be inst alled in the ing rings. Prop erly aligne d conne ctors a ssemble
oil t ank. Co nnect the sender to the I-Command easily.
network. Refer to the I-Command Digit al Net-
work Guide. Do not use Electrical Grease on ICON buss cable
Use Evinrude Diagnostics software to adjust net-

connectors.
2
work settings in th e EMM. From the Settings To assemble the connectors:
screen, select Engine Options. • Use the large t abs and small t abs to carefully
align buss cable connectors.
• Carefully align pins and socket s of conne ctors.
Do NOT force connectors together.
• Tighten locking rings of buss connectors fing er
tight. Do NOT use locking rings to force connec-
tors together.
1
Engine Options Screen 008563 2

1. Large tabs 007883
ICON Network Connections 2. Small tabs
If the outboard is equ ipped for an Evinrude ICON Do not rot ate co nnectors un til t hey a lign. This
control system, con nect the outboard to the net- could result in a mismatched connection. It is pos-
work as follows. sible for each pin to enter a socket even if the tabs
Refer to the ICON Rem ote Control Sys tem are misaligned. Look at the t abs to en sure con-
Installation Guide. nector alignment prior to making the connection.
Connect the buss cable from the rear network hub Engine Mo nitor information is distributed to an
to the outboard’s network harness. ICON or I-Command network through th e ICON
gateway module. Refer to the I-Command Digital
Network Guide.
The ICON Harne ss an d Relay Kit, P/N 76529 6,

1
must b e use d to pro vide power to boat accesso-
ries that requ ire switched B+. This kit is used in
place of connecting accessories to the “A” termi-
nal o f th e key switch. Accessories connected to
the accessory power rela y sho uld not exceed 7
amps.
NOTICE Do not connect boat accessories to

1. ICON network connector 008001 the key switch of an ICON system. Connecting
accessories to the key switc h can ca use low
23
.ROUTINE SERVICE
current, resulti ng in erratic operation of the To send wat er pre ssure da ta to the EMM, alo ng
remote control system. with an I-Command d isplay, in stall a water pres-
sure transducer kit.
For more informati on, refer to t he ICON Remote
Control System Installation Guide. Water pressure readings in excess of 40 psi (275
kpa) are po ssible fo r 90 ° V6 models at bo at
Water Pressure Gauge speeds in excess of 50 mph (80 kph/43 kts).
To displa y engine water p ressure, in stall a water
Use 50 p si W ater Pressure Transducer Kit,
pressure hose fitting in the cylin der blo ck as
P/N 5008640.
shown.
Use Pipe Sealant with Teflon on the threads of the

1
hose fitting. Refer to installation instructions sup-
plied with gauge.
Route the wa ter pressure hose aroun d the st ar-

board side of the powerhead along the same path
as the battery cables.
1. Water pressure transducer 008131
Connect the transducer lead to the e ngine wiring

harness connector.
1. Water pressure hose fitting 005035
For an I-Command wate r pressure displa y, se v-

eral water pressure sensor kit s are available. 2
Refer to the Evinrude/Johnson Genuine Parts 1
and Accessories catalog.
1. Water pressure transducer lead 004120

2. Engine harness connector
24
.ROUTINE SERVICE
BATTERY AND BATTERY CONNECTIONS
BATTERY AND BATTERY Install a st arwasher on the threaded battery post.

Stack cables from the outboard, then cables from
CONNECTIONS accessories. Finish this connection with a hex nut.
A WARNING
3
2
Keep the b attery co nnections clea n, tight,
and insu lated to preve nt thei r shorting or
arcing and causing an explosion. If the bat-
tery mountin g system does not cover the 2
connections, install pro tective cove rs.
Check of ten to s ee th at conn ections st ay
clean and tight. 1
Marine Style Battery Post DR5103
Check battery connections frequently. Periodically 1. Starwasher
2. Hex nut
remove battery to clean and service connections. 3. Terminal Insulator
• Confirm that battery meets the minimum engine
requirements. NOTICE Do not use wing nuts to fasten ANY
• Connections must be clean and tight. battery cable s. W ing nuts can lo osen a nd
• Observe a ll wiring connections prio r to d isas- cause e lectrical sys tem damage no t cov ered
sembly. under warranty.
Disconnect battery negative (–) cable first and the Tighten a ll conn ections securely. Apply Triple-
battery positive (+) cable last. Guard grease to prevent corrosion.
Clean all terminals, batt ery posts, and connectors A WARNING
with a solu tion of b aking soda a nd wate r. Use a
wire brush o r battery terminal tool to remove cor- Battery elect rolyte is acidic—handle with
rosion buildup. Rinse and clean all surfaces. care. If electrolyte contacts any part of the
body, imm ediately flush wit h water and
IMPORTANT: Connect the battery p ositive (+) seek medical attention.
cable to the battery positive (+ ) post FIRST. Con-
nect the ba ttery negative (–) cable to the batte ry
negative (–) post LAST.
25
.ROUTINE SERVICE
OETIKER CLAMP SERVICING
OETIKER CLAMP 1
SERVICING
Clamp Identification
Use Oetiker clamps for making hose connections.
These clamps provide co rrosion resistance, mini-
mize the potential for ab rasion of rigg ing compo-
nents, and provide solid, permanent connections.
The selection and installation of an Oetiker clamp

is essential in the p roper sealing of h ose connec-
tions. The clamp identification numbers appear on
the side of the cla mp, near the top of the ear.
Refer to Clamp Selection chart for dimensions.
1. Clamp identification numbers 000093
A WARNING
DO NOT re-use Oetiker clamps. Fuel leak -
age could contribute to a fire or explosion.
Clamp Selection
To select the c orrect size Oetiker clamp, measure Chose a clamp so that the outside diameter of the
the outside diameter of the hose when installed on hose is appro ximately in the middle of the clamp-
the fitting. ing range of the clamp.
I.D. P/N Clamping Range

440 352110
410 349729
331 352335
316 349759
301 346153
256 346152
238 352703
210 346151
185 346150
170 348839
157 346786
145 346785
140 346931
138 347108
133 347107
113 349516
105 3488 38
95 346930
Hose mm 0 5 10 15 20 25 30 35 40 45
Diameter inch 1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 1-3/4
008458
26
.ROUTINE SERVICE
OETIKER CLAMP SERVICING
Clamp Installation Clamp Removal

A const ant st ress sho uld be ap plied to close the Method 1: Position Oetiker pincers across clamp
ear clamps. This method ensures a positive stress ear and cut clamp.
on the hose and does not result in excessive com-
pression or expansion of the band material.
2
IMPORTANT: Use only Oetiker re commended
tools to close Oetiker stepless clamps.
Oetiker pin cers are ava ilable in the
Evinrude/Johnson Genuine Parts and Accesso-
ries Catalog.
000108
Method 2: Lift end of stepless clamp with screw-

driver.
DP0886
• Position correct size clamp over hose.

• Install hose on fitting.
• Close c lamp ear f ully wi th Oetiker pincers (pli-
ers).
000090
Method 3: Us e Oetiker pincers (pliers) to grip

clamp. Pull clamp off of connection and discard.
1 2
1. Open clamp 000092
2. Closed clamp
000091
27
.ROUTINE SERVICE
ADJUSTMENTS
ADJUSTMENTS Place the outboard in normal operating position.
Rotate the LOWER adjustment tab UP to reduce

Tilt Limit Switch Adjustment the maximum tilt. Rot ate the UPPER adjustment
tab DOWN to increase the maximum tilt position.
A WARNING
If the outboard does not clear all boat parts
when tilted fully or turned side to side ,
safety re lated p arts could be damage d in
the course of such outboa rd mo vement.
Injuries could result from loss of boat con-
trol. 2
Adjust th e tilt limit switch o n all new outbo ard

installations. 1
Check the clearance between outboard(s) and the 1. Lower adjustment tab DR4268
boat’s motor we ll and transo m area. T ilt out- 2. Upper adjustment tab
board(s) to highest point of clearance and turn the
steering system lock to lock. Check the adjustment by tilting the outboard fully.
If the outb oard cont acts the boat's mo tor well Repeat this procedure until the tilt limit switch
when fully tilted, adjust the tilt limit cam t o reduce stops the outboa rd's u pward travel before it co n-
full-tilt position. tacts the motor well.
NOTICE The tilt limit ca m will no t prevent To pre vent da mage to equipment, provide addi-
the outboard from overriding the adjustment if tional motor we ll clea rance when n eeded. Co n-
the outboard is tilted manually. sider eith er chan ging the outboard mo unting
position or modifying the boat if the possib ility for
interference and damage exists.
A WARNING
Adjusting the tilt limit cam will NOT pre-
vent the outboa rd fro m tilting fu lly and
contacting the motor well if the gearcase
hits an object at high speed. Such contact
could damag e the ou tboard and b oat and
injure boat occupants.
DR3916
28
.ROUTINE SERVICE
ADJUSTMENTS
Trim Sending Unit Adjustment Observe the trim gau ge. If the n eedle does not
show cen ter position, tilt the outboard up an d
Tilt the outboard and engage the tilt support.
adjust the sending unit by pivoting it up or down.
Temporarily install a thrust rod, P/N 436541, in the
number 3 hole.
2
1
1. Needle at center position 000662
29072
Lower the outboard against the thrust rod to check
adjustment. Repeat adjustment, if necessary.
Loosen the send ing unit screws, to allow the After a djustment is correct, tilt the outboard u p,
sending unit to pivot. tighten the two sending unit screws, and remove
the thrust rod.
Trim Limiter Rod

The trim limiter rod prevents excessive trim down.
1
As the engine is trimmed to the full down position,
the bow of the boat goes deeper into the water.
• If th e trim limiter rod is lef t out, the bo w could
plow into the wat er cau sing the boa t to “bow
steer” resulting in a loss of control.
• If the trim limiter rod is set too far o ut, the p ro-
peller could ventilate, resulting in poor accelera-
1. Screws 27339 tion when the boat is coming onto plane.
Disengage the t ilt suppo rt. Lower th e outbo ard Set th e trim limiter rod to pre vent excessive trim
against the thrust rod. down and provide good acceleration. The trim lim-
iter rod can be u sed to prevent th e gearcase or
spray deflector from contacting the transom.
A WARNING
When the outboard is returned to the cus-
tomer, the trim limi ter rod must be
installed and in the s ame l ocation as it
was when the motor was brought in for
service. Leaving the trim limiter rod out, or
changing the adjustm ent, cou ld allow the
motor to une xpectedly trim in too far and
cause loss of control.
29
.ROUTINE SERVICE
ADJUSTMENTS
Trim Tab Adjustment Tighten the trim tab screw as follows:

• 115 – 200 HP: 35 to 40 ft. lbs. (47 to 54 N·m).
A WARNING
Improper trim tab a djustment c an cause
difficult steering and loss of control. 1
A propeller will generate steering torque when the

propeller shaft is not running parallel to the water’s
surface. The trim tab is adjustable to compensate
for this steering torque.
IMPORTANT: A single trim t ab adjustment will 1. Trim tab screw COA3663

relieve steering effort under only one set of speed,
outboard angle and loa d condit ions. No sing le Test the boat and, if needed, repeat the procedure
adjustment ca n re lieve steering effort und er all until steering effort is as equal as possible.
conditions.
Outboards with High Transom Heights
If the boat pulls to the left or right when its load is The trim tab may be ab ove the surface o f t he
evenly distributed, adjust the trim tab as follows: water when the out board is trimmed out. Steering
• With the remo te co ntrol in NEUTRAL and the effort might increase. Lower the trim setting to
engine OFF, loosen the trim tab screw. submerge the trim t ab and t o reduce steering
• If the boa t pulled to the right, move rear of the effort.
trim tab slightly to the right.
• If the bo at pulled to the left, move rear of the Dual Standard Rotation Outboards
trim tab slightly to the left. Move both trim t abs equa lly and in the same
direction.
Dual Outboards, One Counter and One

Standard Rotation
Set both trim tabs to the center position.
30
.ROUTINE SERVICE
ADJUSTMENTS
Dual-Outboard Alignment Alignment Adjustment

Dual outboards must b e connected with a tie bar Various bo at/motor comb inations respond differ-
and adjuste d to a lign the o utboards for correct ently to dua l-outboard a lignments. Each app lica-
water flow to the gearcases and propellers. tion must be thoroughly tested until the idea l
combination of performance, steering, and cooling
Incorrect outbo ard alignment co uld cause one or is found. 2
more of the following: A common practice is to set-up the outboards par-
• Propeller ventilation allel, or with a small amoun t of “toe-out,” an d
• Reduction of top speed adjust inward until best results are achieved.
• Improper boat tracking • A typical set-up with 2 -stroke ou tboards
• Engine overheat and powerhead damage mounted directly on the transom often runs best
with a slight amount of “toe-in.”
Follow th e instructions provided by t he tie -bar • Outboards mount ed be hind the transom o n
manufacturer f or tie ba r inst allation and adjust- motor bracket s usually req uire “p arallel” alig n-
ment. ment or “toe-out.”
Measure Alignment Adjust the outboard alignments by adju sting tie
The “toe-in” (gearcase lea ding edge s closer bar. Follow the tie bar manufacturer’s adjustment
together than propeller shaft centers) o r “toe-out” procedures.
(gearcase leading edges farther apart than propel-
ler shaft centers) is determined as follows: Check steerin g opera tion. Make su re that th e
steering system operates properly at variou s trim
• Position outboards straight with the anti-ventila-
tion plates parallel with the bottom of the boat. angles.
• Measure between propeller shaft centers. Confirm Alignment
To confirm proper alignment, perform the following
steps:
• Water test the boat.
• Monitor the water pressure for both outboards.
• Run the boat at various trim angles.
• Perform steering maneuvers and vary the throt-
tle settings.
• Monitor boat and outboard performance.
6365 A sudden loss of water pressure or excessive pro-
peller ventilatio n on one or both outboards may
• Measure between leading edges of gearcase. indicate a misalignment of the gea rcases. Reset
the outboard alignment and retest.
6340
31
.ROUTINE SERVICE
OPERATIONAL CHECKS
OPERATIONAL CHECKS Fuel System

Perform running checks of t he fuel system by fo l-
A DANGER lowing these steps:
• Squeeze fuel primer bulb until hard or activa te
DO NOT run the engine indoors or withou t electric primer. Observe all fuel hoses and con-
adequate ventilation or permit exhaust nections. Repair any leaks.
fumes to accumulate in confined areas . • Start outb oard. Inspect a ll hoses a nd connec-
Engine exhaust contains carbon monoxide tions. Repair a ny l eaks o r mi srouted h oses
which, if inhale d, can cause serious brain immediately.
damage or death.
Emergency Stop / Key Switch
Check e mergency stop fu nction. With outboard
A WARNING running at IDLE, pull saf ety la nyard from emer-
gency s top s witch. Outboard mu st st op im medi-
Contact with a rotating propeller is likely to
ately.
result in seriou s injury o r d eath. Ass ure
the engine and prop area is clear of people Remote Control Operation
and objects before starting engine or oper-
ating boat. Do not allow anyone near a pro- Make sure th at control can be easily moved in to
peller, even when the engine is off. Blades all gear and throttle settings. Do not shif t remote
can be sharp an d the propeller c an con - control when outboard is not running.
tinue to turn even after the engine is off.
Start-In-Gear Prevention
A WARNING
A WARNING
Make certain that the starter will not ope r-
DO NOT run outboard without a water sup-
ate when the outboard is in gear. The start-
ply to the outboard’s cooling system. Cool-
in-gear prevention fea ture is required by
ing system and/or powe rhead damage
the United States Coast Guard to help pre-
could occur.
vent personal injuries.
Engine Monitoring System Start outboard and shift to FORWARD.

Attach emergency stop lanyard.
Turn outboard OFF while control is in FORWARD.
SystemCheck
Try to rest art the o utboard. Ou tboard sho uld n ot
Turn key switch to ON. Warning ho rn shou ld start.
sound for 1/2 second.
Shift back to NEUTRAL and restart outboard.
All SystemCheck warning lights should turn on at
the same time, then turn off one at a time. Shift to REVERSE. Turn outboard OFF while con-
trol is in REVERSE.
I-Command
Try to rest art the o utboard. Ou tboard sho uld n ot
Turn key switch to ON. start.
The Evinrude E-TEC screen should app ear, fo l-
lowed by the tachometer display.
32
.ROUTINE SERVICE
COOLING SYSTEM
Tachometer Pulse Setting COOLING SYSTEM

Confirm accuracy of tachometer reading.
Check the con dition of cooling system compo-
• Adjust dial on back of t achometer to required
nents regularly:
setting (the outboard should not be running).
• water intake screens
Outboard Model Tachometer Setting • water pump 2
200–300 HP 6 Pulse or 12 Pole • all internal water passages
• thermostats
• all external water hoses and fittings
Water Pump Overboard Indicator • vapor separator cooling passages and fittings
A steady stre am o f water should flow from the • EMM cooling passages and fittings
overboard indicator. • overboard water pressure indicator.
Water Intake Screens

Inspect condition of water int ake scre ens. Clean
or replace as needed.
Confirm function of overboard water pressure indi-
cator.
Clean or replace plug and nozzle as needed.
1
1. Water pump overboard indicator 008469B
1 2
Operating Temperature
An o utboard run at id le speed sho uld achieve a
temperature b ased on the engine’s thermostatic
control. In gene ral, the powerhea d temperature
should reach at least 104°F (40°C) after five min-
utes of idling. Check that the powerhea d reaches 1. Water intake screen 008470B
idle temperature. Refer to SERVICE SPECIFICA- 2. Overboard water pressure
TIONS on p. 10.
Idle Speed
Make sure the outboard idles within the specified
idle RPM ra nge. If th e outboard is run on a flush-
ing device, the idle speed and qu ality may no t be
representative of actual in water use.
33
.ROUTINE SERVICE
COOLING SYSTEM
Engine Flushing Thread garden hose into flushing port.

Flush the outboard with fresh water following each
use in brackish, salt, or polluted water to minimize
the accumulation of scale and silt deposits in cool-
ing system passages.
The outb oard can b e flu shed on th e trailer o r at

dockside; running or not running.
IMPORTANT: The outbo ard mu st be lo cated in

a well ven tilated area with appropriate grou nd
drainage during the flushing procedures.
Keep water inlet pressure between 20 to 40 p si 004264

(140 to 275 kPa).
Turn water supply on.
Flushing — Outboard Running
Run outboard at IDLE only until full operating tem-
A WARNING perature is reached.
To prevent inju ry from con tact with rotat-
Reinstall plug and n ozzle. Position th e plug a nd
ing propeller, remove the propeller before
nozzle to allow the water stream to be seen from
flushing. the helm.
Place outboard in VERTICAL (DOWN) position in Leave the outbo ard in VER TICAL (DOWN) posi-
a well ventilated area. tion long enough for the powerhead to drain com-
pletely.
Remove plug and n ozzle (overboa rd in dicator)
from the flushing port. Reinstall propeller.
Flushing — Outboard Not Running

Outboard can be in VER TICAL (DOWN) or
TILTED (UP) position.
Remove p lug a nd no zzle (overboa rd ind icator)

from the flushing port.
Thread garden hose into flushing port.
Turn water supply ON.
Flush outboard for at least five minutes.

004263
Turn off water supply and remove garden hose.
Reinstall plug and n ozzle. Position th e plug a nd

nozzle to allow the water stream to be seen from
the helm.
Leave the outbo ard in VER TICAL (DOWN) posi-

tion long enough for the powerhead to drain com-
pletely.
34
.ROUTINE SERVICE
COOLING SYSTEM
Running the Outboard Using a NOTICE Temporarily cover the s mall hole s
Hose and Flushing Adapter on the front of M2-Type gearcases with water-
proof tape to make sure enough water trave ls
A WARNING to the po werhead. Water can drain from aux il-
iary inlets, resulting in engine overheat.
To prevent inju ry from cont act with rotat-
ing propeller, remove the propeller before
2
running engine with a flushing adapter.
2
A flushing adapter may be used to provide cooling
water when running the outboard to:
• Flush the engine
• Run for a n extende d pe riod of time, such a s 1
when performing diagnostic work
• Run the engine on a dynamometer
• Prepare the outboard for storage.
M2-Type Gearcase 008358
IMPORTANT: The outbo ard mu st be lo cated in 1. Water-proof tape
a well ven tilated area with appropriate grou nd 2. Flushing adapter
drainage.
A st eady stre am of water should flo w f rom th e
Keep water inlet pressure between 20 to 40 p si overboard indicator while the engine is running.
(140 to 275 kPa).
Monitor engine water pressure gauge when:
Be sure water supply is sufficient to run the engine • Engine speed is above 3000 RPM
above idle speed. • Running engine on a dynamometer.
Water Supply Requirements Refer to SERVICE SPECIFICATIONS on p. 10 for
Model Water Flow @ WOT water pressure requirements.
200–250 HP (3.3 L) 20 to 25 GPM1 (75 to 94 LPM)2
NOTICE Engine will overheat if normal water
250–300 HP (3.4 L) 25 to 30 GPM1 (94 to 113 LPM)2
pressure is not maintained. Temporarily install
1. GPM: Gallons per minute an engin e water pre ssure gauge if not
2. LPM: Liters per minute
equipped with one.
Install flu shing adapter onto gearcase water inlet
Be sure to remove wate rproof tape from auxiliary
screens.
water inlets.
NOTICE Engine will ov erheat if auxi liary

water inlet s are restricte d whe n outboa rd is
back in service.
35
.ROUTINE SERVICE
LUBRICATION
LUBRICATION Swivel Bracket and Trailering

Bracket
Steering System Lubricate the swivel bracket wit h Triple-Guard
A WARNING grease.
Failure to regrease as recom mended Apply grease until the grease begins to flo w from
could result in steering system corrosion. the upper or lower swivel bracket areas.
Corrosion c an affec t steering effort, mak -
Coat the pivot points of the trailering b racket with
ing operator control difficult.
Triple-Guard grease.
Grease the stainless steel output end of the steer-

ing cable with Triple-Guard grease.
Use an ap propriate cleaning solvent to remove 1

corrosion and dirt from output end of cable prior to
coating it wit h gre ase. Make sure wip er nu t is
installed and not damaged.
2 3
1. Grease fitting DR5073

2. Pivot points
3. Lower swivel bracket area
2 Throttle and Shift Linkage

1 Disconnect the battery cables at the battery.
Remove cable trunnion cover . Carefu lly, re move

1. Steering cable DR29546 throttle and shift cables from trunnion block.
2. Wiper nut
IMPORTANT: DO NOT disturb cab le trunnion
Tilt Tube adjustments.
Lubricate the tilt tube grease fittings with Triple- Shift remote control into FULL T HROT-
Guard grease. TLE/REVERSE position to fully extend the plastic
casing guides.
Apply Triple-Guard grease to:
• Pivot and slide area of the shift interrupt switch
bracket
• Cable att achment pins of both th e throt tle a nd
shift levers
1 1
1. Tilt tube fittings DR38798
36
.ROUTINE SERVICE
LUBRICATION
• Inner casings of both the thro ttle and shift Gearcase Lubricant
cables.
Draining
A WARNING
3 Gearcase lubricant may be under pressure 2
and/or hot. If plug is remove d from a
recently operated outboa rd, take precau-
tions to avoid injury.
1
2 IMPORTANT: Always check the fill le vel of the
gearcase lub ricant at the u pper plug befo re
removing the lower, drain/fill plug. A tie st rap can
1. Attachment pins, throttle and shift cables DRC6500R be used to check lubricant level.
2. Shift shaft grease fitting
3. Inner casings, throttle and shift cables
Shift the re mote control to the NEUTRAL/IDLE

position.
Install control cables.

Check proper throttle and shift function.
1
Propeller Shaft
Debris from the water can become lodged around
propeller shaft. Frequent inspection can minimize
000072
potential gearcase damage. 1. Tie strap
A WARNING If lubricant level is low, refer to GEARCASE LEAK

TEST on p. 288.
When servicing the propeller, always shift
the outboard to NEUTRAL, turn the key Remove the lubricant level plug, then the lubricant
switch OFF, and d isconnect the batte ry drain/fill plug, an d dr ain the lube from th e
cables at the battery. gearcase into a container.
Remove pro peller. Re fer to Propeller Hardware 1

Installation on p. 287.
Inspect bushing a nd blad e surfa ces. Re place

damaged or worn propellers.
Clean p ropeller shaft. Inspect pro peller shaf t
seals. Replace damaged or worn seals.
Apply Triple-Guard grease to entire length of pro-

peller shaft prior to installing propeller. 2
1. Lubricant level plug 39514
Reinstall propeller hardware and propeller. 2. Lubricant drain/fill plug
37
.ROUTINE SERVICE
LUBRICATION
Inspection Remove the lubricant level plug and th e lubricant

Inspect th e lu bricant a nd th e magnet s on the drain/fill plug.
plugs for metal chips. The presence of metal fuzz
Use Gearcase Filler, P/N 501882, to slowly fill the
can ind icate normal wear of the ge ars, be arings,
gearcase with HPF PRO lu bricant thro ugh th e
or shafts wit hin t he gea rcase. Met al chips can
drain/fill hole until it appears at the oil level hole.
indicate extensive internal damage.
IMPORTANT: Filling the gearcase too quickly
Inspect the lub ricant for water cont amination.
can cause air pockets and th e gearcase may not
Water can make the lubrican t milky in app ear-
fill completely.
ance. Ho wever, n ormal ae ration c an also c ause
the same appearance. Clean plug seal area and install the lubricant level
plug and new seal, then the lubricant drain/fill plug
To che ck f or wa ter co ntamination, put lu bricant
and new seal. Tighten plugs to a to rque of 60 to
into a glass con tainer. Allow the oil to se ttle for a
84 in. lbs. (7 to 9.5 N·m).
minimum of one hour to determine if there is an
abnormal amount of water in the oil.
1
If water is present, re fer to GEARCASE LE AK
TEST on p. 288.
2
Overheated lubricant will have a bla ck color and
burned odor.
Internal gearcase inspect ion is re commended

when lubricant is contaminated or shows signs of
failure.
Filling 1. Lubricant level plug 002386

Refer to the INSPECTION AND MAINTENANCE 2. Lubricant drain/fill plug
SCHEDULE on p. 16 for service freque ncy and

recommended lubricants. IMPORTANT: The recommende d gea r lubr i-
cants are formulate d for marine a pplications. Do
Secure the gearcase in a vertical position. not use automotive gear lubricants, engine oils, or
any other oil or grease.
38
.ROUTINE SERVICE
LUBRICATION
Trim and Tilt

A CAUTION
Correct flui d level must be maint ained to
ensure operation of the impact protection
built into the unit. 2
Check reservo ir fluid level every th ree yea rs or 1
every 300 operating hours.
• System capacity is approximately 21 fl. oz. (620
ml).
Three Ram System 004277
• Tilt the outboard and engage the tilt support. 1. Fill cap
Install the filler cap and tighten to a torque of 45 to

55 in. lbs. (5 to 6 N·m).
• Disengage tilt support.
• Cycle the un it at lea st five complet e cycles to
purge all air f rom the system. When cycling the
unit, hold the trim switch ON a n additional 5 to
10 seconds after the unit reaches the end of its
1 travel before activa ting the switch in th e opp o-
site direction.
1. Tilt support bracket 002279
• Remove filler cap and check fluid level.

• Three Ram Syste m–Add Power Trim/Tilt Fluid
or GM Dexron II, as needed, to bring level to the
bottom of the fill plug threads.
39
.ROUTINE SERVICE
SPARK PLUGS
SPARK PLUGS Apply Triple-Guard grease to th e ga sket surface

of the spark plug. Install spark plug and tighten to
Spark plu gs shou ld be removed and exa mined a torque of 15 ft. lbs. (20 N·m).
periodically. Replace worn , fou led or d amaged
spark plugs. If the mark is in unshaded area do not tighten any-
more.
Use only recommende d spark plugs with the cor-
rect gap setting.
Spark Plug, Champion 1 2
QC8WEP @ 0.028 ± 0.003 in. (0.76 mm)
• Remove spark plugs and inspect condition.

• Set spark plug gap on new, replacement spark
plugs.
• Mark spark p lugs for gro und elect rode orienta-
tion.
• Apply Electrical Grease to the ribbed p ortion of Spark Plug Indexing Diagram 004294
the sp ark plug ceramic an d to t he opening of 1. Unshaded area
2. Shaded area
the spark plug cover to prevent corrosion.
• Install spark plugs using “indexing” procedure. If the ma rk is in the shaded area, reset torq ue
wrench to 30 ft. lbs. (41 N·m) and continue to turn
Indexing until the mark is in the unshaded area.
Spark p lug indexing position s the groun d ele c-
trode of the sp ark plug opp osite the fuel injector If the mark does not rea ch the unsh aded ar ea
nozzle. before the torque of 30 ft. lbs. (41 N·m) is reached,
the spark plug cannot be indexed for that cylinder.
Put an in k mark on the cera mic of the spark plug Try another sp ark plug an d repe at th e ste ps
in line with the OPEN sid e of the ground ele c- above.
trode. Th is mark will be used to orient the sp ark
plug with the OPEN sid e of the ground electrode
facing the fuel injector.
2 1
1. Ink mark 000758

2. Open side
40
.ROUTINE SERVICE
FUEL AND OIL SYSTEMS
FUEL AND OIL SYSTEMS Air Silencer

The air silencer on Evinrude outboards maximizes
Routine replacement of fi lters reduces the possi-
air flow while minimizing noise.
bility of f oreign mate rial restricting the incoming
fuel or oil supplies.
Replacement filter elements are available through
2
Evinrude/Johnson Genuine Parts.
Fuel Filter
Evinrude E-TEC V-model outboards are equipped
with a water-sensing, water-se parating fuel filter .
Refer to FUEL COMPONENT SER VICING on
p. 143.
004218
Routine cleaning of the air silence r is recom-

mended to remove any accumulation of debris.
1
Hoses and Connections
Check cond ition of all hoses and con nections in
both the fuel and oil systems:
• Visually inspect all components.
1. Water-separating fuel filter 005022 • Observe all clamp s, hoses, a nd co nnections
while outboard is running.
Oil Filters and Oil Reservoir • Replace all damaged components.
• Repair all leaks.
Perform visual inspections to identify oiling system
leaks. Make certain the oil t ank is filled a nd oil
supply is not contaminated. A WARNING
Serviceable oil filters are locate d in th e oil inje c- Failure to check for fue l lea kage could
tion tank, and in the oil supply line before the oil lift allow a leak to go undetec ted, resulting in
pump(s). fire or explosion.
1 2
1. Filter, oil supply line 004250

2. Filter, oil injection tank 42785
41
.ROUTINE SERVICE
EXHAUST PRESSURE FITTING
EXHAUST PRESSURE With key ON, outb oard NOT running, the exhaust
pressure sensor reading should be close to zero.
FITTING With the outboard running, make sure the exhaust
pressure reading chang es wit h thrott le settin g.
The exh aust pressure fitting is t hreaded into the This reading will vary, based on actu al outboa rd
adapter housing and protrudes into the inner exhaust pressure conditions.
exhaust.
If the exhaust pressure rea dings are not as
described, clean or replace exhaust pre ssure fit-
tings.
1
1. Exhaust pressure fitting 005026
2
A hose is routed from this fitting to t he EMM. Due
to carbon accumulation in the exhaust, this fitting
must be periodically de-carbonized or replaced. Engine Monitor Screen 008566
1. Barometric pressure reading
Operation Test 2. Exhaust pressure reading
Use the Evinrude Diagnostics sof tware Monitor Cleaning

screen to confirm:
• barometric pressure reading; and Cleaning with Engine Tuner maintenance product
can dissolve carbon build-up.
• changes in exhaust pressure reading.
Spray Engine Tuner through the fitting and allow it
With key ON, outbo ard NOT runn ing, make sure
to soak for four to six hours.
the barometric pressure readin g reflect s actu al
atmospheric conditions. A WARNING
If barometric pressure reading is inaccura te, Wear safety glasse s to avoid personal
remove exhaust/barometric pre ssure hose fro m injury, and set compressed air pressure to
EMM. Retest and observe engine Monitor screen. less than 25 psi (172 kPa).
If b arometric p ressure read ing is accurat e with
hose remo ved, replace hose and diaphrag m
assembly. and inspect ex haust fitting for re stric- Use comp ressed air to blow thro ugh the fitting.
tion. Limit the air pressure to 25 psi (170 kPa). Confirm
movement of air through fitting.
IMPORTANT: Fitting does restrict air move-

ment.
Replace exhaust press ure fittings that are

blocked and cannot be decarbonized.
42
.ROUTINE SERVICE
ANTI-CORROSION PROTECTION
ANTI-CORROSION Testing Procedure – Continuity

Connect ohmmeter leads between engine ground
PROTECTION and anode surface.
Sacrificial Anodes
Galvanic corrosion occurs in fre sh or salt wa ter. 2
Salt, brackish, and polluted water can accelerate
corrosion. “Sacrificial” anodes are intended to pro-
tect the underwater metal components of the out-
board from galvanic corrosion.
Outboards are equ ipped with three sacrificial

anodes. 1
1. Meter lead to anode 000677
1 The mete r sho uld show little or no re sistance. If

resistance is high, check the following:
• Remove the an ode and clean the area where
3 the anode is installed
• Clean the mounting screws
• Install the anode and test again.
2 Metallic Component Protection

Protect metal components on outboards from cor-
rosion. Use the following product s to minimize
1. Stern bracket anode DR5082 corrosion:
2. Propeller shaft bearing housing anode
(inside of gearcase housing) • Anti-Corrosion Spray provides a heavy , waxy
3. Gearcase housing anode coating to protect components
• “6 in 1” Multi-Purpose Lubricant provides a thin
Visually inspect ano des and metal co mponents film of anti-corrosion protection.
below water level. Erosion of anode s is normal
and indicates the anodes are functioning properly. Exterior Finishes
IMPORTANT: Anodes that are no t eroding ma y Maintain the outboard’s ext erior finish to preve nt
not be properly grounded. Anodes and the mount- corrosion and reduce oxidation:
ing screws must be clean an d tig ht for effective • Use a utomotive wa x to prot ect the outboa rd’s
corrosion protection. exterior finish from oxidation
• Clean regularly using clean wa ter and mild
For best anode performance: detergent soap
• Replace all anodes that have eroded or disinte- • Touch-up damage to painted surfaces promptly.
grated to two-thirds of their original size • Protect moving compo nents with app ropriate
• Do not p aint or app ly pro tective co atings to lubricants.
anodes or anode fasteners
• Avoid using metal-based antifouling paint on the
boat or outboard.
43
.ROUTINE SERVICE
STORAGE
STORAGE Software Control Method

Winterization can also be run using Evinrude
IMPORTANT: DO NOT start outboard without a Diagnostics so ftware. With the outb oard ru nning,
water supply to the outbo ard’s cooling system. start the process at the Settings/Adjustments
Cooling system a nd/or powerhead damage could screen and follow the instructions.
occur.
Fuel System Treatment

Stabilize the bo at’s fuel sup ply with
Evinrude/Johnson 2+4 Fuel Conditioner following
the instructions on the container.
Internal Engine Treatment 1

Remove th e propeller , attach gard en hose to
flushing port and turn on water.
Evinrude E-TEC models are designed to be se lf-

winterizing using either of the following methods: 1. Winterization start button 008564
IMPORTANT: Engine MUST be in NEUTRAL

throughout these procedures.
Throttle Control Method

• Mechanical Remote Controls: Advance t hrot-
tle control to 1/2 throttle (50%) position and then
start the outboard. All four SystemCheck lights
will turn on and the outboard will run at id le
speed. 008565
• ICON Remote Controls: Tu rn M aster
Power/Key Switch ON. Press the N switc h. After the o utboard shuts itself off, turn key switch
Advance the co ntrol lever to 1/2 throttle (5 0%) OFF, then detach garden hose.
position and t hen st art the outb oard. All four
IMPORTANT: When f inished, l eave t he out-
SystemCheck lights will turn on an d the out-
board in ve rtical po sition long enough to com-
board will run at idle speed.
pletely drain the powerhead.
• After ap proximately 15 seco nds, the System-
Check light s will go of f. Move thro ttle to IDLE
position. SystemCheck lights will light again.
• Wait ano ther 15 seconds. SystemCheck light s
will go of f. At this poin t, advance thrott le to
FULL (in neutral). SystemCheck lights will flash,
indicating that outboard is in winterize mode.
• Outboard will automatically go to fast idle and
fog it self. Allow outb oard to run un til it shut s
itself off (about one minute).
IMPORTANT: If SystemCheck lights do not

flash, or ou tboard run s above fast id le, immed i-
ately tu rn of f ou tboard and st art the procedure
again.
44
.ROUTINE SERVICE
STORAGE
Digital Gauge Method Additional Recommendations

The ICON Pro 5 inch and I-Command 3.5 inch • Top off oil reservoir.
digital gauges provide a winterize feature for 2008 • inspect the fuel filter. If there is debris in the fuel
and newer V4 and V6 models. filter, it must be replaced.
• Replace gearcase lubricant.
Use the “Mo de” butto n ( ICON Pro 5 inch), or
“Menu” bu tton ( I-Command 3.5 inch ) to access • Remove and inspect propeller. 2
the winterize feature. • Clean and grease propeller shaft.
• Blow water from ge arcase speedometer pickup
system (gearcase speedometer models only).
• Lubricate all grease fittings and linkages.
• Inspect ou tboard, st eering system, and co n-
trols. Repla ce all damaged and wo rn compo-
nents. Refer to man ufacturer’s and lubricatio n
recommendations.
• Touch up p ainted surfaces as nee ded. Coat
outer painted surfaces with automotive wax.
• Remove ba ttery(s) from boat. S tore in a cool,
dry location. Periodically charge battery(s) while
1 stored. Ref er to manuf acturer’s mainte nance
ICON Pro 5 inch Digital Gauge 008686
recommendations when servicing batteries.
1. Mode button • Store outboard in upright (vertical) position.
• Check for fuel leakage.
A WARNING
Failure to check for fue l lea kage could
allow a leak to go undetec ted, resulting in
fire or explosion.
1
I-Command 3.5 inch Digital Gauge 008191

1. Menu button
• Refer to the digital gauge user’s guide for com-

plete instructions.
45
.ROUTINE SERVICE
PRE-SEASON SERVICE
PRE-SEASON SERVICE SUBMERGED ENGINES

If the ou tboard was re moved fro m th e boat for Once a n outbo ard has been submerged in fresh
storage, make sure it is rein stalled with facto ry or salt water , it must be serviced with in three (3)
specified hardware. Refer to the Predelivery and hours o f recove ry. Immed iate service can mini-
Installation Guide. mize the corrosive affect that air has on the pol-
ished surfaces of the crankshaft, connecting rods,
Outboard Mounting Bolts and internal powerhead bearings.
• Check and re-tighten outb oard mou nting bolts
to a torque of 40 ft. lbs. (54 N·m). IMPORTANT: If outboa rd ca nnot b e st arted or
serviced immediately, it should be resubmerged in
Gearcase Lubricant fresh water to avoid exposure to the atmosphere.
• Check the lubricant level.
• Inspect g earcase for leak s. If leak is apparent,
Engine Dropped Overboard
pressure and vacuum test gearcase. (Not Running)
• Repair gearcase as needed. Disconnect the battery cables at the battery.
Battery(s) Rinse powerhead with clean water.

• Replace batteries that cannot be charged. Remove spark plug leads and spark plugs.
Power Trim and Tilt Place o utboard in hor izontal po sition (cylinder
• Remove filler cap and check fluid level. heads do wn). Slowly rot ate flywheel in a clock-
• Inspect the power trim and tilt unit for leaks. wise rotation to work all water out of powerhead.
Repair as needed.
IMPORTANT: If sa nd o r silt may h ave entered
Operational Checks the outbo ard, DO NOT a ttempt to st art it. Disas-
semble and clean.
• Refer to OPERATIONAL CHECKS on p. 32
• Steering system Disassemble all electric al connectors. Clean con-
• Remote controls nectors and terminals, and tre at with water dis-
• All other accessories and instrumentation placing electrical spray. Apply Electrical Grease to
terminals prior to reassembly . Coat all expose d
Check Oil Injection Tank solenoid terminals and engine grounds with Black
• Inspect the oil tank for leaks. Neoprene Dip.
Check Fuel System Clean and inspe ct all electrical componen ts.
• Inspect entire fuel system for leaks prior to start- Replace dama ged or corroded compone nts prior
ing outboard. to returning the outboard to service. Electric start-
• Repair all leaks. ers sho uld be disassemb led, clea ned, flush ed
with clean water, and treated with water displacing
Water Pump electrical spray prior to reassembly.
• Make sure a steady stream of water flows from
overboard indicator. Disconnect fuel supply hose from outboard. Drain
and clean all fuel hoses, filters, and fuel tanks.
A WARNING
Disconnect o il supply h ose a nd oil retu rn hose
Failure to check for f uel le akage could from outb oard. Drain an d clean a ll o il h oses, fil-
allow a leak to go undete cted, resulting in ters, and oil tank assemblies.
fire or explosion.
Refill fuel tank with fresh fuel and oil tank with rec-
ommended oil.
46
.ROUTINE SERVICE
SUBMERGED ENGINES
Prime oil system and fue l system. Refer to FUEL Engine Dropped Overboard
SYSTEM PRIMING on p. 138 and OIL SUPPLY
PRIMING on p. 170. Make sure all oil injection
(Running)
hoses are clean and filled with oil. Follow the same procedures as Engine Dropped
Overboard (Not Run ning). However , if there is
Make sure h igh pressure fue l system doe s not
contain water. Flush as needed.
any binding when th e flywheel is ro tated, it may
indicate a bent connecting ro d and no attempt
2
should be made to start the outboard. Powerhead
Inject a small amount of ou tboard lubricant into
must be disassembled and serviced immediately.
spark plug holes and inst all new spark plug s.
Refer to Spark Plug Indexing on p. 40. Engine Dropped Overboard
Reinstall all removed or disconnected parts. (In Salt Water)
Use Evinrude Diagnostics software to: Follow th e same procedure s u sed for Engine
Dropped Overboard (Not Running) and Engine
• Start break-in oiling
Dropped Overboard (Runnin g). Disa ssemble
• Check fuel pump operation
and clean outboards that have been submerged in
• Check injector operation (fuel and oil) salt water for prolonged pe riods of time. Clean or
• Check timing (once ou tboard is ru nning at full replace electrical components as necessary.
operating temperature)
Run outboard below 1500 RPM for one-half hour.

Prolonged Submersion
(Fresh or Salt Water)
Outboards that have been dropped overboard and
not recovered immediat ely, must be service d
within three hou rs of recovery . Follow the same
procedures used for Engine Dropped Overboard
(Not Running) and Engine Dropped Overboard
(Running).
47
.ROUTINE SERVICE
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
48
ENGINE COVER SERVICE

TABLE OF CONTENTS
UPPER COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
LATCH HOOK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
UPPER COVER CAP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
LOWER COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 3
LOWER COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
LOWER COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
LATCH HANDLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
TRIM SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
49
UPPER COVER SERVICE
UPPER COVER SERVICE Upper Cover Cap Replacement

Place new upper cap into position.
Latch Hook Installation
Place hook into position on bracket.
006815
006962 Tighten self-tapping screws to a torque of 24 to 36

in. lbs. (2.7 to 4 N·m).
Apply Ultra-Lock to screw threads. Tighten screws
to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
1
1
1. Upper cap screws 006964
006963
50
LOWER COVER SERVICE
LOWER COVER SERVICE Lower Cover Installation

Install t he lo wer engine covers and tighten all
Lower Cover Removal screws to a torque of 24 to 36 in. lbs. (3 to 4 N·m).
Remove lower engine cover screws.
1
1
1
3
1
1. Lower cover screws 004122

1. Lower cover screws 004122
Connect trim/tilt switch connector.
Loosen po rt side cover slightly, an d d isconnect
trim/tilt switch con nector. Then, remove port and
starboard covers.
005246
005246
51
LOWER COVER SERVICE
Latch Handle Installation Trim Switch Installation

Apply a light coat of Triple-Guard grease to latch Place switch into position through cover.
handle shaft. Insert handle into lower cover.
006746
1. Triple-Guard grease 006827
Install nut on switch. Tighten nut to a torque of 10
Apply Ultra-Lock to sc rew threa ds. Pl ace spring to 16 in. lbs. (1 to 2 N·m).
washer and ho ok in to positio n and tig hten screw
to a torque of 180 in. lbs. (20 N·m).
006747
006821 Install electrical connector. Refer to CONNECTOR

SERVICING on p. 122.
006748
52
ENGINE MANAGEMENT MODULE (EMM)

TABLE OF CONTENTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
EMM INPUTS AND OUTPUTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INTERNAL SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
EMM TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
55 V CIRCUIT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
12 V CIRCUIT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5 V CIRCUIT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
BAROMETRIC PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4
EXHAUST PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
EXTERNAL SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
ENGINE TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
CRANKSHAFT POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
KNOCK SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
NEUTRAL/SHIFT INTERRUPT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INTERNAL EMM FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
START ASSIST CIRCUIT (SAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ROM VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
IDLE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
RPM LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
NEUTRAL RPM LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ENGINE MONITOR AND WARNING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
FAULT CODE CREATION AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ENGINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
S.A.F.E. WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
SHUTDOWN MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
DIAGNOSTIC SOFTWARE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
STATIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
DYNAMIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
STORED SERVICE CODES (FAULTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
HARD FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PERSISTENT FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
STATIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DYNAMIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
OIL CONTROL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
TPS CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
FUEL INJECTOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
REPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SOFTWARE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
EMM TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
EMM SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
53
DESCRIPTION
DESCRIPTION • Stator to EMM connections; one 6-pin AMP and

J2 connector.
The Engine Manage ment Mo dule (EMM) is a
water-cooled e ngine controller . It contro ls many
1
outboard systems in cluding alternato r ou tput for
the 12 V and 55 V circuit s. Operating vo ltage is
supplied to the EMM by the stator.
This section discusses the functio ns of the EMM 2

and it s variou s in ternal and externa l sen sors. It
also de scribes using Evinrude Diagnostics sof t-
ware to retr ieve and adjust service information
saved in the EMM 3
EMM Functions 1. J2 connector 004197
2. J1-A connector
The EMM co ntrols the following pro cesses and 3. J1-B connector
functions:
• Alternator output; 55 V and 12 V LED Indicators
• Start Assist Circuit (SAC) voltage boost The EMM has LED indicato rs located next to the
• Fuel and ignition timing and duration electrical conn ectors that pro vide informatio n
• Fuel injector activation related to various electrical circuits.
• Oil injector pump activation
• Electric fuel pump control IMPORTANT: LED 1 is to ward the top of t he
• Idle speed control outboard (Closest to EMM J2 connector).
• RPM limiter
• Electrical circuit monitoring
• Service code creation and storage
• Warning system activation
• ROM verification, self-test 1
• Choke-less cold starting
• Output of diagnostic data
• Tachometer signal
• RPM profile and engine hours
• Oiling ratios
• Shift interrupt function 1. LED indicators 004198
• Anti-knock compensation
When the ignition key is turned ON, LEDs 1, 3 and
EMM Connections 4 should light, indicating that the SAC circuit, sen-
sor circuits, and the stop circuit are working.
IMPORTANT: EMM connections an d wiring
must be clean and tigh t. Impro per ele ctrical con- As the outbo ard is being started, all four LEDs
nections can damage the EMM. DO NOT r un the should light and then go off in sequence. If any of
outboard with loose or disconnected wiring. the LEDs d oes NOT light during st arting, refer to
EMM LED INDICATORS on p. 78.
Make sure EMM connections are clean and tight.
• Engine wire harness to EMM connectors; J1-A, When the outboard is running, all LEDs should be
J1-B, J2 off. If any LED is lighted while the outboard is run-
ning, refer to EMM LED INDICATORS on p. 78.
54
EMM INPUTS AND OUTPUTS DIAGRAM
EMM INPUTS AND OUTPUTS DIAGRAM

12 13 11 10 9 5 6 7 8
4 12
ABC
A B
1 2 2 1
345
CBA
14
4
INPUTS
3
J2
B
A
+ 1
2
3
2 4
15 12
J1-A 25
26
1 TnT
J1-B
OUTPUTS
+
2 1
A
C
B
30 40
20
50
10
60
0
x 100 70
RPM
3550
A B
IT
EX
U
P
S
DO GE
WN PA TE R
EN
M EN U
22 23 21 20 24 18 17 16
19
008365
1. Engine Management Module (EMM) 10. Oil Pressure Sensor (component of 18) 19. Rear Oil Injector and Manifold
2. Battery (12 volt) 11. Engine Temperature Sensor(s) 20. Ignition Coil
3. Key switch (switched B+, start signal) 12. Water in Fuel Sensor / Fuel Filter 21. Fuel Injector
4. Stator 13. Trim / Tilt Sending Unit 22. Tachometer/SystemCheck Gauge
5. Knock sensor 14. Water Pressure Sensor w/adaptor harness 23. I-Command (CANbus) Display
6. Crankshaft Position Sensor (CPS) 15. LED indicators 24. Diagnostic Connector
7. Throttle Position Sensor (TPS) 16. Fuel Pump (high pressure) 25. Trim and Tilt Relay Module
8. Shift Interrupt Switch 17. Starter Solenoid 26. Oil Level Switch
9. Air Temperature Sensor (AT) 18. Oil Injection Pump and Manifold
55
INTERNAL SENSORS
INTERNAL SENSORS If sensor reads less than -67°F (-55°C) or greater

than 31 1°F (155°C) a senso r circu it fault is
Sensor inp uts and inte rnal EMM contro llers are detected and the EMM:
used to control outboard operation. Use Evinrude Stores service code 23
Diagnostics software to troubleshoot the sensors.
EMM LED 3: OFF (Cranking)
Refer to t he EMM Servic e Code Chart at the
back of this manual for a comp lete list of all EMM LED 3: ON (Running)
engine fault codes.
Internal sensors are NOT serviceable. Re pro-

55 V Circuit Sensor
gramming or replacement ma y be required to Monitors the EMM’s 55 V alternator circuit.
resolve EMM related issues.
If system voltage exceeds 57 volts, the EMM:
EMM Temperature Sensor Activates S.A.F.E.
Monitors the temperature of the fuel injector driver Stores service code 18
circuits. EMM LED 1: ON (Running)
Engine Monitor CHECK ENGINE display: ON
If the EMM temperature exceeds 176°F (80°C) or
the circuit fails, the EMM:
If system volt age is less than 45 V between 5 00
Activates S.A.F.E. and 1000 RPM, or is le ss than 5 2 V above 10 00
Stores service code 25 RPM, the EMM:
EMM LED 4: ON (Running)
Activates S.A.F.E.
Engine Monitor TEMP display: ON
Stores service code 17
If EMM temp erature excee ds 212°F (100 °C) or
the circuit fails, the EMM:
Activates SHUTDOWN
12 V Circuit Sensor
EMM LED 4: FLASHING Monitors the EMM’s 12 V alternator circuit.
Engine Monitor TEMP display: FLASHING If battery voltage exceeds 15.5 volts, the EMM:
IMPORTANT: The outboard will not restart until EMM LED 1: ON (Running)
the engine cools below 212 °F (100°C) and the
Engine Monitor LOW BATTERY display: ON
EMM temperatu re returns to normal. Re fer to
SHUTDOWN MODE on p. 63.
If battery volt age is less tha n 12 V below 20 00
If EMM temperature is less tha n -22°F (-30°C) or RPM, or is less than 12.5 V above 2000 RPM, the
the circuit fails, the EMM: EMM:
Stores service code 24 Stores service code 26
EMM LED 3: OFF (Cranking) EMM LED 1: ON (Running)
EMM LED 3: ON (Running) Engine Monitor LOW BATTERY display: ON
56
INTERNAL SENSORS
5 V Circuit Sensor Exhaust Pressure Sensor

Monitors the EMM’s 5 V sensor circuit. The exhaust pressure se nsor mon itors exhaust
pressure during all running conditions to compen-
If sensor voltage is less than 4.75 volts, the EMM: sate for engine loads.
If the sen sor reads less than -85 in. wa ter, or
EMM LED 3: OFF (Cranking) greater than 85 in. water , or the senso r or circuit
EMM LED 3: ON (Running) fails, the EMM:
Barometric Pressure Sensor EMM LED 3: OFF (Cranking)
Supplies the EMM with barometric pressure read- EMM LED 3: ON (Running)
ing to compensate for changes in a ltitude and air
density. 4
If exhaust pressure is less than 40 in. water , the
If the BP sensor reads less than 13 KPa or greater EMM:
than 119.0 KPa, or the senso r or circuit fails, the Stores service code 88
EMM: EMM LED 3: OFF (Cranking)
Stores service code 44 EMM LED 3: ON (Running)
If the BP se nsor reads less than 70 KPa, the If exhaust pressure is gre ater than 80 in. wate r,
EMM: the EMM:
Stores service code 45 Stores service code 89
If the BP sen sor reads greater than 105 KPa, the EMM LED 3: ON (Running)
EMM:
57
EXTERNAL SENSORS
EXTERNAL SENSORS If cylinder he ad temperature exceeds 194°F

(90°C) above 2000 RPM for 3 seconds, the EMM:
Sensor inp uts and inte rnal EMM contro llers are Activates S.A.F.E.
used to control outboard operation. Use Evinrude
Diagnostics software to troubleshoot the sensors.
Refer to t he EMM Servic e Code Chart at the If cylinder he ad temperature exceeds 248°F
back of this manual for a comp lete list of all (120°C) for 3 seconds, the EMM:
engine fault codes. Activates SHUTDOWN
The EMM provides a 5 V DC signal for sensor cir- Stores service code 31
cuits. It mon itors all se nsor vo ltage inp uts and EMM LED 4: FLASHING
compares them to pred etermined accept able Engine Monitor TEMP display: FLASHING
ranges. Inputs tha t fall outside of the accept able
range create service codes. The outboard will not restart until the engine tem-
perature returns to normal. Refer to SHUTDOWN
Air Temperature Sensor MODE on p. 63.
The air t emperature sensor mo nitors the air te m-
perature at the throttle body. If sensor values are le ss than -13 °F (-25°C), or
greater than 329°F (165°C), the EMM:
If the A T senso r volt age is ou t of t he expected
Stores service code 41 (port sensor)
range, or the sensor or circuit fails, the EMM:
Stores service code 67 (stbd sensor)
Stores service code 47, 48, or 49 EMM LED 3: OFF (Cranking)
EMM LED 3: OFF (Cranking) EMM LED 3: ON (Running)
If sensor values are below -4°F (-20°C), the EMM:
Engine Temperature Sensor Stores service code 42 (port sensor)
Monitors cylinder head temperature. Stores service code 68 (stbd sensor)
If cylinder h ead temperatu re exceeds 212° F EMM LED 3: OFF (Cranking)
(100° C) below 2000 RPM, the EMM: EMM LED 3: ON (Running)
Activates S.A.F.E.
If cylinder head does not rea ch operating temper-
ature (122°F / 50°C belo w 1000 RPM) in 1 0 min-
Stores service code 70 (stbd sensor) utes, the EMM:
If cylinder h ead temperatu re exceeds 185°F
(85°C) above 2000 RPM for 60 se conds, the EMM LED 3: ON (Running)
EMM:
58
EXTERNAL SENSORS
Oil Pressure Sensor Throttle Position Sensor

The oil pressure sensor monitors oil pressure in The throttle position sensor receives a voltage sig-
the oil distribution manifold. nal from the EMM. As the th rottle lever is rotated,
the EMM receives a return voltage signal through
If the senso r d oes not de tect pressure f or 1 50 a second wire. T his signal increases as the TPS
pump cycles (3.3 L mod els), or 75 pump cycle s lever is advanced. A third wire provides a ground
(3.4 L models), the EMM: circuit back to the EMM.
Activates S.A.F.E.
If TPS voltage is greater than 0.65 V when the key
Stores service code 38 is turned to ON, the EMM:
Creates service code 11
Engine Monitor NO OIL display: ON
If the outboard is started, the code is saved.

4
If o utboard has be en run fo r more th an 5 hou rs
with NO OIL faults (codes 34 & 38), the EMM: If the key ON voltage is greater than 0.78 V when
Activates SHUTDOWN the engine is started, speed is limited to idle.
Stores a service code 33 If code 11 is present as both a Active Fault and a
EMM LED 4: FLASHING Occurred Fau lt, ref er to Control Cable Inst alla-
Engine Monitor NO OIL display: FLASHING tion on p. 19.
If the TPS or TPS circuit fails (less than 0.14 volts

IMPORTANT: The out board will re start for one or greater than 4.92 volts), the EMM:
minute interva ls until prob lem is re solved a nd
code is cleared. To clear code use t he diagnostic Stores service code 12
software program. Limits engine RPM to IDLE
If the sensor reads out of the expected range, or
the sensor or circuit fails, the EMM:
IMPORTANT: When a TPS circuit fault has
been detected, the outboard will no t accelera te
If the senso r circuit indicat es below expected above idle speed. To reset, stop the outboard and
range (<.4 V), the EMM: correct the fault.
Stores service code 72 If the TPS circuit reads below 0.2 volts, the EMM:
If t he se nsor circuit indicates above expected
range (> 4.6 V), the EMM: EMM LED 3: ON (Running)
If the TPS circuit reads above 4.85 volt s, the
EMM:
59
EXTERNAL SENSORS
Crankshaft Position Sensor Neutral/Shift Interrupt Switch

Ribs spaced on the flywheel mark crankshaft posi- A swit ch mounted on the po werhead signa ls t he
tion. As the ribs p ass th e magnetic field of the EMM when the sh ift linkage is moved from FOR-
CPS, an AC volt age signal is gene rated. The WARD or REVERSE into NEUTRAL.
EMM uses this sig nal to identify cranksh aft posi-
tion and speed, generate a tachometer signal, and A cam on the powerhe ad shift arm closes the
control fuel and ignition timing. switch in NEUTRAL , comp leting a g round circuit
to the EMM. This signal is used to control:
If the sensor is damaged or the signa l is intermit- • Neutral RPM limit
tent: • Shift Interrupt function.
• Below 2000 RPM: 5 occurrences
• Above 2000 RPM: 1 occurrences The shift interrupt function shuts off fuel and spark
the EMM: to three cylinders for approximately one second to
reduce drivetra in lo ads a nd ease shif ting, th en
Stores service code 16 immediately restores normal eng ine op eration.
EMM LED 2: OFF (Cranking) The switch mu st be released to its open position
EMM LED 3: ON (Running) before the shift interrupt function can be activated
again. This circuit does no t fun ction a bove 250 0
Approximate air gap between CPS and flywheel RPM.
encoder ribs is 0.073 (1.85 mm). 1
Use the Evinrude Diagnostics sof tware Monitor
screen to check CPS operation. Th e sof tware
should show an RPM reading while the outboard 2
is cranking. If the CPS o r its circuit fails, no RPM
reading will appear and the outboard cannot run.
Knock Sensor 1
Knock sensors (one per cylinder head) detect the
presence of knock (pre-ignition or detonation) dur-
ing the combustion cycle. 1. Switch, neutral/shift interrupt 008366
2. Cam
When knock is dete cted, the EMM tempo rarily
increases fuel flow and retards ignition timing for If t he switch is stuck in th e close d position, t he
the affected cylinder. EMM:
If knock continues, the EMM: Stores service code 28
Activates S.A.F.E. EMM LED 3: ON (Running)
Stores service code 1-6 (code indicates cyl)
If the sensor circuit is OPEN, the EMM:

60
INTERNAL EMM FUNCTIONS
INTERNAL EMM RPM Limiter

This featu re of EMM pr ogramming prevents
FUNCTIONS engine d amage due to excessive RPM. At 625 0
RPM, fuel and ignition to the cylinders is shut off.
Start Assist Circuit (SAC) Normal ope ration resumes when engin e RPM
When the ignition key is ON, the EMM Start Assist returns to the specified range.
Circuit (SAC) boost s battery volt age (12 V) to
30 V on the system (55 V) circuit. Neutral RPM Limiter
If the SAC circuit current exceeds 2 Amps, or if the This feature prevents engine dama ge due to
SAC voltage is less than 20 V, the EMM: excessive RPM if accelerated in NEUTRAL. Neu-
tral engine speed is limited to 1100 RPM.
EMM LED 1: ON (Running) Engine Monitor and Warning 4
Systems
ROM Verification Refer to ENGINE MONITOR SYSTEM on p. 62.
The EMM perfo rms a se lf-test of programming Refer to S.A.F.E. WARNING SYSTEM on p. 63.
every time it is tu rned ON. Service code 15 ind i-
cates a programming (software) issue. Re pro- Refer to SHUTDOWN MODE on p. 63.
gram the EMM with the correct software program
to correct the problem. Fault Code Creation and Storage
Refer to the EMM Service Code Chart at the
Idle Controller back o f this ma nual for a complete list of all
The idle controller reacts to engine operating con- engine fault codes.
ditions. Fu el an d ign ition timings are a ltered to
maintain a specific RPM when e ngine is cold or
warm. The contro ller is inactive when TPS is
advanced from idle position.
61
ENGINE MONITOR SYSTEM
ENGINE MONITOR The EMM activates the warning horn and gau ge
displays as follows:
SYSTEM • LOW OIL means that oil in the tank is at reserve
level (about 1/4 full).
All re mote controlled outboards, 40 HP a nd • NO OIL indicates the oil tank is empty, or the oil
above, must be equipped with an engine monitor- system is damaged.
ing system to warn the ope rator of conditions that • WATER TEMP or HOT ind icates an engine or
could damage the outboard. EMM overheat condition.
The eng ine monitor system includ es sensors on • CHECK ENGINE or FAULT is used to ind icate
the outboard and oil tank, a warning horn, a dash- other fault conditions identified by the EMM.
mounted display, and related wiring. Refer to the EMM Servic e Code Chart at the
The out board’s EMM sen ds information about back of th is manual for a co mplete list of all fault
monitored functions to: codes.
• SystemCheck gauges
• An I-Command or ICON display
System Self-Test
• EMM LED indicators. During engine start-up, pause with the key switch
in the ON position. The horn se lf-tests by sound-
IMPORTANT: Operating the outboa rd without ing a ha lf-second beep . SystemCheck g auges
an engine monito r will void the warranty for fail- self-test by turn ing the indicator lights on simu lta-
ures related t o mon itored function s. For informa- neously, then off in sequence.
tion about bo at mount ed Information Displa y
System o ptions, refer to th e curren t Predelivery Note: The warning horn does NOT sound in an
and Installation Guide included with the se rvice I-Command installation.
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. Ground ing the appropriate light circuit wire
will turn the light o n, but the ho rn will no t sound.
Refer to SystemCheck CIRCUI T TESTS on
p. 106.
Engine Running
All warning circuits are active wh en the eng ine is
Typical I-Command and SystemCheck gauges 007988
running. Th e horn circu it is active when engin e
speed exceeds 500 RPM.
Engine monitor warnings activate the horn for 10

seconds and the appro priate gauge light for a
minimum of 30 seco nds. If the failure is mome n-
tary (for example, oil moving in the tank), the light
will remain ON for the full 30 seconds befo re
going out. If the fault continues, the light remains
ON until the key is turned OFF or the failure is cor-
rected. The warning will reoccur at the next start-
up if the problem is not corrected.
62
S.A.F.E. WARNING SYSTEM
S.A.F.E. WARNING SHUTDOWN MODE

SYSTEM Outboard “sh utdown” will occur if specific fault s
are detected by the EMM.
The S.A.F.E. (Speed Adjusting Failsafe Electron-
ics) warn ing system alert s t he oper ator and pro- Conditions that initiate shutdown
tects a gainst engine d amage fro m t he fo llowing Code 29 Excessive EMM temperature
abnormal conditions:
Code 31 Excessive engine temperature
Code 17 Alternator 55 V below expected range Code 33 Excessive NO OIL condition
Code 18 Alternator 55 V above expected range Code 57 High RPM with low TPS setting
Code 25 EMM temperature above expected
range
Code 34 Oil injector open circuit
Code 57 occurs when the EMM d etects abn or-
mally high RPM relative to the TPS positio n. This
4
Code 36 Oil injector open circuit (cylinder oil condition could be cause d by u ncontrolled fue l
pump, 3.4 L models only) entering the co mbustion cycle. Before removin g
Code 38 No oil pressure feedback the code and ST ARTING the outbo ard, find and
Code 40 Cylinder head temperature above repair the cause.
expected range–low speed • Perform Fuel System Pressure Test on p. 139.
Code 43 PORT Cylinder head temperature Check for external fuel leakage that could allow
above expected range fuel and/o r vapo r to enter th e engine throug h
the air intake.
Code 69 STARBOARD cylinder head tempera-
• Check for internal fue l le akage from a le aking
ture above expected range
injector or vapor separator vent hose.
Code 70 Cylinder head temperature above
expected range–low speed A WARNING
If t he eng ine sh uts OFF and the “CHECK
Activation ENGINE” ligh t or EMM SENSOR FAULT
When one of these conditions occurs, the EMM LED is flashing, the engine canno t be
interrupts fuel injector and ignition o peration, restarted. A hazardous fuel condition may
reducing engine speed to 1200 RPM. The warning exist which could resul t in a fire or explo-
horn sounds and an Engine Monitor message dis- sion.
plays. When S.A.F.E. is active, the engine will run
normally below 1200 RPM. Above 1200 RPM, the
engine will shake excessively.
Recovery
To recover from shu tdown mode, the EMM mus t
Recovery NOT detect the re lated fault at start-up. The o ut-
The engine will oper ate in S.A.F.E. as long as the board will not restart u ntil the cause of th e
fault condition exists. To recover normal operation, occurred service co de is resolved (cod e 29 and
two conditions must be met: 31) and the code is cleared using diagnostics soft-
ware (code 3 3 and 5 7). Then, the EMM mus t be
• Sensor or switch readings must be back with in
turned OFF and ON again.
limits
• The EMM must be reset—stop and restart IMPORTANT: Shutdown relate d to code 57 or
33 re quires the re moval of th e Occurred serv ice
code. Use Evinrude Diagnostics software to cle ar
a code 57 or 33.
63
DIAGNOSTIC SOFTWARE FUNCTIONS
DIAGNOSTIC Static Information

Refers to information viewed when the outboard is
SOFTWARE FUNCTIONS NOT runn ing. This include s manu facturing in for-
The EMM saves valuable info rmation abou t the mation.
outboard and its running history. This info rmation The outboard model and serial numbers displayed
can be used for trou bleshooting, fo r checking on th e Identity scree n must match the identifica-
parts in formation, and for ma king adjustme nts to tion label on the outboard swivel bracket.
the system.
Use Evinrude Diagnostics software, version 5.1 or

higher, and a laptop computer to access progra m
information.
IMPORTANT: For software help, refer to the

“Help” menu in the software.
Communication
Locate the diag nostic connector on th e engine.
Remove the cover and install the Diagnostic Inter-
face Cable (P/N 437955).
Identity Screen 008567
1 The serial number and cylinder location displayed

on the Injector Coefficients screen must match the
actual cylinder placement for each injector.
2
1. Cover 005021
2. Engine harness diagnostic connector
Connect the 9-pin connector of the interface cable

directly to the computer’s serial port.
The EMM must turn ON before it will communicate

with the computer.
Power is normally supplied to the EMM when the

key switch is ON. Swit ched B+ (12 V) ent ers the
EMM at pin 21 (purple) of the EMM J1-B connec- Injector Coefficients Screen 008568
tor.
The EMM is also turn ed ON when it begins to

receive AC volt age from the stator while the out-
board is being cranked.
64
Dynamic Information Active Faults

Dynamic information is viewed while th e outboard An active fault is a se rvice code th at cu rrently
is running. Change s in dat a, such as voltages or exists. Active faults become occurred faults only if
temperatures, are shown as they happen. the outboard is running.
Active Faults Review Screen 008585

Engine Monitor Screen 008566
Occurred Service Codes (Faults) Historical Faults

The Historical Faults screen keeps a history of all
Service codes are saved if an ab normal condition
previous occurred codes, including code number,
occurs while the outboard is running.
the number of times the event occurred, and oper-
The Occurred Faults scree n of the diagnostics ating hours of the last occurrence.
software shows the code nu mber, the number of
Historical faults cannot be erased.
times the event occurred, and operating hours of
first and last occurrences.
Static Tests
Static Tests allow dia gnostic testing o f system
components while the outboard is NOT running.
Occurred Faults Review Screen 008584
Static Tests Screen 008569
65
Ignition Test Dynamic Tests

Use the d iagnostics software to test each ignition Dynamic test s are pe rformed with the outboa rd
circuit. Refer to Static Ignition Test on p. 82. running.
Fuel Test
Use the diagnostics software to t est each fu el
injector circuit. Refer to Fuel Injector Static Test
on p. 85.
Oil Injector
Use the diagnostics software to t est the oil injec-
tion p ump circuit. Refer to OILING SYSTEM
TESTS on p. 173.
Fuel Pump
Use the diagnostics software to test the fuel pump
circuit. Refer to Fuel Pump Static Test on p. 85.
Overheat Dynamic Tests Screen 008570

This test is used to check the “ENG TEMP” or
“HOT” circuit of the Engine Monitoring system. Ignition Test
This test mo mentarily disables the ign ition and
Oil Fault fuel injection circuits to o ne cylinder. By d ropping
This test is used to check the “NO OIL” circuit of one cylinder, RPM and run ning q uality ch anges
the Engine Monitoring system. can be observed . Refer to DYNAMIC TESTS on
p. 77.
Check Engine
This test is used to check the “CHECK ENGINE” Fuel Test
circuit of the Engine Monitoring system. This test mo mentarily d isables one fu el in jector
circuit. By dropping on e cylinder , RPM and ru n-
Tachometer
ning qu ality change s can be observe d. Refer to
This test is used to check operation of the tachom- DYNAMIC TESTS on p. 77.
eter circuit.
Prime Oil
This test is used to cycle the oil injection pump for
priming the o iling syst em. Per form th is test with
outboard running to activate oil injection pump.
66
Oil Control Settings Powerhead Break-In

Use the diagnostic software to initiate break-in oil-
Set Oil Type ing. Brea k-in is a predetermined oiling program
The TC-W3 oil type setting is the standard setting that runs fo r two hours of outb oard op eration,
for all outboards. Set TC-W3 for: above 2000 RPM.
• Operation with all TC-W 3 outboard o ils includ-
ing XD30, XD50, or XD100
• Applications requiring maximum lubrication
• Extreme app lications (racing or harsh cond i- 1
tions)
The XD100 setting provide s an op tion to ru n the

outboard at a reduced oil injection rate. This set-
ting REQUIRES th e use of Evinrude XD100 out-
4
board lub ricant and is not re commended for all
applications.
Use the XD100 setting for:

• Conventional use (runabouts, cruisers) 1. Break-in oil setting 008108
• Moderate applications
1. Oil control setting 008571
A CAUTION
Running an Evinrude E-TEC outboa rd on
other grades of oil while set to the XD100
oil ratio will result in increas ed engine
wear and shortened outboard life.
67
Ignition Timing TPS Calibration

Use the Ignition Timing screen to check a nd TPS Calibration synchronizes throttle plate ope n-
adjust EMM timing. EMM timing must be synchro- ing with throttle position sensor voltage.
nized to crankshaft position.
Refer to TPS CALIBRATION on p. 113.
Refer to TIMING ADJUSTMENTS on p. 112.
1. TPS Calibration button 008571
Perform TPS Calibration after replacing or adjust-

008572 ing any throttle body or throttle linkage parts.
Check timing af ter any of the following proce- Fuel Injector Servicing
dures: All E-TEC fuel inje ctors use so ftware program-
• Powerhead replacement ming to compensate fo r variat ions in fuel flow .
• Crankshaft replacement Each injector a nd it s locat ion on the o utboard is
• Flywheel removal or replacement identified by the EMM. DO NOT inst all an injector
• CPS replacement without updating the compensation software.
• EMM replacement
• EMM software replacement To inst all a service injector, click th e “ Replace”
button on the Injector Coefficients screen and
IMPORTANT: Make su re the timing pointer is select the file for the replacement injector. Refer to
set and the outboard reaches operating tempera- Fuel Injector Service on p. 147.
ture before making adjustments.
008573
68
Reports Software Replacement

Engine rep orts provide service records and can Engine Manag ement Sof tware is loaded into th e
be used to document the running history of an out- EMM at the factory. Periodically, a new program
board. Reviewing this info rmation can help iden- may be available to enhance the opera tion of an
tify or resolve some service issues. outboard. Select Engine Software Update from
the Utilities menu and refer to the instructions pro-
Click the print button in a windo w of the diagnos- vided with the program.
tics software to print engine data, or to export the
information to a computer file.
1
1
4
2
1. Software Update button 008594
1. Print button
2. Print/Export options
008592 IMPORTANT: Software replacement requires
the use of Bootstrap Tool, P/N 586551. Install tool
between engine and boat harness key/stop switch
2 connectors as instructed by update program.
002383
Engine Report data files 008593
1. Exports button
2. Data files
69
EMM SERVICING
EMM Transfer EMM SERVICING

EMM Transfer is used to save engine history data
when the EMM must be replaced. IMPORTANT: If a n ew EMM i s b eing installed,
refer to EMM Transfer on p. 70.
Select EMM Data Transfer from the Utilities menu.
Select Perform Transfer From Memory and follow Removal
the instructions provided with the program.
Disconnect exh aust pressure hose and cooling
hoses from EMM.
1 Disconnect J1-A, J1-B, and J2 connectors.
Remove two EMM retaining screws.
1 1
1. Select EMM Data Transfer 008495

2. Select Perform Transfer From Memory
IMPORTANT: Whenever th e EMM is rep laced,

EMM timing must be synchronized to crankshaf t 1. EMM mounting screws 006967
position. Refe r to TIMING ADJUS TMENTS on
p. 112. Lift EMM away and to the starboard side.
70
EMM SERVICING
Installation
Align slots in starboard side of EMM case with iso-
lator mounts o n cylinder block. Slide EMM into
position.
2 1
1. EMM mounting slots 006968

2. Isolator mounts
Install two EMM retaining screws. Tighten screws

12 to 16 in. lbs. (1.5 to 2 N·m).
1 1
1. EMM mounting screws 006967
Install J1-A, J1-B, and J2 connectors.

Install exhaust pressure hose and cooling h oses.
Secure with tie straps.
71
NOTES
NOTES
Bulletins
Instruction Sheets
Other
72
SYSTEM ANALYSIS
SYSTEM ANALYSIS
TABLE OF CONTENTS
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
VISUAL INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
DIAGNOSTIC SOFTWARE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
OPERATIONAL INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
DYNAMIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CYLINDER DROP TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
FUEL CONTROL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INDUCTIVE AMP METER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
EMM LED INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
KEY ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5
RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
IGNITION OUTPUT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
REQUIRED IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
WIRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
CRANKSHAFT POSITION SENSOR (CPS) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
SYSTEM VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
STATIC IGNITION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
RUNNING IGNITION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
IGNITION CONTROL CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
CAPACITOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
FUEL DELIVERY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
FUEL PUMP STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
FUEL INJECTOR STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
RUNNING FUEL SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
73
SYSTEM ANALYSIS
DIAGNOSTIC PROCEDURES
DIAGNOSTIC Diagnostic Software Inspections

Before running the out board, use Evinrude Diag-
PROCEDURES nostics so ftware to review historical informatio n
saved in the EMM.
Visual Inspections
Inspect wiring and electric al connectio ns. Disas- Check the Active Faults and Occurred Faults
semble a nd clean all corrode d co nnections. screens for current se rvice codes. Correct any
Replace damaged wiring, con nectors, o r termi- problems and clear the codes before further tro u-
nals. Repair any shorted electrical circuits. bleshooting. Refe r to Occurred Servi ce Cod es
• Refer to ELECTRICAL HARNESS CONNEC- (Faults) on p. 65.
TIONS on p. 91. The occurred fault screen displays det ailed infor-
• Refer to WIRING DIAGRAM at the back of this mation about the operating con ditions of the
manual. engine at the time the code was set.
• Refer to CONNECTOR SERVICING on p. 122.
Make su re all g round connections are clean a nd
tight. Refer to GROUND CIRCUITS on p. 93.
1
Occurred Faults Review Screen 008128
1. Detailed information
1. Main engine harness ground 004183 Review informa tion about how the o utboard has
2. Ground stud (battery) been operated using the Profiles screens.
Inspect spark plugs for wea r, oil fowling, or dam-
age. A rich or lean running condition or evidence
of internal eng ine da mage could be identified b y
the appearance of the spark plugs.
Check the fuse an d the emergency st op switch

lanyard.
RPM Profile 008587
• Check the RPM Profile for long period s of low

speed operation or periods of over-revving rpm.
74
SYSTEM ANALYSIS
• Check th e Engine Temperature Profile for evi- The Engine Identity Report provide s a sn ap-shot
dence of cold running or overheating. of current engine and sensor conditions. From the
Identity screen, press the Print button. Next, press
Printer to print, or PDF File to save the report.
Engine Temperature Profile 008588 5

Engine Identity Report 008590
• The Last Two Minutes pro file reports engine
run-time value s during the last two minu tes of Operational Inspections
operation above 15 00 rpm. Info rmation is co l-
Run the ou tboard to confirm actual symp toms
lected once per secon d. The ne west record is
before perfo rming any unnecessary procedures.
first on the list. As ea ch ne w re cord is add ed,
Inspection should include the following:
the oldest record is removed.
• Make sure th e outboard can be cranked easily,
with no mechanical binding.
• Check the EMM LED Indicators for system sta-
tus information. Re fer to EMM LED INDICA-
TORS on p. 78.
Last Two Minutes Profile 008589
75
SYSTEM ANALYSIS
Troubleshooting • Use the diagnostics software Dynamic Tests to

isolate a faulty cylinder. See DYNAMIC TESTS
Outboard will not crank, st arter d oes not on p. 77.
operate: • Use an inductive timing light to check ig nition
• Check co ndition of batt ery and cables (ma in and fuel injector circuits. Refer to Running Igni-
battery switch and cables). Make sure battery tion Tests on p. 83 and Running Fuel System
cables are not reversed. Tests on p. 86.
• Confirm that switched B+ is present at “A” termi- • Use the diagn ostics software Fuel Control
nal (pu rple wire) o f st arter so lenoid with ke y Adjustment test to help identify a cylind er that
switch in the ON position. may be too rich or too lea n. Refer to Fuel Con-
• Refer to ELECTRIC START TESTS on p. 101. trol Adjustment on p. 77.
Repair starter or start circuit as needed. • Use an inductive amp meter to monitor injector
circuit current. Compare readings of all circuits
Outboard cranks, will not start:
to identify possible failure.
• Check emergency stop switch and lanyard
• Check the EMM LED Indicators for system sta- • Check fuel quality and that fuel is present at
injectors.
tus information. Refer to EMM LED INDICA-
TORS on p. 78. • Use the diagnostics sof tware Logging fun ction
to record engine data as a problem is occurring.
• Use the Evinrude Diagnostics sof tware
Occurred Faults screen to check for current ser-
vice codes. If there are multiple occurred sensor
codes, inspect all 5 V sensor circuits for broken
or grounded wiring.
• Perform a Static Ign ition test using Evinrude
Diagnostics so ftware and a n ind uctive t iming
light. Refer to Static Ignition Test on p. 82.
• If ignition test indicates steady sp ark, refer to
FUEL DELIVERY TESTS on p. 85.
Outboard runs, low on power, misfires:

• Check the EMM LED Indicators for system sta-
tus information. Refer to EMM LED INDICA-
TORS on p. 78.
• Use the Evinrude Diagnostics software Monitor Logging Screen 008574
screen to chec k sy stem (55 V) and TPS vo lt-
ages. System volt age should b e steady , a nd • AFTER all the above inspections, if the cause of
TPS voltage should be between 0.2 and 4.85 V. a running quality problem still cannot be identi-
fied, perform a compression test to check for
IMPORTANT: Use a digital multimeter to check internal powerhead damage.
voltage on external circui ts only whe n necessary.
All EMM output currents are DC current. IMPORTANT: Remove a cylinder head or disas-
semble the engine only as a last resort.
76
SYSTEM ANALYSIS
DYNAMIC TESTS
DYNAMIC TESTS Fuel Control Adjustment

Use this test is to help identify a cylinder that may
Cylinder Drop Tests be too rich or too lean. This feature should not be
Use the Evinrude Diagnostics sof tware Dynamic used by itself to identify a faulty injector.
Tests to moment arily disable one cylinder while
the outboard is running. Evinrude Diagnostics software a llows temporary
adjustments to the fuel flo w characteristics of th e
• The Dynamic Ig nition test disables the ig nition
injectors. Factory fuel flow settings are restore d
and fuel injection circuits to a cylinder.
when power to the EMM is returned to OFF.
• The Dynamic Fuel te st mome ntarily disable s
one fuel injector circuit. Test the outboa rd at the RPM whe re the problem
is occurring.
By dropping one cylinder, RPM and running qual-
ity changes can be compared for each cylinder.
IMPORTANT: Test the out board at the RPM

where the problem is occurring. Use the test pro-
cedures to identify inconsistencies in voltages and 5
cylinder perfo rmance. On ce a circuit has been
identified a s malfun ctioning, inspect all rela ted
wiring and connections. Check all vo ltage in puts
and grounds; and perform resistance tests for all
circuits before replacing any suspect components.
Dynamic Tests can be used with:
• A timing light to determine how other cylinders
are affected by one cylinder being “dropped”; or
• A digital mult imeter to check volt age change s 008575
on electrical circuits.
If th e outbo ard run q uality improves with a fue l
control adjustment, eliminate ot her possibilities
before replacing an injector:
• Refer to Fuel System Pressure Test on p. 139.
• Refer to Running Fuel System Tests on p. 86.
IMPORTANT: DO NOT misinterpret tests run at
IDLE. The idle speed controller in the EMM com-
pensates to maintain a constant IDLE speed.
Inductive Amp Meter Test

Use a n ind uctive amp me ter to monito r battery
charging and current flow . Ident ifying erratic
amperage in a circuit c an b e used to isolate a
Dynamic Tests Screen 008570 problem component.
IMPORTANT: DO NOT misinterpret tests run at

IDLE. The idle speed controller in the EMM com-
pensates to maintain a constant IDLE speed. The
Dynamic Tests screen includes a fun ction to te m-
porarily disable the idle controller.
77
SYSTEM ANALYSIS
EMM LED INDICATORS
EMM LED INDICATORS LED 2 – CRANK POSITION OKAY – inpu t from

CPS, EMM powered ON. For NO LIGHT, check
The EMM LED ind icators provide a quick refer- for:
ence to the st atus of several outb oard systems. • Code 16 – CPS, intermittent loss of sync
Checking the LEDs FI RST when diagnosing an
engine problem can save time. LED 3 – SENSORS OKAY (5 V). For NO LIGHT ,
check for:
IMPORTANT: LED 1 is t oward th e top of the • Code 7 – PORT Knock sensor circuit fault
outboard (closest to EMM J2 connector). • Code 8 – STBD Knock sensor circuit fault
• Code 12 – TPS circuit fault
1 • Code 13 – TPS below expected range
• Code 14 – TPS above expected range
• Code 23 – EMM temp. sensor circuit fault
• Code 24 – EMM temp. below expected range
• Code 37 – Water in fuel
• Code 41 – Port temp. sensor circuit fault
• Code 42 – Port temp. below expected range
• Code 47 – AT sensor circuit fault
• Code 48 – AT sensor below expected range
• Code 49 – AT sensor above expected range
1. LED indicators 004197 • Code 58 – Operating temp. not reached, port
004198 • Code 59 – Operating temp. not reached, stbd
• Code 67 – Stbd temp. sensor circuit fault
Key ON • Code 68 – Stbd temp. below expected range
When the EMM is ON (engine not run ning), the • Code 71 – oil pressure circuit fault detected
following LEDs should light: • Code 72 – oil pressure below expected range
• Code 73 – oil pressure above expected range
LED 1 – SAC Circuit wo rking – 30 V present on
• Code 74 – water pressure circuit fault detected
55 V circuit.
• Code 75 – water pressure below range
LED 3 – Sensor Circuit s working . FLASHING • Code 76 – water pressure above range
LIGHT indicates Code 57 – engine will not start. • Code 78 – sensor supply voltage fault
• Code 79 – starter solenoid circuit open
LED 4 – S top Circuit not g rounded–okay to start.
• Code 87 – Exhaust pressure circuit fault
FLASHING LIGHT indicates severe overheat or
no oil – engine in SHUTDOWN mode.
• Code 88 – Exhaust pressure low
• Code 89 – Exhaust pressure high
Starting For FLASHING LIGHT, check for Code 57.
Starting mo de occu rs fro m t he time the f lywheel
begins to turn until t he o utboard is ru nning for 2 LED 4 – LANYARD/STOP OKAY. For NO LIGHT,
seconds. Du ring s tarting, a ll f our LEDs s hould check for:
light and then go off in sequence. • Grounded stop circuit.
LED 1 – CHARGING OKAY – Stator signal 30 V For FLASHING LIGHT, check for:
or higher. For NO LIGHT, check for: • Code 29 – EMM temp. OVER range (flashing)
• Code 77– SAC circuit fault • Code 31 – Engine temp. OVER range (flashing)
• Code 33 – Engine shut down, excessive no oil
condition
78
SYSTEM ANALYSIS
EMM LED INDICATORS
Running • Code 7 – PORT Knock sensor circuit fault

When the outbo ard is runn ing, all of the LEDs • Code 8 – STBD Knock sensor circuit fault
should be off. If a light is on, check for: • Code 12 – TPS circuit fault
• Code 13 – TPS below expected range
LED 1 – CHARGING FAULT: • Code 14 – TPS above expected range
• Code 17 – System voltage (55 V) below range • Code 16 – CPS, intermittent loss of sync
• Code 18 – System voltage (55 V) above range • Code 23 – EMM temp. sensor circuit fault
• Code 26 – Low battery (12 V) voltage • Code 24 – EMM temp. below expected range
• Code 27 – High battery (12 V) voltage • Code 28 – Shift switch malfunction
• Code 77– SAC circuit fault • Code 37 – Water in fuel
LED 2 – INJECTOR/IGNITION FAULT: • Code 41 – PORT temp. sensor circuit fault
• Code 51 – No. 1 injector circuit open • Code 42 – PORT temp. below expected range
• Code 52 – No. 2 injector circuit open • Code 47 – AT sensor circuit fault
• Code 53 – No. 3 injector circuit open • Code 48 – AT sensor below expected range
• Code 54 – No. 4 injector circuit open • Code 49 – AT sensor above expected range
• Code 55 – No. 5 injector circuit open • Code 57 – high RPM with low TPS setting 5
• Code 56 – No. 6 injector circuit open • Code 58 – PORT operating temp. not reached
• Code 61 – No. 1 injector circuit short • Code 59 – STBD operating temp. not reached
• Code 62 – No. 2 injector circuit short • Code 67 – STBD temp. sensor circuit fault
• Code 63 – No. 3 injector circuit short • Code 68 – STBD temp. below expected range
• Code 64 – No. 4 injector circuit short • Code 71 – oil pressure circuit fault detected
• Code 65 – No. 5 injector circuit short • Code 72 – oil pressure below expected range
• Code 66 – No. 6 injector circuit short • Code 73 – oil pressure above expected range
• Code 81 – No. 1 ignition coil circuit open • Code 74 – water pressure circuit fault detected
• Code 82 – No. 2 ignition coil circuit open • Code 75 – water pressure below range
• Code 83 – No. 3 ignition coil circuit open • Code 76 – water pressure above range
• Code 84 – No. 4 ignition coil circuit open • Code 78 – sensor supply voltage fault
• Code 85 – No. 5 ignition coil circuit open • Code 79 – starter solenoid circuit open
• Code 86 – No. 6 ignition coil circuit open • Code 87 – exhaust pressure circuit fault
• Code 91 – Fuel pump circuit open • Code 88 – exhaust pressure below range
• Code 92 – Exhaust valve circuit open • Code 89 – exhaust pressure above range
• Code 94 – Fuel pump circuit short • Code 97 – Intermittent switched B+ detected
• Code 101 – No. 1 ignition timing circuit shorted LED 4 – Engine overh eat, EMM tempera ture or
• Code 102 – No. 2 ignition timing circuit shorted sensor, oil inje ction pump or se nsor, “NO OIL /
• Code 103 – No. 3 ignition timing circuit shorted OVERHEAT.” For LIGHT ON, check for possible
• Code 104 – No. 4 ignition timing circuit shorted fault codes:
• Code 105 – No. 5 ignition timing circuit shorted • Code 25 – EMM temp. above expected range
• Code 106 – No. 6 ignition timing circuit shorted • Code 29 – EMM temp. OVER range (flashing)
LED 3 – Sensor circuits (5 V), “SENSOR FAULT.” • Code 31 – engine temp. OVER range (flashing)
For LIGHT ON, check for possible fault codes: • Code 33 – excessive NO OIL faults
• Code 1 – No. 1 cylinder excessive knock • Code 34 – oil injection pump circuit open
• Code 2 – No. 2 cylinder excessive knock • Code 38 – oil pressure feedback not detected
• Code 3 – No. 3 cylinder excessive knock • Code 40 – engine overheat, low rpm
• Code 4 – No. 4 cylinder excessive knock • Code 43 – PORT temp. above expected range
• Code 5 – No. 5 cylinder excessive knock • Code 69 – STBD temp. above expected range
• Code 6 – No. 6 cylinder excessive knock • Code 70 – engine overheat, low rpm
79
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
IGNITION OUTPUT Crankshaft Position Sensor

• Provides EMM with input.
TESTS • Outboard cranking speed exceeds 75 RPM and
a steady CPS signal is generated.
A DANGER Alternator Output/System Voltage
The electrica l syste m present s a serious • System voltage from EMM (white/red) provides
shock hazard. Allow outboard to sit for 55 VDC to the oil injection pump, the fuel injec-
two minutes after running before handling tors, and the ignition module of EMM.
capacitor or 55 V electrica l components.
Failure to handle ca pacitor properly can Capacitor
result in uncontrolled electrical discharge • Connected to 55 V circuit (white/red) to stabilize
and possi ble ele ctrical sh ock to humans. current on 55 V circuit
DO NOT handle primary or secondary igni- • Negative terminal of cap acitor mu st be
tion components while outboard is run - grounded.
ning or flywheel is turning.
Ignition Coil
• Primary circu its are powered by system (55 V)
Use the Evinrude Diagnostics sof tware Occurred voltage
Faults screen to check for current service code s • EMM provides control signal to ignition coil
before troubleshooting. Correct any problems and • Output from ignition coil secondary winding and
clear the codes FIRST. high tension spark plug wire.
Required Ignition Systems Wiring Inspection
Following is a comp lete list of circuits required for Visually in spect all wi ring, con nections, and
ignition output: grounds.
Stop Circuit Use a digit al ohmmete r to test resist ance on all
• Black/yellow wire NOT grounded (eme rgency ground circuits and connections. Ohmmeter read-
stop switch lanyard in place). ings should be approximately 0.0 Ω.
Battery Check that all engine wire harness g rounds have
• Battery switched B+ input to power up EMM continuity to the cylinder/crankcase.
• Battery B+ input to Start Assist Circuit (SAC) of
EMM
Stator Output Voltage

• Provides A/C voltage to EMM J2 co nnector:
Outboard cranking, typ ical range is 20-40 VAC
(AC output voltage is related t o cranking RPM );
Outboard running approximately 55 VAC.
EMM 1
• Controls ignition grounds, injector grounds, and
ignition timing.
• Start Assist Circuit (SAC) converts battery volt- 1. Main engine harness ground 004128
age (12 V) to 30 V for system circuit (55 V).
Clean or repair all ground circuits, wiring, and con-
nections as needed.
80
SYSTEM ANALYSIS
Crankshaft Position Sensor (CPS) System Voltage Test

Test The ig nition system is po wered by the 55 V sys-
When the CPS is working properly , EMM LED 2 tem.
turns on while the outboard is being started. Use the Evinrude Diagnostics so ftware Monitor
Use the Evinrude Diagnostics software CPS Sync screen to check system voltage.
and engine RPM displays to confirm a valid CPS
signal while the outboa rd is cranking or running.
An RPM display higher than zero indicates a CPS
signal to the EMM.
Engine Monitor Screen, System Voltage 008566
Results:
• EMM ON (not running) - 30 V ± 2, system volt-
age is GOOD.
Engine Monitor Screen, Engine RPM display 008566
• EMM ON (not ru nning) - less tha n 30 V ± 2,
If the Monitor screen says “Check CPS Sync,” check 12 V power to EMM. Repair conne ction
refer to Crankshaft Position Sensor (CPS) Test or wiring. Possible fault in EMM SAC circuit.
on p. 94. • RUNNING - 55 V ± 2, system voltage is GOOD.
• RUNNING - less tha n 55 V ± 2, check st ator
output to EMM. Rep air connection o r wirin g.
Possible faulty stator or EMM. Refer to STATOR
TESTS on p. 96.
IMPORTANT: The EMM must be ON for voltage

to be present on the system voltage (55 V) circuit.
Power is normally supplied to the EMM when the
key switch is turned ON. The EMM is also turned
ON when it begins to receive AC voltage from the
stator while the outboard is being cranked.
81
SYSTEM ANALYSIS
Static Ignition Test IMPORTANT: You may n eed to remove shield-

ing from wire if pickup does not read signal.
Perform the static ignition test using Evinrude
Diagnostics software and an inductive timing light.
IMPORTANT: DO NOT use a spark checker

tool. Ra dio Frequ ency Interference (RFI) gener-
ated by the arcing current can cause erratic EMM 2 1
operation.
The outboard must NOT be running and the emer-

gency stop switch lanyard must be installed.
1. Timing light pick-up 004255

2. Spark plug lead
Results:
No spark on one or more cylinders:
• Inspect or replace spark plugs
• Refer to Ignition Control Circuit T ests on
p. 84
• Refer to Ignition Coil Tests on p. 84.
Steady spark on all cylinders:
• Refer to Running Ignition Tests on p. 83 and
Testing, Static Test Screen 008569 DYNAMIC TESTS on p. 77.
Connect timing ligh t pickup to the secondary cir-

cuit (spark plug lead) of the cylinder being tested.
Activate test an d observe timing light strobe for
consistent flash.
82
SYSTEM ANALYSIS
Running Ignition Tests Results:

Use Evinrude Diagnostics software to monitor Steady voltage and strobe, engine misfires:
system voltage (55 V). • Inspect or replace spark plugs
• Voltage readings a t a specific speed (RPM) • Refer to FUEL DELIVERY TESTS on p. 85.
should be steady. • Check for internal engine damage.
• Refer to System Voltage Test on p. 81.
Steady voltage, erratic strobe, engine misfires:
Use an inductive timing ligh t to monito r the sp ark • Inspect or replace spark plugs
signal through each of the secon dary circu it • Check CPS air gap and resistance.
(spark plug lead) wires. • Refer to Ignition Control Circuit T ests on
p. 84.
Start outb oard a nd observe timing light stro be. • Refer to Ignition Coil Tests on p. 84.
Look for a consistent flash and only one flash per
revolution. The strobe of the timing light should be Voltages fluctuate, engine misfires:
the same for each cylinder. • Inspect battery and connections
• Test capacitor and all ground connections.
• Refer to System Voltage Test on p. 81 5
• Refer to Ignition Control Circuit T ests on
p. 84.
2 1
• Refer to Ignition Coil Tests on p. 84.
IMPORTANT: If a running pro blem occurs at
about 1200 RPM, the outboard may be in S.A.F.E.
Refer to S.A.F.E. WARNING SYSTEM on p. 63.
1. Timing light pick-up 004255

2. Spark plug lead
83
SYSTEM ANALYSIS
Ignition Control Circuit Tests With EMM OFF, remove the EMM J1-B connector
and test t he continuity of each ignition control cir-
Use a digital multimeter to test the following:
cuit (orange). Check resistance bet ween J1-B
• System voltage supply to ignition coil. connector an d ig nition coil connector. Refer to
• Ignition control signal from EMM. engine wiring diagram.
• Engine harness resistance.
If circuits test good, replace EMM.
Disconnect ignition coil connector.
Ignition Coil Tests
Supply voltage test:
There are no simple ignition coil test s available.
Use an ap propriate adapter to connect the red
Before replacing an ignition coil, be sure:
meter lead to pin 3 (wh ite/red) of the engine har-
ness connector and the black lead to ground. With • 55 V is supplied to the white/red wire of the igni-
EMM ON, voltage should be approximately 30 V. tion coil connector
• A control signal is present on the orange wire of
Control signal test: the ignition coil conn ector. Re fer to Ignition
Set meter to the Hz scale to check ignition control Control Circuit Tests on p. 84.
signal. • The black wire of the ignition coil connector pro-
vides continuity to ground.
Use an ap propriate adapter to connect the red • The secondary spark plug le ad provides cont i-
meter lead to pin 2 (orange) of the engine harness nuity.
connector and the black le ad to ground. Activate
diagnostics sof tware Static Ignition test and If all of the ab ove tests a re g ood, and a cylinder
observe me ter for consist ent read ing (a pproxi- does not have spark, replace the ignition coil with
mately 2 Hz). a known good coil.
If control signal is present, connect bla ck meter Capacitor Test

lead to p in 1 (black) and re peat te st to confirm
harness ground. IMPORTANT: Make sure the ca pacitor is dis -
charged before testing. Ma ke a mo mentary co n-
nection between the two terminals to ground any
stored energy.
Remove capacitor from electrical harness.

Use an ohmmeter set on the high ohms scale to
test the capacitor. Connect the meter leads to t he
capacitor terminals:
• If the capacitor is working co rrectly, it will sto re
energy from the meter. The resist ance reading
will increase until it goes to (nearly) infinity.
006609 • If th e ca pacitor is shorted, the reading will
immediately show full continuity.
Harness resistance test: • If there is an open circuit in the ca pacitor, the
If control signal is NOT present, calibrate multime- meter will show no continuity.
ter to low ohms scale . Use appro priate adapte rs
on mete r leads to avoid dama ging harness con- If the resistance reading starts as a negative num-
nectors. ber, or the reading goes down in value, the capac-
itor already ret ains some sto red e nergy. Ground
the capacitor and test again.
84
SYSTEM ANALYSIS
FUEL DELIVERY TESTS
FUEL DELIVERY TESTS If the pump does not run:

• The EMM controls power to the fuel pump (pur-
ple/black wire). Check voltage at p in 1 of fue l
A WARNING pump connector. Voltage should be 12 V when
Protect ag ainst hazardous fue l spray. KEY is first ON, when fuel pump test activated,
Before st arting any fuel syst em service, or when outboard is cranking or running.
carefully relieve fuel system pressure. • Use an ohmmeter to che ck continuity bet ween
pin 2 of fuel pump connector and ground.
Refer to Relieving Fuel Sy stem Pre ssure on • Refer to Circulation Pump Resistance Test on
p. 143. p. 141.
Check the Evinrude Diagnostics sof tware If the pump runs:

Occurred Faults screen for curren t service codes • Refer to Fuel System Pressure Test on p. 139.
before troubleshooting. Correct any problems and • Refer to Running Fuel System Tests on p. 86.
clear the codes FIRST.
Fuel Injector Static Test
Inspect all fuel hoses, filte rs, and co nnections. Use the Evinrude Diagnostics software Fuel Injec- 5
Check quality of fuel supply. tor Static Test to activate each fuel injector. Listen
for an a udible click from each injector when it is
Fuel Pump Static Test actuated. If the injector activates, the EMM an d
Use the Evinrude Diagnostics software Fuel Pump injector circuits are not at fault.
test to activate the electric fuel pump. If the pump
runs, t he EMM a nd fu el pump circuit are not at
fault.
IMPORTANT: This test is operating the injectors

Static Tests Screen 008569 with 30 V on the system voltage (55 V) circuit. The
start assist circuit (SAC) of the EMM converts bat-
tery voltage (12 V) to 30 V of system voltage. Bat-
tery must be fully charged and co nnections must
be clean and tigh t. Injector act ivation should be
carefully confirmed.
85
SYSTEM ANALYSIS
FUEL DELIVERY TESTS
Results: Results:
No injectors actuate: No light activation on any injector wires (outboa rd
• Use the Monitor screen of the diagnostics soft- cranks and starter turns flywheel):
ware t o make su re volt age is present on the • Check stator input to EMM, CPS operation, and
system voltage circuit. all grounds and wiring connections.
• Refer to Running Fuel System Tests on p. 86. • Eliminate all other possibilities to isolate a faulty
EMM.
Some injectors actuate; some do not:
• For non-working injectors, test the resistance of Irregular or n o light activa tion o n some in jector
individual inje ctor circuits bet ween th e injector wires:
connector and injector control wire at the EMM. • Test the resist ance of individual injector circuits
• See Fuel Injector Resistance Test on p. 141. 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. 86. • Make sure all grounds are clean and tight.
• See Fuel Injector Resistance Test on p. 141.
Running Fuel System Tests
Run or crank the outboard. Steady light activation o n all in jector wire s a nd
consistent voltage readings, EMM injector contro l
Use the Evinrude Diagnostics sof tware Monitor function is good:
screen to check syste m voltage. If vo ltage is low, • Use the diagnostics software Dynamic Fuel Test
or drops as RPM increases, refe r to Stator Volt- to isolate a faulty cylinde r. See DYNAMIC
age Output Test on p. 96. TESTS on p. 77.
Use an inductive timing light to monit or the injec-
tor control wire (connector pin 2) for each injector.
Make sure the pickup is attached to only one wire.
Flashes on th e timing light indicate current in the
circuit is being switche d by the EMM. The
Dynamic Tests screen allows the contr ol signal to
be turned off to a particular injector.
IMPORTANT: Some t iming lights may not flash

consistently at cranking speeds. Always check the
orientation of the timing light pickup and the oper-
ation of the timing light.
Dynamic Tests Screen 008115
• Refer to Fuel Injector Pressure Test on p. 140.

• Refer to Fuel System Pressure Test on p. 139.
86
ELECTRICAL AND IGNITION

TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
IGNITION SYSTEM CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
ELECTRICAL HARNESS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
GROUND CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
SENSOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
CRANKSHAFT POSITION SENSOR (CPS) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
THROTTLE POSITION SENSOR (TPS) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
ENGINE TEMPERATURE SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
AIR TEMPERATURE SENSOR (AT) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
KNOCK SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
STATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
STATOR RESISTANCE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
STATOR VOLTAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 6
CHARGING SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
12 V CHARGING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
AUXILIARY BATTERY CHARGE WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
55 V ALTERNATOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
ELECTRIC START CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
ELECTRIC START TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
REMOTE CONTROL SWITCH TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
TILT/TRIM RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SYSTEMCHECK CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
TACHOMETER CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
FLYWHEEL AND STATOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
STATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
IGNITION COIL SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
IGNITION COIL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
IGNITION COIL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
TIMING ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
TIMING POINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
TIMING VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
TPS CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
ELECTRIC STARTER SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
STARTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
STARTER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
STARTER CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
STARTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
STARTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
CONNECTOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
87
SERVICE CHART
SERVICE CHART
60-84 In. lbs.
(7-9.5 N·m)
50-70 In. lbs.

(5.6-8 N·m)
30-42 In. lbs. 30-42 In. lbs.

(3-5 N·m) (3-5 N·m)
F
30-42 In. lbs.
(3.5-4.7 N·m)
F B
30-42 In. lbs. 140-160 Ft. lbs.
(3.5-4.7 N·m) (190-217 N·m)
X
15-30 Ft. lbs.
(20-41 N·m) F
F Apply to inner flywheel taper
60 to 84 in lbs. 24-36 In. lbs.
(2.7-4 N·m)
(7 to 9.5 N ·m)
60-84 In. lbs.

(7-9.5 N·m)
F
30-42 In. lbs.
(3.5-4.7 N·m)
14-16 Ft. lbs.

10-16 In. lbs. (19-22 N·m)
(1-2 N·m)
T
60-84 In. lbs.
(7-9.5 N·m)
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F F Blue Nut Lock
60-84 In. lbs.
(7-9.5 N·m) J Thermal Grease
T Liquid Neoprene
004116 X See Service Manual Text
88
SERVICE CHART
N 60-84 in. lbs

(7-9.5 N·m)
60-84 In. lbs.

(7-9.5 N·m)
6
T
60-84 In. lbs.
(7-9.5 N·m)
F
168-192 in. lbs
(19-21.5 N·m)
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
N Starter Bendix Lube
T Liquid Neoprene 00803
89
IGNITION SYSTEM CIRCUIT DIAGRAM
IGNITION SYSTEM CIRCUIT DIAGRAM

FUSE
6 2
5
B A
1 2 3
3
4 5 6
123
+
8
9
11 12 13
1 2 3 4
20 21 22 23
14 15
J2
5 6 7 8 9 10
24 25 26 27 28 29
4
16 17
18 19
26 27 28 29 30 31 32 33 34
1 2 3 4 5 6 7 8 9
18 19 20 21 22 23 24 25
10 11 12 13 14 15 16 17
4
3
J1-A
5
2
6
1
1
20 21 22 23 24 25 26
1 2 3 4 5 6 7
14 15 16 17 18 19
8 9 10 11 12 13
J1-B
2 1
7 7
321
321
4 3
321
321
6 5
321
321
1. Key switch (stop circuit) 4. EMM 7. Ignition coil

2. Fuse 5. Crankshaft position sensor 8. Main harness ground
3. Stator 6. Capacitor 9. +12 V from battery
90
ELECTRICAL HARNESS CONNECTIONS
ELECTRICAL HARNESS EMM J1-A Connector

CONNECTIONS
Inspect wiring and electric al connectio ns. Disas-
semble a nd clean all corrode d co nnections.
Replace damaged wiring, con nectors, o r termi-
nals. Repair any shorted electrical circuit s. Refer
to wirin g diagrams and refere nce ch arts for spe-
cific wiring details.
Refer to CONNECTOR SERVICING on p. 122.
Engine Harness to Stator

001875
Connector
Pin
Description of Circuit Wire Color
No.
1 Oil Pressure sensor Tan/White
2 Diagnostic connector Red
3 Diagnostic connector White
4
5
Ground, water in fuel (digital)
Oil level switch
Black
Tan/Black
6
6 Crankshaft position sensor (CPS) Yellow
7 Ground, CPS (digital) White
8 Bootstrap connector (programming) Blk/Orange
9 Stop circuit Blk/Yellow
004050 10 Sensors 5 V Red
11 Ground (analog) Black
Pin 12 Engine temperature sensor, port Pink/Black
Description of Circuit Wire Color
No. 13 CANbus, NET-L Blue
1 Stator winding (1S) Yellow 14 CANbus, NET-H White
2 Stator winding (3S) Orange 15 Water pressure Pink
3 Stator winding (2S) Brown 16 Tachometer Gray
4 Stator winding (1F) Yellow /White 17 CHECK ENGINE signal, SystemCheck Tan/Orange
5 Stator winding (3F) Orange/White 18 TPS Green
6 Stator winding (2F) Brown/White 19 Engine temperature sensor, starboard Pink/Black
20 Air temperature sensor Pink/Blue
21 CANbus, NET-S Red
22 CANbus, NET-C Black
23 Water in fuel Pink/Green
24 NO OIL signal, SystemCheck Tan/Yellow
25 WATER TEMP signal, SystemCheck Tan
26 Start signal Yellow/Red
27 Ground, knock sensors Tan/Blue
28 vacant
29 Shift switch (shift linkage) Black/Yellow
30 Knock sensor, stbd Yellow/Green
31 Knock sensor, port Yellow/Blue
32 Trim sender, IN White/Tan
33 Trim sender, OUT White/Tan
34 LOW OIL signal, SystemCheck Tan/Black
91
ELECTRICAL HARNESS CONNECTIONS
EMM J1-B Connector EMM J2 Connector
001876 004046
Pin Pin
Description of Circuit Wire Color Description of Circuit Wire Color
No. No.
1 Injector, cylinder 1 Blue 1 B+ Red
2 Injector, cylinder 2 Blue 2 vacant
3 Injector, cylinder 3 Purple 3 Isolated B+ Red/Black
4 Rear oil injector control (ground) Blue/Red 4 Battery ground Black
5 Fuel pump Red/White 5 Battery ground Black
6 Ignition, cylinder 4 Orange/Purple 6 vacant
7 Ignition, cylinder 3 Orange/Purple 7 Winding 1S Yellow
8 Injector, cylinder 6 Green 8 Winding 2S Brown
9 Injector ground Black 9 Injector, generator ground Black
10 Injector ground Black 10 Winding 3S Orange
11 Starter solenoid OUT Brown/White 11 B+ Red
12 vacant 12 B+ Red
13 Ignition, cylinder 5 Orange/Green 13 Isolated B+ Red/Black
14 Injector, cylinder 5 Green 14 Battery ground Black
15 Injector ground Black 15 Battery ground Black
16 Injector ground Black 16 Battery ground Black
17 Trim relay, UP Blue/White 17 Winding 1F Yellow/White
18 Trim relay, DOWN Green/White 18 Winding 3F Orange/White
19 Ignition, cylinder 2 Orange/Blue 19 +55V White/Red
20 Injector, cylinder 4 Purple 20 B+ Red
21 Switched B+ (12V) Purple 21 Isolated B+ Red/Black
22 Injector ground Black 22 Isolated B+ Red/Black
23 Oil solenoid Blue 23 Battery ground Black
24 Rear oil injector +12 V Red/Yellow 24 Battery ground Black
25 Ignition, cylinder 6 Orange/Green 25 Battery ground Black
26 Ignition, cylinder 1 Orange/Blue 26 vacant
27 Injector, generator ground Black
28 Winding 2F Brown/White
29 +55V White/Red
92
GROUND CIRCUITS
GROUND CIRCUITS Additional Ground Tests

Check connections and continuity at the followin g
All groun d circuit s are essential to reliable out-
locations:
board performance. Make sure all ground connec-
• Trim and Tilt module ground at main ground ter-
tions are clean and tight. Refer to wiring diagrams
minal.
for specific wiring details.
• Check contin uity between g round te rminals at
EMM Ground Tests port cylinder head gro und screw and th e main
harness ground.
Disconnect the battery cables at the battery.
Use an ohmmeter to check co ntinuity of grou nd

circuits. Calibrate the ohmmeter on the high ohms
1
scale. Resistance readings fo r all gro und circu its
should be 0 Ω.
• System/power supp ly groun ds: Check continu-
ity between terminal pins 4, 5, 9, 14, 15, 16, 23,
24, 25 and 2 7 of EMM J2 connector and the
main harness ground.
• Injector circu it gr ounds: Check continuity
between terminal pins 9 and 27 of the EMM J2
connector and the main harn ess grou nd; a nd 1. Ground, port cylinder head 007172
6
between te rminal p ins 9, 10 , 15, 16 a nd 22 of
the EMM J1-B connector and the main harness
ground. FUSE
• Sensor circuit g rounds: Check continuity The engine h arness 12 V (B+) circu it is pro tected
between termina l pins 4 and 1 1 of the EMM by one automotive style 10 amp minifuse.
J1-A co nnector and the appropriate sensor
ground connections. Refer to wiring diagrams. The fuse is located on the st arboard side of th e
powerhead, fastened to the capacitor.
1
2
1. Main engine harness ground 004183

2. Ground stud (battery) 1. Fuse 004080
IMPORTANT: Repeat failures of fuse could be

the result of faulty conne ctions or a ccessories.
The 12 V a ccessory circuit (purple wire from ter-
minal “A” of key swit ch) is of ten used to power
accessories.
93
SENSOR TESTS
SENSOR TESTS (1.85 mm). Th e accep table clearance is 0 .036 to

0.110 in. (1 to 2.8 mm).
All senso r circu its a re de pendent o n wiring a nd
connections, EMM supplied current (5 V), and 1
sensor resist ance. The supplied current flows
through the wiring circuit and sensor be fore
returning to the EMM.
IMPORTANT: Use Evinrude Diagnostics sof t-

ware to monitor sensor circuit voltages or values.
004200
Crankshaft Position Sensor (CPS) 1. CPS gap
Test Throttle Position Sensor (TPS) e

Tst
Use the Evinrude Diagnostics software CPS Sync Use Evinrude Diagnostics sof tware to monitor
and engine RPM displays to confirm a valid CPS TPS volt age while the ou tboard is running. Volt-
signal while the outboa rd is cranking or running. age sho uld change evenly as se nsor lever is
An RPM display higher than zero indicates a CPS moved.
signal to the EMM.
Remove the electrical co nnector from the throttle
Disconnect the crankshaft position sensor. position sensor.
Use a digital multimeter to measure sensor resis- Use a digital multimeter to measure sensor re sis-
tance betwee n the yellow a nd white wires. The tance.
complete circuit can b e tested by measuring
between pins 6 and 7 of the EMM J1-A connector. Sensor Resistance (between “A” and “B”)
.
3000 to 7000 W @ 77°F (25°C)
Sensor Resistance
560 W ± 10% @ 77°F (25°C)
Sensor Resistance (between “A” and “C”)
4000 to 8000 W @ 77°F (25°C)
1
1. CPS Connector 004199
The CPS is mounted to throttle body housing and 1. TPS 004256

requires no adjustment. Air gap or cleara nce to
flywheel is fixed at ap proximately 0 .073 in.
94
SENSOR TESTS
Connect red meter lea d to terminal “A” and black Air Temperature Sensor (AT) Test
meter lead to terminal “C.” Rotate the sensor lever
Remove the electrical connector from the air tem-
through it s range of trave l. Resistance reading
perature sensor.
must change evenly as the sensor lever is moved.
Use a digital multimeter to measure sensor re sis-
Connect red meter lead on terminal “B” and black
tance.
meter lea d to terminal “C.” Ro tate the sensor
lever. Resistance reading must chang e evenly as AT Sensor Resistance
the sensor lever is moved. 680 Ω ± 5.25% @ 212°F (100°C)
10000 Ω ± 1.5% @ 77°F (25°C)
Engine Temperature Sensor Test 32654 Ω ± 3.0% @ 32°F (0°C)
Remove the ele ctrical connector from the engine
temperature sensor.
Use a digital multimeter to measure sensor resis-

tance.
1
Engine Temperature Sensor Resistance
680 Ω ± 5% @ 212°F (100°C)
10000 Ω ± 1% @ 77°F (25°C)
32654 Ω ± 2.5% @ 32°F (0°C) 6
1. AT sensor 004216
1
Knock Sensor Test
There are no te sts for the knock senso r. If
Evinrude Diagnostics reports Service Code 7 or 8,
replace with a new sensor.
Make sure sensor retaining screw is tightened to a

torque of 14 to 16 ft. lbs. (19 to 22 N·m).
1. Engine temperature sensor (2) 004196
95
STATOR TESTS
STATOR TESTS To che ck for a g rounded winding, conne ct on e

meter lead to ground and alternately connect the
The st ator consists of 3 windings (6 poles each) other meter lead to each stator wire. Meter should
on a 7 inch diameter core and gene rates an out- read no contin uity. If meter rea ds continuity,
put volt age of 5 5 V AC (1700 watts maximum). replace stator.
This voltage is converted by the EMM and used to
provide 12 VDC for b attery charging (10 A at 5 00 Stator Voltage Output Test
RPM and 50 A from 2000 RPM to WOT) an d 55 Use a voltmeter to check the stator output voltage.
VDC for fuel injector, fuel and oil pump operation. Set meter to read 110 VAC output.
The ignit ion module of EMM is also powere d by
the 55 VDC output. A WARNING
Stator Resistance Tests To prevent accidental starting of outboard,
disconnect crankshaft positio n sens or
Use a digital multimeter to check resistance of sta- (CPS).
tor windings.
Disconnect EMM J2 connector from EMM. Disconnect CPS.
Stator Winding Resistance Disconnect st ator (6-pin) con nector from t he
Yellow & Yellow / white engine harness (6-pin) connector.
.512 ± .020 Ω @ 73°F (23°C)
Brown & Brown / white Connect Stator Test Adaptor tool, P/N 5006211, to
.512 ± .020 Ω @ 73°F (23°C) stator connector.
Orange & Orange / white Connect meter leads to terminals of adaptor tool.
.512 ± .020 Ω @ 73°F (23°C)
With a fu lly charged battery, crank outb oard (100
RPM minimum) and observe meter reading:
1 • 20 VAC at 100 RPM
• 30 VAC at 150 RPM
1
1. EMM J2 Connector 004325
Connect meter leads to the following pins:

• Yellow/white and yellow (pins 17 and 7)
• Brown/white and brown (pins 28 and 8)
• Orange/white and orange (pins 18 and 10)
IMPORTANT: A reading of less th an 2 ohms is 1. Stator Test Adaptor 004326
acceptable. Make sure meter is calibrated to read

1 ohm or less.
96
CHARGING SYSTEM TESTS
CHARGING SYSTEM
4 3
TESTS
12 V Charging Circuit 1
To test the operation of the regulator in the EMM,
you must be able to run the outboard continuously
5
at approximately 5000 RPM, such as in a test tank
or on a marine dynamometer. 2
The test consist s of monito ring th e system’ s

response t o a partially disch arged battery. Use a
variable load tester to discharge the battery. Variable Load Test Diagram 002077
1. Red wires (alternator output from EMM)
IMPORTANT: The regulator req uires volt age to 2. Starter solenoid
3. Battery cable terminal (B+)
operate. Before proceeding, make sure there is at 4. Variable load tester
least 7 V on t he positive t erminal o f the st arter 5. Ammeter
solenoid.
Start and run th e outboard at appr oximately 3500
Disconnect the battery cables at the battery. RPM. Use the variable load tester to draw the bat-
Use an inductive amp meter or connect a 0 to

tery down at a rate equivalent to the stator’s full 6
output.
50 A ammeter in series between the red wire(s) of • The ammeter should indicate nearly full output,
engine wire harness (alternator output from EMM) approximately 50 A (or 25 A for each outp ut)
and th e p ositive (B+) battery cable te rminal of between 2000 and 4000 RPM.
starter solenoid. • Above 4000 RPM, charging output is reduced to
IMPORTANT: This outboard has dual out put 40 A.
charging. Each ou tput is isolated and regulated.
Each output is 25 A. Combined output is a pproxi-
mately 50 A. Refer to engine wiring diagram.
Fluke † model 334 or 336, Snap-On † model MT110

or EETA501, an d various o ther a mp meters
should be available through local tool suppliers.
Reconnect the battery cables.
Following the manufa cturer’s dire ctions, conne ct

the variable lo ad teste r (carbon pile) across the
battery terminals. Stevens mo del LB-85 a nd
Snap-On model MT54 0D are examples o f testers
available. Battery Charging Graph 004286
A WARNING Decrease the battery load toward 0 A.

• Ammeter should show a reduced output. As the
Excessive battery disch arge rates might
current draw decreases, th e battery volt age
overheat battery causi ng electrolyte gas -
should stabilize at approximately 14.5 V.
sing. This might create an explosive atmo-
• If results vary, check stator BEFORE replacing
sphere. Alway s work in a well v entilated
the EMM. See STATOR TESTS on p. 96.
area.
97
CHARGING SYSTEM TESTS
Auxiliary Battery Charge Wire With outboard running at 1000 RPM, voltage must
read higher than with key OFF and increase
The auxiliary battery charge feature requires aux- steadily t o appr oximately 1 4.5 V as the outboard
iliary battery charg e kit, P/N 500625 3 (or equiva- RPM increases.
lent).
If there is no increase, turn the key switch to OFF
IMPORTANT: Disconnect all accessories fro m and test red/black wire between the EMM an d
the auxiliary battery. Auxiliary battery must read a auxiliary battery connection.
minimum of 8.5 V at the beginning of these tests • Continuity indicates fa ulty ou tput from EMM.
and remain connected to th e outboard during the Check 12 V altern ator ou tput before replacin g
tests. EMM for faulty auxiliary b attery, charge isolator
Check battery ground cable for continuity. circuit.
• No continuity indicates faulty wiring.
With the key switch OFF, check battery voltage at
auxiliary battery , th en che ck voltage at auxilia ry 55 V Alternator Circuit
battery conne ction. If the rea dings are no t the Check battery ground cable for continuity.
same, replace wire t o auxiliary ba ttery. The auxil-
iary battery wire must be at least 10-ga uge and it With the key switch ON, che ck battery voltage at
must be prote cted by a 50 A fuse or circuit battery (12 V).
breaker at the battery.
Then, use Ele ctrical Test Probe Kit, P/N 342677,
and a dig ital multimeter set to read 55 VDC to
check voltage on white/red wires at J2 connector
of EMM. V oltage at EMM conne ctor should b e
approximately 30 V.
1
1. Auxiliary battery charge wire connection 004329
1. J2 connector of EMM 004197
With o utboard ru nning a t 1 000 RPM, voltage on

white/red wires should increase to 55 V . Voltage
readings at a sp ecific spe ed (RPM) should be
steady.
If there is any other reading, refer to STATOR

TESTS on p. 96. Inspect the st ator wiring a nd
connections. Inspect the capacitor wiring, connec-
tions, and capacitor. Repair the wiring or replace a
faulty capacitor, stator, or EMM.
98
ELECTRIC START CIRCUIT

Start Circuit Diagram
8 B M
M C S
A
9
15
13
61 4 3 5 2
NEG FUSE 5
7
B A
17 6 1 4 3 5 2
16
6
4
6
A POS 2
B
+
11 12 13
20 21 22 23
1 2 3 4
3
14 15
J2
24 25 26 27 28 29
5 6 7 8 9 10
3
16 17
13
18 19
12
26 27 28 29 30 31 32 33 34
1 2 3 4 5 6 7 8 9
18 19 20 21 22 23 24 25
10 11 12 13 14 15 16 17
11
J1-A
14
9
20 21 22 23 24 25 26
10
1 2 3 4 5 6 7
14 15 16 17 18 19
8 9 10 11 12 13
J1-B +
1
004112
1. Marine battery 10. 26-pin J1-B EMM connector

2. RED wire (POS) 11. 34-pin J1-A EMM connector
3. BLACK wire (NEG) 12. Engine Management Module (EMM)
4. Starter solenoid 13. YELLOW/RED wire, start
5. Fuse (10 amp) 14. BROWN/WHITE wire, start signal
6. RED/PURPLE wire 15. Neutral Safety Switch (remote control)
7. 6-pin connectors 16. RED starter motor cable
8. Ignition switch 17. Electric starter motor
9. PURPLE wire (switched B+)
99
Start Circuit Operation Instrument Wire Harness

The st arter must engag e and tu rn the flywhee l. Contains the following circuits:
The outboard must crank a minimum of 100 RPM • Red/purple wire provides 12 V to key switch ter-
to st art. Normal cranking speed is approximately minal “B”.
175 RPM. • Purple wire pro vides switch ed 12 V to engine
wire harness.
Starter performance depends on the following: • Yellow/red wire from terminal “S” of key switch
• Proper battery and cable capacity. provides swit ched 12 V to EMM (key sw itch in
• Clean, tight cable connections. START position).
• Solenoid activation through the key switch, neu-
tral safety switch, and EMM. Key Switch, ON position
12 V is ap plied to the accessory circuit. Key
Refer to Predelivery and Installation Guide for switch ON:
battery, terminal, and cable requirements. • Switches 12 V to terminal “A” of key switch and
to the purple wires of the wire harnesses.
Solenoid Wiring
• Provides 12 V input to terminal 21 of EMM J1-B
The positive (B+) battery cable connects to a large
connector. EMM turns ON.
terminal of the starter solenoid. This terminal also
• EMM provide s 12 V to terminal “A” of st arter
provides the 12 V power supply to the engine har-
solenoid.
ness (red wire) and the 10 A fuse. The red/purple
wire from th e fuse holder (10 A) provides 12 V to 1
terminal “B” of key switch.
B B B
The negative (B–) batte ry ca ble co nnects to the
M M M
main ground stud next to starter solenoid.
M M M
C A C A C
A S S S
Engine Wire Harness

Contains the following circuits:
• Red/purple output wire from fuse provides 12 V B
to instrument harness. M
C
M
• Purple wire p rovides switched 12 V to so lenoid A

S
(terminal “A”) and EMM.

• Yellow/red wire provides switched 12 V to EMM.
• Brown/white wire from terminal 11 of EMM J1-B 4 5 6
connector pro vides switche d ground (NEG) to

starter solenoid (terminal “B”).
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)
100
ELECTRIC START TESTS
Key Switch, START Position ELECTRIC START TESTS

Key switch START:
• Switches 12 V to terminal “S” of key switch and Starter Solenoid Test
to the neutral safety switch (in remote control). Disconnect the B+ (POS) battery cable at the bat-
• A closed neutral safety switch provides 12 V to tery.
the en gine wire ha rness yellow/red wire an d
terminal 26 of EMM J-1A connector. IMPORTANT: Disconnect all wiring from sole-
• EMM grounds brown/white wire to activate solenoid terminals before proceeding with this test.
noid.
Use a digital multimeter to measure resistance.
1
Put on e me ter lea d on th e st arter p ositive (+)
B
cable terminal an d th e ot her lead on the battery
M M positive (+) cable terminal:
A C
S
• Meter must not show continuity (high reading).
• If meter shows continuity (low reading), replace
the solenoid.
B
1 3
M
6
C
M
S
A
4 5 6
3 2 1
2 3
1. Ignition switch, START position – Continuity 000691R
between terminals “B” and “A”; “B” and “S”
2. Terminal “S”, 12 V
3. Neutral safety switch
2 4
1. “A” terminal, B+ (purple) 004121
2. “B” terminal, NEG (brown/white)
3. Starter positive (+) cable terminal
4. Battery positive cable (B+) terminal
Apply B+ to te rminal “A” of solenoid and groun d

(NEG) to terminal “B” of solenoid. Measure re sis-
tance between the starter positive (+) cable termi-
nal and the positive battery (+) cable terminal.
• The solenoid must close with an audible click.
• Meter must show continuity (low reading).
• If met er shows no con tinuity (hig h reading),
replace the solenoid.
After re-installing the solenoid, coa t all wires an d
terminals with Black Neoprene Dip.
101
ELECTRIC START TESTS
Starter Voltage Drop Test • Observe voltage reading.
A WARNING STEP 4: Connect positive (+) lead to starter cable

of solenoid terminal. Connect negative (–) lead to
To prevent accidental starting of outboard, starter motor terminal.
disconnect cranksha ft posi tion sen sor • Activate st arter motor a nd observe volt age
(CPS). reading.
Use a digit al voltme ter to me asure the volt age No Load Current Draw Test
drop on each section of the start circuit. Securely fasten starter in a vise or suitable fixture
before proceeding with this check.
If an y vo ltage read ing is greate r than 0.5 VDC
check that connections are clean, tight and free of Use a batte ry rated at 500 CCA (60 amp-hr) or
corrosion. Clean or replace an y corroded or dam- higher that is in good condition and fully charged.
aged cables or connections.
IMPORTANT: The d riven ge ar a nd p inion
STEP 1: Con nect voltmet er positive (+) lead to assembly must be removed for this test.
the terminal for the ne gative (–) batter y cab le at
powerhead. Conn ect vo ltmeter negat ive (–) le ad Use an inductive ammeter or connect a 0 to 1 00
to negative (–) battery post. amp amme ter in series with a heavy jump er
• Activate st arter motor and ob serve volt age between the b attery positive (+) terminal and t he
reading. starter positive (+) terminal.
V–
Fluke model 33 4 or 336, Snap-On model MT110
NEG V or EETA501, and various other ammeters should
1
be available through local tool suppliers.
Attach or hold a vibration t achometer, such as a

Frahm † Reed tachometer, to the starter.
2 4
+
1. Negative battery cable 008464

2. Positive battery cable
3. Solenoid
4. Starter cable
TYPICAL 24083
STEP 2: Connect positive (+) lead to battery posi-
tive (+) terminal. Connect nega tive (–) lead to Complete the circuit with a heavy jumper between
starter solenoid terminal. the batte ry n egative (–) te rminal a nd t he st arter
• Activate st arter motor and ob serve volt age frame.
reading.
Monitor the starter RPM and current draw.
STEP 3: First, activate st arter motor . Conne ct • At 10 ,500 RPM the a mmeter should sh ow a
positive (+) lead to starter solenoid terminal. Con- maximum of 30 A.
nect negative (–) lead to o pposite starter solenoid
terminal.
102
REMOTE CONTROL SWITCH TESTS
REMOTE CONTROL Neutral Start Circuit Test

Use an ohmmeter or con tinuity light to test the
SWITCH TESTS continuity of th e circu it while p ositioning th e
remote control in NEUTRAL, FOR WARD, an d
Key Switch Test REVERSE.
Refer to Wiring Diagrams at back of manual.
IMPORTANT: Turn propeller shaft or disconnect
Use an ohmmeter or a continuity light to test key shift cab le to allo w proper re mote cont rol shif t
switch operation. Replace switch if re sults are action while o utboard is not runn ing. Disconnect
incorrect with any of the following tests. the instrument h arness conn ector from the key
switch harness connector.
IMPORTANT: Disconnect ba ttery and ke y
switch wiring before proceeding with the following Make sure the remote contro l han dle is in NEU-
tests. TRAL. Connect mete r between termina l 5
(red/purple wire) a nd terminal 2 (yellow/red wire).
Stop/Ground Terminals (M) – Conn ect meter Turn the key switch to START. Meter must indicate
between the two “M” terminals. Me ter mu st ind i- continuity.
cate NO continuity at START or ON.
Move the remote con trol hand le to FOR WARD
Turn key switch OFF. Meter must indicate continu- and turn the key swit ch t o ST ART. Meter must
ity. NOT indicate continuity. 6
Accessory T erminal (A) – Mak e sure the ke y Move the remote control handle to REVERSE and
switch is OFF. Connect the ohmmeter or continu- turn the key switch to START. Meter must NOT
ity light between terminals “B” (battery) an d “A” indicate continuity.
(accessory) of key switch. Meter must indicate NO
continuity.
Turn switch ON. Meter must indicate continuity.
Turn key switch to START. Meter must continue to

indicate continuity.
Starter Terminal (S) – Hold key switch at START.

Connect meter between terminal “B” and terminal
“S.” Meter should indicate continuity.
IMPORTANT: The cho ke function or ter minal

“C” of the key switch is NOT used. 1 3 2
1 2 3 1. Key switch harness connector 000443
2. Neutral start switch
3. Key switch
IMPORTANT: Reconnect shif t cable an d MWS

instrument ha rness co nnector to key switch h ar-
ness connector.
1. OFF 000443
2. ON
3. START
103
REMOTE CONTROL SWITCH TESTS
Neutral Start Switch Test Emergency Stop Switch Test

Use an ohmmeter or a continuity light to test neu- This switc h can be part of the ke y switc h or
tral start switch operation. installed as a separate swit ch. Either st yle con-
nects the “M” terminals of the key switch.
IMPORTANT: All wiring must b e disco nnected
from the switch before proceeding with this test. The emergency stop switch function grounds the
stop circuit wire (black/yellow) whe n th e lanya rd
Disassemble the remote co ntrol an d remove the clip is removed. One “M” terminal is the grou nd
neutral start switch. wire (black) and one “M” terminal is the stop circuit
wire (black/yellow).
Connect on e mete r lead to each terminal o f the
switch. 4 1 2
• Meter must indicate continuity when the plunger
is depressed
• Meter must indicate no con tinuity when the
plunger is released.
2
3
1. Lanyard and clip assembly 000444
2. Emergency stop switch, separate from key switch
3. Stop circuit wire (black/yellow)
4. Ground wire (black)
TYPICAL 3224
1. Plunger Install th e clip on the emergency stop switch or
2. Neutral start switch
key switch. S tart the outb oard. Pull the clip from
the switch. The outboard must stop running.
Replace switch if results are incorrect.
104
TILT/TRIM RELAY TEST
TILT/TRIM RELAY TEST Test Procedure

Make sure re d and b lack wires are conne cted to
The tilt and trim (TNT) modu le con tains the cir-
12 V battery power supply.
cuitry and relays required for power trim and tilt
operation. Set voltmeter to 12 VDC scale. Connect test leads
to terminals “A” and “B” of TNT motor connector.
Use a wire jumper to alternately connect B+ to ter-

minals “1” and “2” of tilt and trim switch connector.
The met er mu st indicate battery vo ltage ( 12 V)

with B+ connected to either terminal.
1
1. Tilt and trim module 004183 4
The tilt an d trim switch provides B+ inp ut to

green/white or blue/white wire of the TNT module. 1 6
Operation
The relay activates when B+ input from the switch 2
is supplied to terminal 86 of the internal relays.
Terminal 87a connects to ground (B–).
6
Terminal 87 connects to B+. 5
Terminal 30 connects TNT motor.
Tilt and Trim Module Diagram 002063
1. Green/white wire
Terminals 87a and 30 are connected when relay is 2. Blue/white wire
not activated. This supp lies ground (B–) connec- 3. B+, red wire
4. B–, black wire
tion to TNT motor. 5. TNT motor connector
6. TNT switch connector
Terminals 87 and 30 are no rmally ope n. B+ is
applied to terminal 30 when relay is activat ed.
This supplies ground B+ connection to TNT motor.
Refer to Tilt and Trim Module Diagram.
105
SystemCheck CIRCUIT TESTS
SystemCheck CIRCUIT instrument harne ss terminal 1 (purple wire) and

terminal 2 (black wire).
TESTS
Make sure the SystemCheck engine monitor can
alert the opera tor durin g a “NO OIL,” “W ATER
TEMP” or “HOT ,” “CHECK ENGINE,” or “LOW 2
OIL” condition. Check the condition of the warning
system and associated wiring and connections.
Test the engine monitor regularly and anytime you
suspect an alert situation has been missed.
The instrument harness must be connected to the 1

outboard be fore perfo rming the following test s.
Refer to the Engine W iring diag ram and the 1. Test adapter(s) 42761
2. Connector, SystemCheck gauge
MWS Instrument W iring diagram in th e back of
this manual.
• If battery voltage is present, replace the gauge.
IMPORTANT: Use jumper wires ma de with the • If there is no battery voltage, check that 12 V is
appropriate terminals to test the warning circuits. present at terminal “B” of the key switch. Check
condition of the instrument harness, key switch,
and connections.
If the lights worked, but the warn ing horn did n ot

sound fo r one-h alf seco nd, turn the key switch
OFF. Disconn ect the warning hor n 2-pin connec-
tor. Substitute a known good warning h orn. Turn
the key switch ON.
• If the substitute horn beeps, the original horn is
defective and must be replaced.
• If the subst itute horn does not beep, check for
battery vo ltage between instrument harness 2-
42811 pin con nector, terminal 2 (purple wire) a nd
ground with the key switch ON. Also, check t he
Gauge Self-Test Check tan/blue wire for continuity between pin 8 of the
Turn the key switch to ON with the outboard NOT 8-pin connector a nd pin 1 of the 2-pin connec-
running. The gauge warning lig hts for NO OIL, tor.
WATER TEMP, CHECK ENGINE, and L OW OIL • If batt ery vo ltage is present at the purple wire
must a ll ligh t at once, th en turn off in se quence, and the t an/blue wire has cont inuity bet ween
and the warnin g hor n mu st sound for one-half
second.
If the gauge lig hts do not turn on, turn the key
switch OFF. Disconnect the gauge 8-pin connec-
tor from the back of the gauge an d turn the ke y
switch ON. T est for b attery volt age be tween
106
SystemCheck CIRCUIT TESTS
the two connectors, r eplace SystemCheck WATER TEMP/ HOT Circuit Test
gauge.
The tan wire of engine harness and the MWS har-
ness receives a signal f rom the EMM. The EMM
receives information from the temperature sensor
on the cylinder head.
Using a ju mper wire, con nect tan wire (pin 6 ) of

the engine harn ess connector to a cle an engin e
ground.
2 1
1. Purple wire DRC6280
6
2. Tan/blue wire
002079
Turn the key switch OFF and reconnect all discon-
nected circuits.
Turn the key switch ON. After the normal se lf-test
sequence, t he ga uge WATER TEMP / HOT indi-
CHECK ENGINE Circuit Test cator should stay on.
Separate th e 6 -pin SystemCheck connector of • If L ED is n ot on, test circuit for continuity . Test
MWS instrument harness from engine harness. for con tinuity of both the engine harness (t an
Black wire (pin 3) must be grounded. wire) and th e MW S instrument harn ess (t an
Using a jumper wire, connect tan/orange wire (pin wire).
2) to a clean engine ground. Turn the key switch OFF and reconnect all discon-
Turn the key switch ON. After the normal self-test nected circuits.
sequence, the CHECK ENGINE light should stay IMPORTANT: To test the temp erature sensor
on. itself, refer to Engine Temperature Sensor Test
• If the CHECK ENGINE light is not on, test circuit on p. 95.
for continuity. Check continuity of the MWS
instrument harness (tan/orange wire).
• Check cont inuity of the engine wire harness
between terminal 2 (tan/orange wire) of the Sys-
temCheck connector and pin 17 of the EMM J1-
A connector.
Turn the key switch OFF and reconnect all discon-

nected circuits.
107
TACHOMETER CIRCUIT TESTS
LOW OIL Circuit Test TACHOMETER CIRCUIT

Turn the key switch ON. Using a jumper wire, con-
nect tan/black wire (pin 4) of the engine harness TESTS
connector to a clean en gine ground. The LOW Check voltage at the battery. Use this reading as a
OIL light should turn on after 40 seconds. reference for battery voltage.
1 2
002079
If the LOW OIL ligh t does not turn on af ter con-

necting the terminal to ground, test circuit for con-
tinuity. 3
Turn the key switch OFF and reconnect all discon- 1. Purple lead 004287
nected circuits. 2. Black lead
3. Gray lead
NO OIL Circuit Connect the red meter lead to the tachometer pur-
Separate th e 6 -pin SystemCheck connector of ple wire and the black meter lea d to the tachome-
MWS instrument harness from engine harness. ter black wire (key ON, outboard NOT running).
Black wire (pin 3) must be grounded. • If meter shows battery voltage, go to next step.
• If meter shows less than battery voltage, check
Using a jumper wire, connect tan/yellow wire (p in
the purple, red/purple, and black wiring circuit s;
5) to a clean engine ground.
fuse, key switch, and battery connections.
Turn the key switch ON. After the normal self-test
Disconnect g ray a nd black wires at t achometer.
sequence, the NO OIL light should stay on.
Set Fluke 29 Serie s II mete r, or equivalent, to Hz
• If the NO OIL light is not on, test circuit for conti-
scale. Co nnect mete r between gra y wire a nd
nuity. Test for continuity of the MWS instrument
black wire. With outboa rd running at 100 0 RPM,
harness (tan/yellow wire).
meter should indicate 90 to 105 Hz.
• Test for continuity of the eng ine wire harness
• If meter read s 90 to 1 05 Hz, replace tachome-
between terminal 5 (tan/yellow wire) of the Sys-
ter.
temCheck connector and pin 24 of the EMM J1-
• If meter reads low or no signal, confirm outp ut
A connector.
on gray wire at pin 16 of EMM J1-A connector.
Turn the key switch OFF and reconnect all discon- – Reading OK – Check condition of tachometer
nected circuits. circuit (gray wire). Repair as needed.
– Reading not OK – Check connection at EMM;
replace faulty EMM.
108
FLYWHEEL AND STATOR SERVICING
FLYWHEEL AND STATOR Apply Moly Lube grease to th e thre ads of th e

puller pressing screw, P/N 307637, and the center
SERVICING hole of the crankshaft.
Place the puller on flywheel with body flat side up.

IMPORTANT: Weak flywheel mag nets can Attach the puller b ody with the th ree should er
cause lo w alternator output and af fect outboard screws and washers. Hold p uller bod y with ha n-
performance. Weak flywheel magnets ca n also dle, and tighten pressing screw un til flywhee l
cause low read ings on ignition test equipme nt, releases. T urn the center screw an d lif t t he fly-
such as a pe ak-reading voltmeter , which might wheel off of the crankshaft.
cause unnecessary parts replacement.
An accurate test o f alternat or ou tput can he lp

determine the flywh eel’s co ndition. Refer to
CHARGING SYSTEM TESTS on p. 97.
Flywheel Removal
A WARNING
To preve nt accid ental s tarting while s er-
vicing, discon nect battery cable s at the 6
battery.
000772
Use Flywh eel Holder, P/N 771311, or equivalent,

and a 1 7/16 in. so cket to remo ve flywheel nut.
Stator Service
Discard flywheel nut. Remove six allen head screws to remove stator.
1. Flywheel holder 000774 1. Stator screws 006864
Assemble the following components from Univer- To install stator, p osition stator on cylin der block.
sal Puller Set, P/N 378103: Apply Nut Lock to screw threads. Inst all scre ws
• Body, P/N 307636 and tighten in crossing pattern to a torque of 24 to
• Screw, P/N 307637 36 in. lbs. (3 to 4 N·m).
• Handle, P/N 307638
• Three screws P/N 309492
• Three washers, P/N 307640
109
FLYWHEEL AND STATOR SERVICING
Flywheel Installation IMPORTANT: DO NOT over apply Nut Lock on

flywheel t aper. This pr events Nut Lock from
A CAUTION migrating into upper seal of crankshaft.
To avoi d injury , keep han ds and finge rs Align the flywheel keyway and install the flywheel.
clear from underside of flywheel. Flywheel Coat the threads of the flywheel nut with Gasket
can snap toward stator with great magnetic Sealing Compound. Install the nut and tighten to a
force. torque of 140 to 160 ft. lbs. (190 to 217 N·m).
Install the outer edge of flywheel key parallel with

centerline of crankshaft.
DP0567
IMPORTANT: Perform the timing ve rification

1. Flywheel key DRC2116 procedure after flywheel removal or replacement.
Refer to TIMING ADJUSTMENTS on p. 112.
Thoroughly clean t he crankshaf t and f lywheel
tapers with Cleaning Solvent and let dry.
49623
Apply a thin, even coa t of Nut Lock to the inside

taper of the flywheel.
110
IGNITION COIL SERVICING
IGNITION COIL Remove four screws and bracket.
SERVICING 1
Ignition Coil Removal
Remove spark plug lead from ignition coil.
Disconnect ignition coil electrical connector.
Remove two ignition coil retaining screws.
Do not lose the rub ber washers between coil a nd

bracket.
1. Screws 007206
1
2
Ignition Coil Bracket Installation
Install bracket with four screws. Tighten screws to
a torque of 60 to 84 in. lb. (7 to 9.5 N·m).
Install spark plug leads with ground screw. Tighten

screw securely. 6
Ignition Coil Installation
Connect ignition coil e lectrical conne ctor. Place
1. Screws 007204 electrical connector on its retainer.
2. Connector
Install one rubber washer on each screw . Inst all
Ignition Coil Bracket Removal screw through ignition coil.
Remove all ignition coils from bracket. Install remaining rubbe r washers on scre ws
between coil and bracket.
Remove spark plug lead ground screw.
2
1 1
1. Electrical connector 007207

1. Ground screw 007205 2. Rubber washers
Install coil with washers on bracket.
Tighten screws to a torque of 60 to 84 in . lb. (7 to

9.5 N·m).
Install spark plug lead on ignition coil.
111
TIMING ADJUSTMENTS
TIMING ADJUSTMENTS Rotate flywheel counterclockwise until the num-

ber 1 piston con tacts the tool. Keep pressure on
Timing Pointer the flywh eel t o position the piston firmly ag ainst
the tool. Mark the flywheel directly across from the
A WARNING pointer. Label this mark “A.”
To preve nt acci dental s tarting while s er-

vicing, discon nect the battery cable s at
the battery. T wist and remove all sp ark
plug leads.
The timing pointer must be ad justed to in dicate 1

top dead cente r (TDC) o f the number 1 pist on.
This reference to the position of the number 1 pis-
ton is used to synchronize the electro nic timing
controlled by the EMM with the mechanical posi-
tion of the number 1 piston. 1. Timing pointer 005025
Always check timing po inter adjustment be fore

using t he Evinrude Diagnostics sof tware Timing Rotate th e flywheel clockwise until the p iston
Verification procedure. contacts the tool. Mark the flywheel directly across
from the pointer. Label th is mark “B.” Rot ate fly-
Disconnect the battery cables at the battery. wheel counterclockwise slightly t o release t ool
then remove it from spark plug hole.
Remove spark p lugs. Rot ate the flywhe el clock-
wise to approximately 30° ATDC. Use a fle xible measuring device, such as a piece
of string, to find the exact center b etween marks
Install Piston S top T ool, P/N 342679, into the “A” and “B.” Measure alon g the edge of the fly-
spark plug hole of the number 1 cylinder. wheel. Mark and label the center point “C.”
If mark “C” and the cast-in TDC boss on flywheel

are in align ment, the timing pointer is in the cor-
1 rect location.
If the pointer alignment is NOT correct, rotate the

flywheel clockwise to align the mark “C” with t he
pointer. Hold the flywheel in this po sition. Loosen
the pointer retaining screw and ad just the pointer
1. Piston stop tool 007208
112
TIMING ADJUSTMENTS
location to align with the cast-in TDC boss on the Check ignit ion timing a fter any of t he followin g
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 poin ter is
set and the outboard reaches operating tempera-
2 3 1 ture before making any timing adjustments.
1. Mark “A’” DR1233
2. Mark “B”
3. Mark “C”
TPS CALIBRATION
Use Evinrude Diagnostics sof tware to te ll th e
Repeat the entire ad justment process to make EMM what throttle position sensor voltage is when
sure pointer is aligned correctly. the throttle plates begin to open.
Install spark plugs. Refer to S park Plug Indexing Set TPS Calibration af ter replacing or adju sting
on p. 40. any throttle body or throttle linkage parts.
6
Timing Verification Remove the air silencer.
Use Evinrude Diagnostics software to synchronize A WARNING
the mechanical timing of the outbo ard with the
electronic timing of the EMM. To prevent accidental starting of outboard,
disconnect crankshaft positio n sens or
Start the outboard. (CPS).
Use t he Settings/Ignition Timing screen of the
diagnostics sof tware and follow the on-screen Turn th e key swit ch to the ON p osition. Do NOT
instructions. start the outboard.
MODELS WITH ICON ELECTRONIC SHIFT AND

THROTTLE
Rotate th e prope ller sha ft a nd use the ICON
remote control to shif t t he o utboard in to F OR-
WARD gear. Rotate the propeller shaft to confirm
the outboard is in FORWARD gear.
Fully adva nce the throttle. The throttle actuator

should move the thrott le plates to the wide ope n
throttle position.
Timing Adjustment Screen 008572
113
TIMING ADJUSTMENTS
Use Ball Socket Remover, P/N 342226, to remove While holdin g the throt tle plates closed, advance
throttle link from actuator arm. the throttle linka ge un til it stop s. Th e “Me asured
TPS Calibration” field on the screen will increase.
Click the “Working” button in the software to cali-

brate the TPS.
MODELS WITH ICON ELECTRONIC SHIFT AND

THROTTLE
Use Ball Socket Inst aller, P/N 342225, to install
throttle link onto actuator arm.
1
1. Ball socket remover 008034
Allow the throttle plates to return to the idle posi-

tion. 1
ALL MODELS
On the Settings/Adjustments screen of the diag-
nostics sof tware, click the “Set TPS Calibration”
button.
1. Ball socket installer 007303
Return the ICON remote control to the NEUTRAL

position. The thro ttle actuator should move the
throttle plates to the idle position.
ALL MODELS
Connect the cra nkshaft position senso r (CPS).
Install the air silencer.
1
1. TPS Calibration button 008571
114
ELECTRIC STARTER SERVICING
ELECTRIC STARTER Remove t he screws, lock washers, and p inion

housing.
SERVICING
Starter Removal
IMPORTANT: Do not clean the st arter drive
while the st arter motor and drive are in stalled on
the powerhe ad. Th e cleaning a gent could dra in
into the st arter motor, washing dirt from the drive
into the starter bearings and commutator.
Remove the starter positive (+) cable from post on

starter.
30373
Remove the fou r frame and bracket mounting

screws. Lift and remove the starter. Starter Disassembly
Lift and remove the wave washer and bushing.
6
004181
Loosen the two nut s used to faste n the starter

bracket. Remove the nuts and bracket.
30372
Place a n ap propriate-sized de ep socket on th e

spacer.
30374
115
Hit the socket with a ma llet to lower th e sp acer Remove pin ion and plastic weathe r cover from
and expose the retaining ring under the spacer. pinion shaft.
30368
Remove the driven gear and thrust washer.

30371
30367
30360
Using No. 2 external retaining ring pliers, re move
Remove t he ret aining ring, sp acer, an d spring the retaining ring and drive gear from the armature
from pinion shaft. shaft.
30366
30369
116
Remove the two thru-bolts. Mark the end ca p ori- Note the alignment marks by the positive terminal
entation, and remove the cap. stud. Hold the armature in place, and slide the
frame away from the gear housing.
30365
Gently tap the starter frame with a rubber mallet to

loosen it. 30352
Find the insulato r cap (end of the shaft or inside

Slowly remove the armature and thru st washe r.
the end cap). Inspect and replace, if necessary.
Do not lose the brush springs. 6
30354B
30351
117
Starter Cleaning and Inspection matter which could con tribute to fa ilure of win d-
ings.
Inspect the brushes fo r wear an d dama ge.
Replace brushes if dama ged or worn. Replace
weak brush springs.
TYPICAL 24058
Check permanen t magn ets. Ma ke sure they

30349 strongly attract any steel or iron object held inside
frame. W eak ma gnetism could cause excessive
Inspect an d rep lace locat ing ring on armature RPM on No Load Current Draw Test on p. 102.
shaft, if necessary.
TYPICAL 24057
30345
After disassembling the drive, clean each part with
Clean the commut ator with 30 0-grade eme ry Cleaning Solvent and inspect for wear and distor-
cloth. If commutator surface is u nevenly worn or tion.
pitted, turn it on a lathe. Remove any trace of oil or
metal dust from the commutator. If th e pinion does not p roperly eng age th e fly-
wheel, the pinion and screw shaft assembly could
Check the armature on a growler for shorted turns be worn, distort ed, or dirty. Locate the ca use of
using a test light or met er. Inspect armature insu- binding and cor rect it be fore completing t he
lation for ind ications of overheat ing or d amaged assembly.
windings. Clean off any carbon deposits or foreign
Inspect and replace end cap thru st washer if dis-
torted or worn excessively.
Inspect an d re place armature shaf t snap ring if

worn or distorted.
118
Starter Assembly Align the st arter frame and make sure th e lon g
alignment mark matches the mark next to the pos-
IMPORTANT: If removed, apply Locquic Primer itive terminal stud on the gear housing.
and Screw Lock to the brush card screws be fore
installing. Push the arma ture down firmly and slide the
frame into place. Align the not ches in th e ge ar
Route the brush leads and install the sp rings and housing and frame.
brushes. Compress the spring with a mo dified
putty knife.
30364
6
30352
IMPORTANT: Incorrect orien tation of the Install insulator cap on end of shaft.
brushes could damage the st arter or cause
reverse rotation.
Apply Moly Lube to th e armature bushing. Install

the thrust washer and armature.
30354B
Apply a ligh t coat of Moly Lube to the end ca p

bearing, and install the end cap.
30351
119
Install the two thru-bolts. Tighten to a torque of 50 Guard grease. Install the thrust washer and driven
to 65 in. lbs. (5.6 to 7.3 N·m). gear.
30362
30363
Install the weather cover.
Lightly coa t the drive gear with Triple-Guard
grease, and install it on the armature shaf t. Install
the retaining ring (flat side up) with No. 2 e xternal
retaining ring pliers.
30361
If removed , install the spring and sp acer (lar ge

diameter up) on the pin ion shaf t. Secure with
retaining rin g. Install bushing and wave wash er
(convex side down).
30366
Lightly coa t the gear housing bearing with Moly

Lube. Lightly coat th e d riven ge ar wit h Triple-
30369
120
Lightly coat the pinion s haft splines (helix) with Install the bracket . Apply Nut Lock to th e th ru-
Starter Bendix Lube. Lower th e pinion into place bolts. Install the nuts and tighten to a torque of 50
without disp lacing the driven gear or thrust to 65 in. lbs. (5.6 to 7.3 N·m).
washer.
30357
30359 To test th e assembly and operation of the starter,

refer to No Load Current Draw Test on p. 102.
Lightly coat the pini on housing bearing with
Starter Bendix Lube, and install the pinion housing Starter Installation
screws and lock washers. Tighten the screws to a Apply Locquic Primer and Nut Lock to the threads 6
torque of 60 to 84 in. lbs. (7 to 9.5 N·m). of th e four starter mounting screws. Position th e
starter and install the screws and lock washers.
First, tighten the top two screws, then the bottom

two screws, to a torque of 168 to 192 in. lbs. (19.0
to 21.5 N·m).
30358
004201
Attach starter positive (+) cable to post with lock

washer and nut; tigh ten securely . Coat connec-
tions with Black Neoprene Dip.
121
CONNECTOR SERVICING
CONNECTOR Release terminal latch and gently pull on wire.
SERVICING
1
DEUTSCH Connectors 2
IMPORTANT: Electrical Grease is reco m-
mended. Incorrect grease applica tion can cause
electrical or warning system problems.
1. Terminal latch (receptacle) 423293
To disconnect th e connector, press the latch and 2. Terminal latch (plug)
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 . Cle an o ff any old gre ase and dirt fro m Fill conn ector 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 sea l o nly. Push connectors to gether until
latched.
2
1
2
1 1. Ledge of plug 42330

2. End of plug
1. Latch 42079A
2. Seal
Push we dge in until latched. W edge in 2-pin
Terminal Removal receptacle is not symmetrical; position latch shoul-
Use hook-end of Co nnector Se rvice T ool, ders next to terminals.
P/N 342667, to pull out wedge from receptacle, or
Crimping Terminals
use other end of tool to pry ou t wedge fro m plug.
Use need le-nose p liers to remo ve wed ge fro m Strip insulation back 3/16 in. (5 mm). Place termi-
3-pin receptacle. nal in 18-g auge notch of Crimping Pliers,
P/N 322696. Position end of wire strands in termi-
nal past wire crimp area, and position end of insu-
lation past insulation crimp area. Ca pture all wire
strands in crimp; leave no loose stran ds. Crimp
1 wire s ecurely. Do not s older. Cri mp insulation in
14/16-gauge notch of crimping pliers.
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
122
CONNECTOR SERVICING
AMP Connectors
IMPORTANT: Always use the appropriate meter
test probe s and ada pters when testing compo-
nents fitted with these terminals. Electrical grease
is NOT used on AMP connectors. 1 2
SUPERSEAL 1.5
Disconnect
Lift latch. Pull connectors apart.
1. Locking tab, plug 002447
Connect 2. Locking tab, receptacle
Confirm the seal is in place. Push conn ectors Terminal Installation

together until latched.
Align terminal with co nnector housing. Push con-
1 nector and seal into housing until seated.
6
2
1. Latch 002448
2. Seal
002451
Terminal Removal 1. Terminal and seal
Use Secondary Lock Tool, P/N 777078, to release Align anti-backout d evice with conne ctor housing
anti-backout device of conn ector hou sing. Next, and terminals. Use Seco ndary Lock In staller,
use Primary Lo ck Tool, P/N 77 7077, to release P/N 777079, to seat device in connector.
locking tab of connector housing. Release locking
tab a nd pull on wire to remove fro m connector Crimping Terminals
housing. Crimping Superseal 1.5 terminals requires AMP
Crimp Tool with dies, P/N 777281.
1
2
2
1
1. Terminal 002452
2. Seal
1. Anti backout device, plug 002449
2. Anti backout device, receptacle 002450
123
CONNECTOR SERVICING
SUPER SEAL POWER TIMER SERIES

The J1-A and J1-B conn ectors of the EMM are The J2 con nector of the EMM is a AMP Power
AMP Super Seal connectors. Timer Series connector.
Disconnect Disconnect
Depress BOT H latches and pull con nector from Use a screw driver to open latch. Pull co nnector
plug. from plug.
Connect Connect
Push connector into plug until latches engage. Push connector until seate d in plug. Close latch
completely.
1
1
2
1. Latch 002118
1. J2 connector 002120
Terminal Removal 2. Latch (closed)
Open lock me chanism and remove terminal from

connector housing. Terminal Removal
Use Terminal Rele ase T ool, P/N 351413, to
release BOTH locking mechanisms of con nector.
2 2
Pull terminal from housing.
1
1 1
1. Latch 002453
2. Lock mechanism
1
1. Locking mechanism(s) 002455
Push terminal through seal until it is seated in con-
nector housing. Close lock mechanism.
1. Terminal release tool 002313

1. Terminal 002454
124
CONNECTOR SERVICING
Terminal Installation Terminal Removal

Align terminal with connector housing and push A tab on the back sid e of the terminal engages a
terminal with se al in to conn ector housing until shoulder in the connector housing to hold the ter-
seated. minal in place. The terminal is removed by releas-
ing the tab and then pushing the terminal and wire
1 through connector housing.
Insert a thin tool into the connector above the ter-

minal to release tab.
002456
1. Latch
2. Terminal with seal
1
Packard Connectors
IMPORTANT: Always use the appropriate meter
test probe s and ada pters when testing compo-
6
1. Tab DRC5940a
nents fitted with these terminals.
Disconnect
Install wire gasket o n wires and fe ed wires
Lift latch(s). Remove connector.
through the corr ect terminal position of the co n-
Connect nector housing. Terminal is crimped onto wire and
then pulled back into connector housing until lock-
Confirm the seal is in place. Push connector o nto
ing tab engages and terminal is seated.
housing until latched.
002304
Crimping Terminals
dsc02124
Strip insulation back 3/16 in. (5 mm). Position end
of wire strands in terminal past the wire crimp area
and the end o f insulation in the insula tion crimp
area of the terminal.
Capture all wire st rands in crimp ; leave no loose

strands. Crimp wire and insulation securely using
crimping pliers.
125
NOTES
NOTES
Bulletins
Instruction Sheets
Other
126
FUEL SYSTEM
FUEL SYSTEM
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
FUEL SYSTEM HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
FUEL SYSTEM CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
FUEL SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
REGULATIONS AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
PORTABLE FUEL TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
FUEL FLOW REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
FUEL LIFT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
VAPOR SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
FUEL CIRCULATION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
FUEL MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
FUEL SYSTEM PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
VENT LINE CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
PRIMING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
FUEL SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7
FUEL SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
PRESSURE REGULATOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
VAPOR SEPARATOR VENT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
FUEL INJECTOR PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
FUEL INJECTOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
CIRCULATION PUMP RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
LIFT PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
LIFT PUMP VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
LIFT PUMP DIAPHRAGM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
ANTI-SIPHON VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
FUEL COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
RELIEVING FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
FUEL FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
FUEL LIFT PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
VAPOR SEPARATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
FUEL MANIFOLD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
FUEL INJECTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
INTAKE MANIFOLD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
127
FUEL SYSTEM
SERVICE CHART
SERVICE CHART
FUEL PUMP, FUEL FILTER, VAPOR SEPARATOR
F
30-42 In. lbs. L
(3.5-4.7 N·m)
60-84 In. lbs.

(7-9.5 N·m)
100-110 In. lbs.

(11-12 N·m)
60-84 In. lbs.

(7-9.5 N·m)
60-84 In. lbs.
(7-9.5 N·m)
P
(Lower screw only)
Hand tighten to seal

contact then 1/2 - 1 turn
60-84 In. lbs.

(7-9.5 N·m)
C Adhesive 847
E Red Ultra Lock
F
F Blue Nut Lock
H Outboard Engine Lubricant
L Pipe Thread Sealing Compound
006971
P Permatex #2
128
FUEL SYSTEM
SERVICE CHART
REED PLATE ASSEMBLY AND THROTTLE BODY
Important: DO NOT lubricate

TPS to throttle shaft surface
B
10-18 in. lbs.
(1-2 N·m)
60-84 in. lbs.

(7-9.5 N·m)
Start at center and use
a spiral torque pattern
7
60-80 in. lbs.
(7-9.5 N·m)
K
30-42 in. lbs.
(3.5-4.7 N·m)
B
F
96-120 in. lbs.
(11-13.5 N·m)
A Triple-Guard Grease 60-80 in. lbs.

F
B Gasket Sealing Compound (7-9.5 N·m)
72-96 in. lbs.
C Adhesive 847 (8-11 N·m)
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
G Needle Bearing Grease
K Purple Screw Lock 004099
129
FUEL SYSTEM
SERVICE CHART
FUEL MANIFOLDS AND INJECTOR
Tighten in 3 stages
60-84 in. lbs.

1 (6.8-9.5 N·m)
A
120 in. lbs.
2 (14 N·m)
H A 3 24-26 Ft. lbs.

24-36 in. lbs (33-35 N·m)
(2.7-4 N·m)
R R R
S
R
R
S = Supply
R R = Return
S
S
S
S
R
R
S S
S
S
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
S STP Oil Treatment 004101
130
FUEL SYSTEM
FUEL SYSTEM HOSE ROUTING
FUEL SYSTEM HOSE ROUTING

3 11
7
2 5 10
3 10
14
1 10
4 6 10
8
Fuel Supply
10
Fuel Return 10
13 12
3.3 L Models 9 003985
3 3
3 11
7
2 7
2 5 10
10
3 14
1 4 10
6 10
Fuel Supply 8
10
Fuel Return
10
13 12
3.4 L Models 9
006977
1. Fuel supply from boat fuel system 8. Electric fuel circulation pump (20 to 35 psi)
2. Fuel lift pump (2 to 8 psi) 9. Fuel supply manifold
3. Pulse hose(s) from cylinder/crankcase 10. Fuel injector(s)
4. Water Separator / Fuel filter 11. Fuel return manifold
5. Fuel supply to vapor separator 12. Pressure regulator (high pressure)
6. Vapor separator 13. Test fitting (low pressure)
7. Vent hose to throttle body 14. Test fitting (high pressure)
131
FUEL SYSTEM
FUEL SYSTEM CIRCUIT DIAGRAM
FUEL SYSTEM CIRCUIT DIAGRAM

5
4
11 12 13
2 1
1 2 3 4
20 21 22 23
1 2
14 15
J2
5 6 7 8 9 10
24 25 26 27 28 29
2
16 17
18 19
7
8 3
26 27 28 29 30 31 32 33 34
1 2 3 4 5 6 7 8 9
18 19 20 21 22 23 24 25
10 11 12 13 14 15 16 17
J1-A
6
20 21 22 23 24 25 26
1 2 3 4 5 6 7
14 15 16 17 18 19
8 9 10 11 12 13
J1-B
1 2
12
2 1
1 1
1 2
12
4
3
12
12
6 5
007109
1. Injectors 4. Capacitor 7. High pressure fuel pump

2. EMM 5. Grounds (neg) 8. Fuel filter/water separator
3. 55 V circuit (white/red) 6. Fuel Injector grounds
132
FUEL SYSTEM
FUEL SYSTEM REQUIREMENTS
FUEL SYSTEM Portable Fuel Tanks

REQUIREMENTS A WARNING
Regulations and Guidelines If engine is equi pped with a quick -discon-
nect fuel hose, you MUST disc onnect the
Vessel man ufacturer, and /or inst aller of an EP A fuel hose from the engine and the fuel tank
certified outboard, must meet minimum specifica- to prevent fuel leaks:
tions for boat fuel systems established by: • Whenever the engine is NOT being used
• U.S. Environmental Protection Agency (EPA) • Whenever the engine is being trailered
– 40 CFR 1045.112 • Whenever the engine is in storage.
– 40 CFR 1060
• U.S. Coast Guard (USCG) NOTE: A small a mount o f fuel m ay be
– 33 CFR 183 released when the fuel connector is dison-
• American Boat & Yacht Council (ABYC) nected.
– Standard H-24
Store portable fuel tanks in well-ve ntilated
– Standard H-25.
areas, awa y from hea t sources a nd open
flames. Close th e ve nt sc rew of the fuel
tank cap, if equipped, to prevent escape of
fuel or fuel v apors which c ould ac ciden-
tally ignite. Do not a llow disconnected fuel
hoses to leak fuel.
NOTICE Do not use port able fuel tanks for 7

outboards larger than 1 15 HP. Inadequate fuel
flow to hig h horsepower outboa rds can res ult
in serious powerhead damage.
Fuel Flow Requirements

15 – 30 HP 40 – 90 HP 115 – 300 HP
Fuel tank pickup tube 1/4 in. (6.4 mm) min. ID 5/16 in. (7.9 mm) min. ID 3/8 in. (9.5 mm) min. ID
Fuel fittings 5/32 in. (4.1 mm) min. ID 1/4 in. (6.4 mm) min. ID 9/32 in. (7.1 mm) min. ID
Fuel supply hoses 1/4 in. (6.4 mm) min. ID 3/8 in. (9.5 mm) min. ID 3/8 in. (9.5 mm) min. ID
ALL MODELS
Fuel tank pickup 100 mesh, 304 grade stainless steel wire, 0.0045 in. wire diameter, 1 in. (25
screen mm) long
Antisiphon valve 2.5 in. (63.5 mm) Hg maximum pressure drop at 20 gph (76 l/hr) flow
Remote fuel filter 0.4 in. Hg maximum pressure drop at 20 gph (76 l/hr) flow,
150 in.2 (1290 cm2) of filter area
Maximum fuel pump Fuel pump should not be located more than 30 in. (76.2 cm) above bottom of
lift height fuel tank
133
FUEL SYSTEM
FUEL SYSTEM REQUIREMENTS
Fuel Requirements When using alcoho l-extended fue ls, be aware of

the following:
A WARNING • The b oat’s fuel system may h ave different
requirements regarding the use of alcohol fuels.
Gasoline is e xtremely flammable and Refer to the boat’s owner guide.
highly explosive under certain conditions. • Alcohol at tracts and ho lds moisture that can
Improper handling of fue l could result in cause corrosion of metallic parts in the fuel sys-
property damage, serious injury or death. tem.
• Alcohol blend ed fuel ca n cause engine pe rfor-
Always turn off the ou tboard before fuel -
mance problems.
ing.
• All parts of the fuel system should be inspected
Never pe rmit anyone ot her than an adul t frequently and replaced if signs of deterioration
to refill the fuel tank. or fuel leakage are found. Inspect at least annu-
ally.
Do not fill the fuel t ank all the way to the
top or fuel may overflow when it e xpands IMPORTANT: Always use fresh gasoline. Gaso-
due to heating by the sun. line will oxidize, resulting in loss of octane and vol-
atile compounds, as well as the production of gum
Remove portable fuel t anks from the boa t
and varnish deposits which can damage the out-
before fueling.
board.
Always wipe off any fuel spillage.
Additives
Do not s moke, allow op en fla mes or
sparks, o r use e lectrical devices su ch as IMPORTANT: The only fuel additives ap proved
cellular phones in the vicinity of a fuel leak for use in Evinrude outboards are 2+4 ® fuel condi-
or while fueling. tioner a nd Evinrude/Johnson Fue l System
Cleaner. Use of other fuel additives can res ult
Minimum Octane in poor performance or engine damage.
Evinrude/Johnson outboards are certified to oper- Evinrude/Johnson 2+4 Fuel Conditioner will
ate on unleade d automotive ga soline with an help prevent gum and varnish deposits from form-
octane rating equal to or higher than: ing in fue l syste m co mponents and will re move
• 87 (R+M)/2 AKI, or moisture from the fuel system. It can be used con-
• 90 RON tinuously an d should be use d during any period
Use unleaded gasolin e tha t co ntains met hyl ter- when the outboard is not being operated on a reg-
tiary b utyl ethe r (MTBE) ONLY if the MTBE con- ular basis. It s use will reduce sp ark plug fo uling,
tent does not exceed 15% by volume. fuel system icing, and fuel system compone nt
deterioration.
Use alcoho l-extended fue ls ONLY if th e alcoh ol
content does not exceed: Evinrude/Johnson Fuel System Cle aner will
• 10% ethanol by volume help keep fuel injectors in optimal operating condi-
• 5% methanol with 5% cosolvents by volume tion.
134
FUEL SYSTEM
COMPONENTS
COMPONENTS Fuel Filter

The fuel filter protects the vapor separator and the
The fuel syste m includes the following compo-
high-pressure components of the fuel system from
nents:
contaminants. Refer to INSPECTION AND MAIN-
• Fuel Lift Pump TENANCE SCHED ULE on p. 16 for service fre-
• Fuel Filter quency.
• Vapor Separator
• Fuel Circulation Pump
• Fuel Supply Manifolds
• Fuel Injectors
• Fuel Return Manifolds
1
Fuel Lift Pump
The fuel lift pump is a mechanical, pressure-pulse
pump. T he diaphrag m of t he pump is driven b y
two pu lse hoses that connect to the cylin-
der/crankcase assembly.
1. Filter 005022
Fuel lift pump pulse hose locations:
• Front mounted pump: cylinders 3 and 6
• Side mounted pump: cylinders 2 and 5 Vapor Separator
The vapor separator:
• Serves as a water-cooled fuel reservoir to accu-
mulate incoming fuel from the fuel lift pump and
7
1 from the fuel return manifold
• Contains a flo at con trolling the venting of fue l
vapors
2 • Contains a fue l pressu re regulator for t he hig h
pressure fuel system.
The va por separator is serviced as an assembly

and includes the fuel circulation pump.
1. Front mounted pump 006989

2. Side mounted pump
Vacuum from the fuel lif t pump pulls fuel from the
fuel t ank. Once fuel reaches the pump, internal 1
pump pressure forces the fuel from the pump
through the fuel filter and into the vapor separator.
Vapor Separator Assembly 004186

1. Circulation pump
135
FUEL SYSTEM
COMPONENTS
Fuel Reservoir to flow t o the int ake manifold through the ve nt

The vapor separator accumulates fuel in an inter- hose.
nal fuel reservoir and supplies fuel to the electric
As the vapor pressu re in the va por sep arator
circulation p ump. It is water-cooled to e nhance
decreases, the fuel level begins to in crease. An
vapor separating capabilities.
increase in the fuel level raises the float valve and
Cooling the vent closes.
Water is use d to cool the f uel as it flo ws through Pressure Regulator
the vapor sep arator. Th e cooling p assage of the
The fuel pressure regulator helps maintain consis-
separator self-drains when the ou tboard is sto red
tent fuel pressure in the fuel system.
vertically. Refer to HOSE ROUTING AND WATER
FLOW DIAGRAM 3.3 L on p. 184. Fuel returning from the injecto rs ente rs the fue l
chamber o f t he vapor sep arator th rough a pres-
Venting sure regu lator. The p ressure reg ulator ma intains
The fuel vapor vent regulates fuel vapor pressure approximately 20 to 30 psi (138 to 207 kPa) of fuel
in the reservoir. pressure in the high pressure side of the fuel sys-
tem.
1
Fuel Circulation Pump
The fuel circulation pump is an electric high pres-
sure fuel pump.
Fuel Supply
The pump is mounted to the vap or separator and
draws fuel from the fuel chamber. It pumps pres-
surized fuel throu gh a fuel su pply manifold co n-
nected to the fuel injectors.
1. Vent 004187
Electrical Circuit
The circulation pu mp is co ntrolled by the EMM
and ope rates on the 12 V circuit. The circu lation
1 pump is activated momentarily wh en the EMM
powers up. The EMM controls pump opera tion by
rapidly co nnecting and d isconnecting the pump’ s
internal coil to ground.
1. Vent hose connection to intake 004188
The vapor separator vent is opened and closed by

a float valve. The float valve moves relative to the
fuel level in the fuel chamb er. Hot fuel causes an
increase in vapor pressure. This results in a lower
fuel level in the vapor sep arator. The float valve
005024
drops and the vent opens. This allows fuel va por
136
FUEL SYSTEM
COMPONENTS
Fuel Manifolds The EMM is programmed to compensate for vari-

ations in fuel flow. Each injector and its location on
The fuel supply and return manif olds route fu el
the outb oard is identified b y t he EMM. DO NOT
through the high pressure side of the fuel system.
install an injector without updating the compensa-
Fuel Supply Manifold tion software.
The fuel supply manifold supplies pressurized fuel Each se rvice injector includes it s fu el flow in for-
to the inlet port of each fuel injector. mation on a 3 .5 in . flop py d isk. This sof tware
allows the EMM to be reprogrammed for this injec-
Fuel Return Manifold
tor’s unique fuel flow characteristics.
The fuel return manifold provides a route for fuel
passing through the f uel injectors to flo w back to NOTICE Fuel injectors MUST NOT be moved
the fuel chamber of the vapor separator. from one cyl inder to another . EMM pro gram-
ming is assoc iated with the cy linder loca tion
1 of each injector . Inst alling an injector on the
wrong c ylinder can result in po werhead fa il-
ure.
2
Injector Fuel Supply
Fuel is supplied to the injectors by the fuel circula-
tion pump and the fuel supply manifold.
Each inje ctor ha s int ernal fu el p assages. These
passages are designed to:
• Provide fuel to the injector's injection chamber 7
1. Inlet ports 004246
2. Return ports • Route fuel through the injector hou sing to coo l
the injector coil and armature.
Fuel Injectors
Fuel injectors are fuel metering, electric solenoids
(55 V) bo lted directly to th e cylinde r he ad. The
EMM controls the a ctivation of each injector b y
rapidly connectin g and disco nnecting the injec-
tor’s internal coil to ground.
Fuel Flow Compensation

The flow rate of each injector is measured as part
of the manufacturing process. This information is
recorded an d a ssigned to the injector b y serial
number. 006619
137
FUEL SYSTEM
FUEL SYSTEM PRIMING
FUEL SYSTEM PRIMING Priming the Fuel System

Vent Line Clamp A WARNING
Federal Reg ulations require that a ll o utboards Fuel vapors are highly flammable. Perform
with a fuel vapor separator must be shipped with a the foll owing procedure in a well venti-
vent line clamp inst alled. Th is clamp must be lated area. Extinguish all smoking materi-
removed before priming the fuel system or starting als and m ake c ertain no ignition sources
the outboard for the first time. are present.
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.
Once fue l flow is observed, co nnect fuel supply

hose from fuel tank to hose fitting on outboa rd.
Secure hose with Oetiker clamp.
Use the primer to fill the vapor separator.
004223 The high-pressure fuel circu its and in jectors will

prime as the outboard is cranked with the starter.
IMPORTANT: Failure to remove the clamp may
cause fuel starvation and poor running qualities. Observe all fuel lines, both in the boat and on the
outboard. Repair any fuel leaks.
A WARNING
Failure to ch eck for fuel leaks could allow
a leak to go undetected, resulting in fire or
explosion a nd ma y caus e person al injury
or property damage.
138
FUEL SYSTEM
FUEL SYSTEM TESTS
FUEL SYSTEM TESTS Shut OFF outbo ard. Mo nitor pr essure gaug e.
Pressure should not drop below 15 psi (103 kPa).
A WARNING IMPORTANT: If outb oard does not run, prime

fuel system and crank outboard; check circulation
Use cau tion whe n working on any pres-
pump operation; check fuel system pressure.
surized fuel system. W ear sa fety g lasses
and wo rk in a we ll ven tilated area. Extin - Results:
guish all smoking materials and make cer-
Normal pressure
tain no open flame s or ign ition sources
• Observe pressure reading after outboard is shut
exist. Before starting any fuel system ser-
OFF.
vice, carefully reliev e fuel system pres-
sure. Fai lure to properly relieve fuel • Refer to Lift Pump Pressure Test on p. 141.
system pressure can result in spraying Pressure drops after outboard is shut OFF:
fuel and/or e xcessive fue l spill age during • Check for leaking fuel injector.
servicing. Fue l is flammab le and can be
• Check for leaking pressure regulator.
explosive under certain conditions.
• Check for external fuel system leak.
Fuel System Pressure Test High pressure:

• Check for re stricted filter or fuel return fitting of
Relieve fuel system pressure. See Relieving Fuel vapor separator, damaged pressure regulator in
System Pressure on p. 143. vapor sep arator, or restricted fuel return mani-
fold.
A WARNING
Protect ag ainst hazardous fue l spray. Low pressure 7
Before st arting any fuel syst em service, • Check fuel supply to fuel lift pump. Refer to Lift
carefully relieve fuel system pressure. Pump Vacuum Test on p. 142. Higher vacuum
readings indicate restrictions in the fuel supply.
Repair or replace as needed.
After relieving fuel system pressure, install a 0 to
• Restricted fuel filter/water separator assembly.
60 p si (0 to 415 kPa ) Fuel Pressur e Gau ge,
• Lift pump not supplying adequate fuel to vapor
P/N 5007100 or equivalent, to the upper fuel pres-
separator. Refer to Lift Pu mp Pre ssure T est
sure test fitting.
on p. 141.
• If the above tests are good and vapor separator
2 remains full of fu el, check for da maged circula-
tion pump. Replace vapor separator assembly.
No pressure
1
• Check electrical circuit and ground connections
for circulation pump.
• If volt age is present and pump does not run,
repair connection or replace vapor separator
assembly.
1. Fuel pressure gauge 004324

Relieve fuel system pressure before removing fuel
2. Test fitting pressure gauge. Refer to Relieving Fuel System
Pressure on p. 143.
START outboard and che ck pressu re. Syste m
pressure should be 20 to 35 psi (138 to 241 kPa).
139
FUEL SYSTEM
FUEL SYSTEM TESTS
Pressure Regulator Test Fuel Injector Pressure Test

Refer to Vapor Sep arator Service on p. 146 to This te st re quires Inj ector T est Fi tting ki t,
remove vapor separator. P/N 5005844.
Make su re filter is no t clogg ed. Clean or r eplace Disconnect the battery cables at the battery.
as needed.
Relieve fuel system pressure. See Relieving Fuel
Apply oil to valve and connect pressure pump and System Pressure on p. 143.
hose to the fuel return fitting of vapor separator.
A WARNING
Apply pressure to ch eck regulator ope ration. The
pressure sh ould open check valve at a pproxi- Protect aga inst hazardous fuel s pray.
mately 15 psi (103 kPa). Before st arting any fuel syste m service,
carefully relieve fuel system pressure.
IMPORTANT: Perform test with in jector

mounted to cylinde r h ead and fittin gs installed
with manifold retainer.
Use cap and tie strap to seal off outlet fitting. Con-
nect a 0 to 30 psi (0 to 207 kPa) pressure tester to
the inlet fitting . Pressurize the inje ctor to 30 psi
(207 kPa). Pressure must h old f or at least five
minutes.
1
2
3 1
1. Filter 000249
2. Fuel return fitting
3. Pressure regulator 1. Outlet fitting 002379
2. Inlet fitting
Vapor Separator Vent Check Refer to FUEL DE LIVERY TESTS on p. 85 for

Monitor the vapor separator vent hose. No fuel or additional test procedures.
a trace of fuel is accep table. Exce ssive fuel dis-
charge indicates a vapor separator vent malfunc-
tion. Monitor vent f or presence of fuel during
testing. Temporarily install cle ar tubing for mon i-
toring. Replace vapor sep arator if th e ve nting of
fuel is continuous.
140
FUEL SYSTEM
FUEL SYSTEM TESTS
Fuel Injector Resistance Test Circulation Pump Resistance Test

Disconnect the battery cables at the battery. Disconnect the battery cables at the battery.
Use a digital multimeter to measure the injector Use a digital multimeter with app ropriate adapter
coil resistance. leads to measure the fue l pump circuit an d coil
resistance.
Fuel Injector Coil Resistance
2 to 3 Ω @ 72°F (22°C) Fuel Pump Resistance
3 Ω @ 77°F (25°C)
006865
004217
Use a dig ital multimeter with ap propriate ada pter
leads to measure resistance of the complete injec- Lift Pump Pressure Test 7
tor circuit, including injector and associated wiring.
Install a 0 to 15 p si (0 to 103 kPa) Fue l Pressure
Measure resist ance betwee n pin 1 (wh ite/red) of Gauge, P/N 5006397 or equ ivalent, to the lower
injector con nector (connected) and the approp ri- fuel pressure test fitting.
ate pin lo cation o f EMM J1-B co nnector (discon-
nected). Refer to engin e wiring diag ram for
specific EMM J1-B connector pin location for the
injector circuit being tested (blue, purple or green).
1
1. Fuel pressure gauge 004587

2. Test fitting
Prime the fuel system and check for leaks. START

outboard and run at idle speed. Hold gaug e level
004342
with inlet fitting and monitor g auge for pre ssure
Resistance should be the same as, o r slightly reading.
higher than, the injector alone. Pressure shou ld st abilize a nd gau ge must n ot
indicate less than 4 psi (27 kPa).
141
FUEL SYSTEM
FUEL SYSTEM TESTS
Results: START outboard and run at FULL THROT TLE for

Normal pressure at least two minutes. Monitor clear vinyl ho se for
• Perform the Lift Pump Vacuum Test on p. 142. the presence of air . Air bubbles ind icate a faulty
Make sure no a ir lea ks or restrictions ex ist in hose, connection, o r f uel tank p ick-up. Repair, if
the fuel supply hose or boat fuel system. necessary, before proceeding.
Low pressure There should be no air or vapor bubbles visible in

• Check pulse hoses and fittings for restrictions. the clear hose. The maximum inlet fuel va cuum
should not exceed 4 in. Hg. (13.5 kPa) at the inlet
• Perform the Lift Pump Vacuum Test on p. 142.
to the fuel lif t pu mp under any o perating cond i-
Make sure no a ir lea ks or restrictions ex ist in
tions (IDLE to WOT).
the fuel supply hose or boat fuel system.
• Check fuel flow through fuel lift pump. Use fu el A higher vacuum indicate s an excessive restric-
primer bulb to force fuel through pump. tion in the fuel supply. Repair as needed. Refer to
FUEL SYSTEM REQUIREMENTS on p. 133 for
No pressure
fuel supply component requirements.
• Check pulse hoses and fittings restrictions.
• Check fuel flow through fuel lift pump. Use fu el Lift Pump Diaphragm Test
primer o r primer bulb to force fu el throu gh
Perform this test only if a damaged pump is sus-
pump.
pected. This test does not check the performance
• Momentarily prime or squee ze p rimer bulb to
of internal fuel pump check valves.
check gauge operation.
• Check pulse hose and fittings for restrictions. Remove both pulse ho ses from th e crankcase fit-
tings.
Lift Pump Vacuum Test
Apply 15 psi (103 kPa) to each of the pulse hoses
Confirm fuel supply to the fuel lift pump.
of the pu mp. Replace lif t pu mp if either side of
Temporarily install a vacu um gauge, T-fitting, and pump fails to hold pressure.
8 in. (20.3 cm) of clear vinyl hose between the fuel
supply hose and fuel lift pump (inlet). Secure con-
nections with tie straps to prevent fuel or air leaks.
NOTICE Do not use fuel primer bulb, manual 1

fuel primer, or ele ctric fuel pump primer to
restart o utboard. A posit ive pressu re in the
fuel suppl y could dama ge som e vac uum
gauges.
1. Pulse fitting 000670
000243
142
FUEL SYSTEM
FUEL COMPONENT SERVICING
Anti-Siphon Valve Test FUEL COMPONENT

Remove anti-sip hon valve from fuel t ank. Inst all
adapter fittings and a 36 in. (91.4 cm) len gth of SERVICING
clear hose to the inlet side (tank end) of valve.
A WARNING
Gasoline is ex tremely fl ammable and
3 highly explosive under certain conditions.
Use caution when working on any part of
the fuel system.
Protect aga inst hazardous fuel s pray.
20 in. (500 mm)
Before st arting any fuel syste m service,
2 carefully re lieve fuel sys tem pressure.
Refer to Relieving Fuel System Pressure.
Always disco nnect the batte ry cables at
1 the batte ry befo re servicing the fuel sys-
tem unless instructed to do otherwise.
Always work in a well v entilated area and
1. Anti-siphon valve DR2277
2. Adapter fitting wipe off any fuel spillage.
3. Clear hose
DO NOT smoke and make certain no open
Fill clear hose with water to a height of 20 in. (500 flames or ignition sources exist.
mm). W ater must NOT flow throug h valve . An After servicing the fuel system check for 7
occasional d rip is accep table. Rep lace valve if leaks. Failure to c heck for fuel le akage
water drips continuously. could allow a l eak to go unde tected,
resulting in fire or explosion.
Increase height of water to 25 in. (630 mm). Water
should flow through valve a s water level re aches
25 in. (630 mm). Replace the anti-siphon valve if Relieving Fuel System Pressure
test results are different.
IMPORTANT: Minimize fue l sy stem pre ssure
prior to disassembly. Temporarily restrict the fue l
supply hose from fuel t ank with hose pincer.
Remove prop eller and disco nnect circulation fue l
pump ele ctrical connector. If outb oard runs, start
and run at IDLE for 5 se conds a nd ST OP o ut-
board. If o utboard doe s NOT run, crank for 1 0
seconds.
143
FUEL SYSTEM
Wrap a shop towel complete ly a round the pre s- Fuel Filter Service
sure te st valve while connecting f itting from Fu el
Pressure Gauge, P/N 5007100, to top test fitting Removal
of fuel pump/vapor separator assembly. Disconnect the battery cables at the battery.
Use an appropriate filter wrench to turn the filter in

a counte rclockwise d irection. Remove the filter
carefully to prevent spilling the filter’s contents.
Inspect contents for any presence of wa ter. If

1
water is pre sent, iden tify the source and correct
the problem. T ake ad ditional fu el samples a nd
drain fuel tank(s), if necessary.
1. Shop towel 004335
Insert venting hose of gauge into a suit able con-

tainer.
1
Slowly open gauge’s venting valve.
Clean up any spilled fuel with shop towels.
1. Fuel filter 005022
Installation
1 Lubricate filter seal with outb oard lubricant an d
3 position filter on threade d mo unting tube o f filter
bracket. Take care not t o damage water in fue l
sensor probe . Turn filter clockwise o nto th e tu be
until seated against the bracket.
2
Tighten filter approximately 3/4 turn after the gas-
ket contacts the bracket.
1. Test fitting 004334
2. Venting hose
3. Venting valve
Squeeze primer bulb to prime fuel system. Hold
pressure on bulb and check for fuel leaks.
Connect battery cables.
Run outboard and check for fuel leaks.
144
FUEL SYSTEM
Fuel Lift Pump Service Installation

The fuel lif t pump is servicea ble as a co mplete Place fu el pu mp bracket, with rubb er isola tor
assembly. Refer to parts catalog for service parts. mounts, in front of the throttle body.
Removal Apply Nut Lock to screws and inst all screws in to

throttle body. Tighten screws to a torque of 24 to
36 in. lbs. (2.8 to 4.0 N·m).
Disconnect the fue l su pply hose from the in-line
fitting.
Disconnect the fuel outlet hose from tee.
Disconnect the fu el lif t pump pulse hoses at the

crankcase fittings. 1
1. Screws 004220
1
Connect th e fuel lif t pump pulse ho ses to th e
crankcase. Secure with tie straps.
Connect the f uel outlet ho se to t he fu el filter.

Secure with Oetiker clamp.
7
1. Pulse hose crankcase fitting 005028
Connect the fuel sup ply hose to the in-line fitting.
Remove clamp scre w, clamp, and oil injection Secure with Oetiker clamp.
pump from fuel pump bracket. Squeeze primer bulb to prime fuel system. Hold
Loosen the fue l lif t pump mou nting screws. pressure on bulb and check for fuel leaks.
Remove the fuel lif t pump and bracket as an Install o il injection pump on bra cket with clamp
assembly. and screw.
004333
145
FUEL SYSTEM
Vapor Separator Service Fuel Manifold Service

Removal Removal
Disconnect the battery cables at the battery. Disconnect the battery cables at the battery.
Relieve fuel system pressure. Refer to Relieving Relieve fuel system pressu re. Refer to Relieving
Fuel System Pressure on p. 143. Fuel System Pressure on p. 143.
Disconnect circulation pump electrical connector. Remove clamps and disconnect the fuel manifolds
as follows:
Remove clamp and fuel supply manifold from top • Fuel supply manifold to circulation pump
of circulation pump. Remo ve clamp and va por
• Fuel return manifold to vapor separator
vent hose from separator cover.
Remove clamp s and vap or separator cooling
1
water hoses.
Remove clamps and fuel return manifold and fuel

supply hose from bottom of vapor separator.
Remove the vapor separator housing retainer clip.
1. Fuel supply manifold 004189

1 2. Fuel return manifold
Remove fuel manifold retainer screws and remove

retainers from fuel injectors.
1
1. Retainer clip 004189
Remove vapor sep arator/fuel pump from the 3

mounting stud and slide vapor separator housing 2
from the grooves of the isolator mounts.
Installation
Slide th e va por sep arator bracket no tches into
grooves of the isolator mounts. Install forward iso-
lator o f vapor separator on mounting stud a nd 1. Retainer screw 004266
2. Fuel supply manifold fitting
secure with retainer clip. 3. Fuel return manifold fitting
Install all hoses and manifolds in original locations Disconnect fuel manifold fittings from fuel in jector
and secu re wit h ap propriate clamps. Squeeze ports, then remove the manifold assemblies.
primer b ulb to prime fuel system. Hold p ressure
on bulb and observe for fuel leaks.
146
FUEL SYSTEM
Installation Fuel Injector Service

Check condition of sealing O-rings on fuel man i- Mark fuel injectors to show cylinder locations.
fold fittings. Lubricate O-rings wit h outboard lubri-
cant a nd inse rt fue l manif old fittings into in jector. NOTICE Fuel inje ctors m ust be inst alled in
Both fittings must be fully se ated into the injector the correct cy linder lo cations. Use Evinrude
fuel ports. Diagnostics So ftware to make sure that EMM
Install retainer in the outer groove of the manifo ld programming matches injector positioni ng.
fittings. Install and tighten screw to a torque of 24 The Injector Coefficients screen display s
to 36 in. lbs. (2.7 to 4 N·m). injector serial numbers.
1. Retainer 005342
7
2. Manifold fitting groove
1 Injector Coefficients Screen 008568
Use caution when handling fuel injectors. Prevent

dirt and debris from entering fuel inlet and outlet
3 ports of in jectors or fuel ma nifolds. Cover th e
2 injector nozzle port in cylinder h ead to prevent
contamination of combustion chamber.
Removal
1. Retainer screw 004266
2. Fuel supply manifold fitting Relieve fuel system pressu re. Refer to Relieving
3. Fuel return manifold fitting Fuel System Pressure on p. 143.
Install the fuel manifolds to the fuel pump assem- Remove f uel manifolds. Refer to Fuel Mani fold
bly and secure with clamps: Service on p. 146.
• Fuel supply manifold to circulation pump. Disconnect the fuel injector electrical connector.
• Fuel return manifold to vapor separator.
147
FUEL SYSTEM
Remove injector screws. tor filter. Install new crush ring and O-rings. Lubri-
cate O-rings with STP † Oil Treatment.
1. Injector screws 008195

1. Adaptor 002196
Remove fuel injector and insulator.
Crush Ring Replacement

2
NOTICE Injector crush rin gs must be
replaced if i njector is installed in a different
head or cylinder location.
1
Use Slide Hammer assembly , P/N 3910 08, with
Slide Hammer Adaptor kit, P/N 390898, to remove
injector from mounting cup.
Thread adaptor and stud into face of injector. Hold

mounting cup securely. Work slide hammer to 1. Crush ring 002317
2. O-rings
separate injector from mount housing.
Install injector into mount housing. Press on injec-
tor face until injector seats in mount housing.
002345
Remove adaptor from injector. Remove crush ring

002318
and O-rings from injector. Inspect and clean injec-
148
FUEL SYSTEM
Installation Use the drop down menu to navigate to the saved

coefficient file location.
NOTICE All injectors must be installed in the
correct cylinde r by serial number. Improper The co efficient file name must match t he seria l
injector inst allation can result in powerhead number of the injector.
failure.
Select the correct file for the injector.
Installation of a replacement injector requires that
Select the Replace Injector button.
coefficient data for the new injector is uploaded to
the EMM. 1
Coefficient data for some replacement injectors is
supplied on a computer disk shipped with the
injector. If a disk is not included with th e injector,
coefficient dat a can be do wnloaded from the
Evinrude/Johnson dealer website. Refer to the
instructions provided with the injector kit. 2
3
Upload Coefficient Files to EMM
Use the Evinrude Diagnostics sof tware Settings
screen to upload the coefficient file to the EMM.
1. Navigation menu 008573
Select the Injectors tab. 2. Injector coefficient file
3. “Replace Injector” button
Select the cylinder tab for injector being replaced.
After th e u pload is complete, th e pro gram will 7
Select the Replace Injector button. return to the Cylinder tab.
Make su re the serial number displayed on the

screen ma tches the serial nu mber pri nted o n t he
serial number label of the replacement injector.
1. “Replace Injector” button 008568A
1. Serial number 008568A
149
FUEL SYSTEM
Install Injector Tighten screws in st ages, st arting with the lower

The followin g it ems and their mating su rfaces screw.
must be cleaned before reassembly: • First torque is 5 ft. lbs. (7 N·m)
• Injector • Second torque is 10 ft. lbs. (14 N·m)
• Cylinder head • Final torque is 24 to 26 ft. lbs. (33 to 35 N·m).
• Adapter
• Screws
• Threaded areas
A CAUTION
All injector components must be clean to
ensure correct torque tig htening specifi-
cations. To prevent fuel leaka ge, carefully
follow these installation instructions.
Place injector an d insulator in t he proper cylinder Tighten Screws in Stages 007210

location.
Reconnect fuel injector electrical connectors.
IMPORTANT: Be careful not to pinch any wiring
or hoses during assembly. Install fuel manifolds. Refer to Fuel Manifold Ser-
vice on p. 146.
Lubricate mo unting screw threads and und er the
head of the screw with a light coat of Triple-Guard
grease. Install washers (on e per screw) on injec-
tor ret aining screws. I nstall screws and washers
through mounting flange of injector and into cylin-
der head.
002316
150
FUEL SYSTEM
Intake Manifold Service Disassembly

All reed plat e assembly and reed valve assem-
Removal blies must be cleaned before reassembly . DO
Disconnect vapor sep arator vent hose, thrott le NOT use strong carb uretor cleaner or the hot
position sensor connector, and throttle link arm. soaking tank method for cleaning.
Use Ball Socket Remo ver T ool, P/N 342226, to Remove th e re ed v alve re tainer s crews a nd
remove throttle link arm. remove the assembly.
Remove crankshaft position sensor fro m re ed
plate assembly.
Remove oil/fuel pump bracket.

Remove thrott le body screws and throttle body
assembly.
004191
Use caution t o prevent d amaging r eed valve

assemblies.
7
004258
Remove gasket from throttle body.
Remove screws and reed plate assembly from the

crankcase.
004192
NOTICE DO NOT d isassemble ree d valv e

assemblies. Damaged reed plates are not ser-
viceable and are replaced as an assembly.
Inspection
Inspect the leaf plate a ssemblies for da mage or
004190
contamination:
• Leaf plates must not be distorted.
• Leaf valve must not be cracked or chipped.
• Leaf plate stops must not be distorted or loose.
• Leaf plate assemblies must be clean.
151
FUEL SYSTEM
Inspect the int ake manifold . All gasket su rfaces Installation

must be cleaned, smooth, and free of nicks. Use a Install ga sket on reed plate assembly . DO NOT
machinist’s st raight-edge an d a feeler gaug e to use sealer on the gasket.
check flatness in all directions. Surface mu st be
flat, ±0.004 in. (0.10 mm). Place reed plate assembly on cylinder/crankcase.
Apply Nut Lock to screws. Install all screws.

1
Tighten the cente r screws first and exp and o ut-
ward. Tighten in st ages to a final to rque of 96 to
120 in. lbs. (11 to 13.5 N·m).
1. Straight-edge 004193
Assembly
Remove old adhesive from reed valve ret aining
screws.
004205
Prime screw th reads with Locquic Primer and let
dry. Apply Nut Lock to threads. Position reed valve Place gasket on throttle body. Install throttle body,
on reed plate an d inst all screws. T ighten screws with o il pump bracket on reed plate and inst all
to a torque of 30 to 42 in. lbs. (3.5 to 4.7 N·m). screws.
Tighten the cente r screws first and exp and o ut-

ward. Final torque is 60 to 84 in. lbs. (7 to 9 .5
N·m).
004194
004257
Install crankshaft position sensor.
Install vapor separator vent hose and oil recircula-

tion hose. Secure with tie straps.
152
FUEL SYSTEM
Connect throttle linkage a nd throttle position sen- Position clamps as shown.

sor connector.
IMPORTANT: DO NOT lu bricate TPS to thrott le

shaft surface.
1
1
2
2
3
3
4
1
1. Throttle linkage 004248

2. TPS electrical connector
3. Vapor separator vent hose
1. Clamps 006990
4. Oil recirculation hose
2. Idle air hose
3. Oil/fuel pump bracket
Install oil/fuel pump bracket. Tighten screws 30 to
42 in. lbs. (3.5 to 4.7 N·m). Refer to TPS CALIBRATION on p. 113.
153
FUEL SYSTEM
NOTES
NOTES
Bulletins
Instruction Sheets
Other
154
OILING SYSTEM
OILING SYSTEM
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
OILING SYSTEM CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
OIL SUPPLY DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
OIL RECIRCULATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
OIL SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
RECOMMENDED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
OIL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
OIL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
ELECTRICAL CIRCUIT (55 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
REAR OIL MANIFOLD (3.3 L MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
REAR OIL PUMP (3.4 L MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
ELECTRICAL CIRCUIT (12 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
LOW OIL WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
NO OIL WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
CYLINDER AND CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
OIL RECIRCULATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
OIL CONTROL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
OIL INJECTION RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
BREAK-IN OILING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
OIL SUPPLY PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
OIL HOSE PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
8
OIL PUMP PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
OILING SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
OIL INJECTION PUMP STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
OIL INJECTION PUMP VOLTAGE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
OIL INJECTION PUMP CIRCUIT RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
CYLINDER OIL PUMP VOLTAGE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
CYLINDER OIL PUMP RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
OIL SUPPLY VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
OIL INJECTION PUMP FUNCTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
OIL INJECTION FITTINGS FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
LOW OIL SENDING UNIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
OIL COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
OIL DISTRIBUTION HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
OIL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
REAR OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
155
OILING SYSTEM
SERVICE CHART
SERVICE CHART
Engine Oil Programming Labels

NOTICE NOTICE
XD 30
This outboard has
been programmed
for use of
Evinrude®/Johnson®
This outboard has
been programmed
for use of
Evinrude®/Johnson®
XD 100
XD25™, XD30™, XD100™ oil.
XD 50 XD50™ oil or TC-

W3 equivalent.
See your Dealer if you
See your Dealer
if you decide to
discontinue using
decide to upgrade to Evinrude/Johnson
Evinrude/Johnson XD100™ oil.
XD100™ oil.
Refer to the Refer to the
Operator’s Guide for Operator’s Guide for
Oil Requirements. Oil Requirements.
355624 355625
NOTICE
This outboard has been programmed for
the use of Evinrude ® /Johnson® XD100™
outboard oil ONLY.
XD 100
Failure to use Evinrude ®/Johnson® Boat Label
XD100™ outboard oil may harm engine
performance and shorten engine life.
355627
This outboard has been programmed
XD100 outboard oil may harm engine
WWW.EVINRUDE.COM
for the use of Evinrude®/Johnson®

Failure to use Evinrude/Johnson
XD100™ outboard oil ONLY.
*IMPORTANT*
24-36 in. lbs.

(3-4 N·m)
P/N 352927
XD 100
Tank Label
(Accessory)
004097a
156
OILING SYSTEM
OILING SYSTEM CIRCUIT DIAGRAM
OILING SYSTEM CIRCUIT DIAGRAM
1
5
12345
12345
4
8
11 12 13
9
1 2 3 4
20 21 22 23
7
14 15
J2
5 6 7 8 9 10
24 25 26 27 28 29
3
16 17
18 19
26 27 28 29 30 31 32 33 34
1 2 3 4 5 6 7 8 9
18 19 20 21 22 23 24 25
10 11 12 13 14 15 16 17
J1-A
10
8
20 21 22 23 24 25 26
1 2 3 4 5 6 7
14 15 16 17 18 19
8 9 10 11 12 13
13
1
11 J1-B
6
2
5
3
4
A B
14 15
2 12
2 1
008364
1. Crankcase Oil Injection Pump 9. Oil Pressure Sensor Signal (TAN/WHITE)

2. Cylinder Oil Injection Pump 10. Rear Oil Injector control (BLUE/RED)
3. EMM 11. Rear Oil Injector +12 V (RED/YELLOW)
4. 55 V Circuit (WHITE/RED) 12. Low Oil Switch (TAN/BLACK)
5. Capacitor 13. NO OIL Signal (TAN/YELLOW)
6. Grounds, NEG (BLACK) 14. LOW OIL Signal (TAN/BLACK)
7. EMM to Oil Solenoid (BLUE) 15. SystemCheck Connector
8. Oil Pressure Sensor, +5 V analog (RED)
157
OILING SYSTEM
OIL SUPPLY DIAGRAMS
OIL SUPPLY DIAGRAMS

200 – 250 HP (3.3 L) MODELS
6
1
2
Rear oil manifold delivers
5 3 oil to cylinder sleeves
4
1. Cylinder 2
2. Cylinder 4
3. Cylinder 6
4. Cylinder 1
5. Cylinder 3
6. Cylinder 5
1. Oil tank assembly

2. Oil pick-up
3. Oil supply hose
4. In-line oil filter
5. Oil injector assembly
6. Oil distribution hoses
7. Oil pressure sensor
8. Rear oil manifold
Primary oil manifold delivers

5 6
oil to crankcase fittings and
4 7 1 rear oil manifold
3 2
1. Cylinder 1
2. Cylinder 2
3. Cylinder 3
4. Cylinder 4
5. Cylinder 5
6. Cylinder 6
7. Rear oil manifold
008212
158
OILING SYSTEM
OIL SUPPLY DIAGRAMS
Port View
Starboard View
008208
159
OILING SYSTEM
OIL SUPPLY DIAGRAMS
250 – 300 HP (3.4 L) MODELS
8
1
Rear oil pump delivers
6 2 oil to cylinder sleeves
5 3
4 1. Cylinder 2
2. Cylinder 4
3. Cylinder 6
4. Cylinder 1
5. Cylinder 3
6. Cylinder 5
1. Oil tank assembly

2. Oil pick-up
3. Oil supply hose
6 6 4. In-line oil filters
5. Oil injector assembly
6. Oil distribution hoses
7. Oil pressure sensor
8. Rear oil pump
Primary oil manifold

delivers oil to
6 4
5 6
1
crankcase fittings
3 2 1. Cylinder 1
2. Cylinder 2
3. Cylinder 3
4. Cylinder 4
5. Cylinder 5
6. Cylinder 6
5
2
4 7
3 1
008433
160
OILING SYSTEM
OIL SUPPLY DIAGRAMS
Port View
Starboard View
008432
161
OILING SYSTEM
OIL RECIRCULATION DIAGRAMS

Complete View
1
2
3
4
5
6
008205
Top View
1. Recirculation fitting 008206
162
OILING SYSTEM
Port View
Starboard View
008207
163
OILING SYSTEM
OIL SYSTEM REQUIREMENTS
OIL SYSTEM COMPONENTS

REQUIREMENTS The oiling system consists of the following compo-
nents:
Recommended Lubricants • Oil tank
Evinrude/Johnson XD100, XD50, or XD30 out- • Oil injection pump and manifold assembly
board oils are recommende d for use in Evinrude • Oil pressure sensor
E-TEC outbo ards. If these oils are no t available, • Electrical circuit
you must use a TC-W3 certified oil. • LOW OIL and NO OIL warning systems
• Cylinder and crankcase
Evinrude/Johnson XD100 o utboard oil is h ighly
• Rear oil manifold assembly (3.3 L models)
recommended for all conditions and applications.
• Rear oil pump (3.4 L models)
Engine Lubricant Below 32°F (0°C) • Oil recirculation system
If the outboard will be operat ed in temperature s
below freezing (32°F, 0°C), use Evinrude/Johnson Oil Tank Assembly
XD100. The oil tank must be properly positioned and t he
oil level must be monitored. Refer to the Predeliv-
IMPORTANT: For new o utboards, test low oil ery and Installation Guide.
warning before filling oil tank.
Oil Tank Components:
Turn key switch to ON. The engine mon itor warn- • Tank, 1.8 or 3.0 gallon capacity
ing display should show “LOW OIL.” • Oil pickup and filter assembly
Add enough oil to raise level to at least one-quar- • LOW OIL sending unit
ter capacity. • Mounting bracket and hardware
• Protective cover (1.8 gallon tank only)
The “LOW OIL” warning should not display. • Primer bulb and supply hose.
NOTICE Failure to follow these recom men-
dations could void the outboard warranty if a
lubrication-related failure occurs.
1.8 Gallon Oil Tank Kit 44839B
164
OILING SYSTEM
COMPONENTS
Oil Injection Pump Oil Pressure Sensor

The oil injection pump is an electric (55 V) actua- The oil pressure sensor react s to chang es in oil
tor st yle pump. It d raws oil from the oil tank manifold pressure. The EMM supplies and moni-
through th e oil supp ly h ose [2 5 f t. (7.6 m) maxi- tors electrical current to the sensor.
mum] and supplies pressurized oil to the oil mani-
fold. The EMM supplies 5 5 V and controls
activation of the pump.
1
2
1
1. Oil pressure sensor 04220
• The se nsor provide s an o utput voltage to th e

1. Oil injection pump 004220 EMM based on oil manifold pressures.
2. Oil manifold
• 5 VDC Input on RED wire
• 0.5 - 4.5 V Output on TAN / WHITE wire
The oil manifold distributes the oil supplied by the
oil injection pump to the crankcase. On 3.3 L mod- • Ground on BLACK wire
els oil is also distributed to the rear oil manifold. The EMM monitors the oil pressure sensor’s elec-
trical circuit. If circuit voltage is beyond the speci-
Electrical Circuit (55 V) fied range (< 0.15 V, > 4.85 V), the EMM:
The oil inje ctor is powered by the 55 V electrical
8
circuit. The EMM controls pump operation by rap-
idly con necting and d isconnecting the pump’ s EMM LED 3: ON (Running)
If oil pressure is be low expected range (< 0. 4 V),
The EMM mo nitors the oil injection pump e lectri- the EMM:
cal circuit. If circuit voltage is beyond the specified
range (open circuit), the EMM: Stores service code 72
Activates S.A.F.E.
EMM LED 4: ON (Running) If oil pressure is ab ove expected range (> 4.6 V),
Engine Monitor NO OIL display: ON the EMM:
Refer to Oil Pressure Sensor on p. 59.
165
OILING SYSTEM
COMPONENTS
Rear Oil Manifold (3.3 L models) Electrical Circuit (12 V)

The rear oil manifold receives oil from the primary The rear oil pu mp is powered by the 12 V electri-
manifold and distributes it to the cylinder sleeves. cal circuit. The EMM controls pu mp operation by
rapidly co nnecting and d isconnecting the pump’ s
The EMM mon itors the o il inje ction pump electr i-

cal circuit. If the circuit is open, the EMM:
Activates S.A.F.E.
1 EMM LED 4: ON (Running)
Engine Monitor No OIL display: ON
1. Rear oil manifold 008363

LOW OIL Warning
A sen ding unit in the oil t ank p ick-up assembly
Rear Oil Pump (3.4 L models) monitors the oil level in the oil tank.
The oil injection pump is an electric (12 V) actua- If the oil level falls below one-quarter capacity, the
tor style pump. It d raws oil from a fit ting at the oil EMM signals:
injection pump and supplies pressurized oil to the
cylinder sleeve s. The EMM su pplies 12 V and Engine Monitor LOW OIL display: ON
controls activation of the pump
An optional oil tank sending unit kit is available to
display actual oil level through an I-Command net-
work.
NO OIL Warning
The EMM monitors th e electric al circuit of the oil
pressure sensor. If the sen sor or circuit fails, or if
1 there is a lack of oil pressure in the oil distribution
manifold, the EMM:
Activates S.A.F.E.
Engine Monitor NO OIL display: ON
1. Rear oil pump 008444
166
OILING SYSTEM
COMPONENTS
Cylinder and Crankcase Oil Recirculation System

The p rimary oil distributio n manifold provides External hoses and fittings, inte rnal cylin-
crankcase lub rication th rough o il d istribution der/crankcase passages, and intake manifold pas-
hoses an d p ressed-in fitting s at t he front of the sages are used to recirculate any accumulation of
crankcase, port side. oil from various locations in the po werhead. Th e
movement of oil is controlled by check valves.
Cylinder Recirculation
Internal po werhead oil drain passages connect
the lowest point of the intake port area of the cylin-
1 der block to external check valves. External hoses
connect these ch eck valves to a h ose fitting
pressed into the top of the intake manifold / throt-
tle body. Intake manifold vacuum draws any accu-
mulation of oil from the int ake port are a of th e
cylinders in to th e in coming air stream in front of
the top reed valve.
1. Pressed-in fitting 008456
The rear oil distribution manifold provides lubrica-

tion fo r each cylinder . Each cylind er of the cylin-
der/crankcase h as a pressed -in f itting which is
connected to an oil distribution hose. 1
8
1
1. Check valves 004337
2 1
1. Cylinder sleeve oil fittings – port 008456
1. Recirculation hose 004336

2. Hose fitting
1. Cylinder sleeve oil fittings – stbd 008457
167
OILING SYSTEM
OIL CONTROL SETTINGS
Check valves pre ssed into the cra nkcase b elow

#4 and #6 ree d valve assemblies connect to
hoses which route to a fitting at the top of the Oil Injection Rate
block, above #2 cylinder.
The Engine Management Module (EMM) controls
the oil in jection rate based on engine RPM. This
1 3 rate can be adjusted for the type of oil being used,
and also for powerhea d break-in. Use Evinrude
Diagnostics software to access these features.
The Set Oil Type option controls the injection rate

4 for the oil being used and typical operating condi-
2 tions.
The TC-W3 oil type setting is the standard setting
for all outboards. Set TC-W3 for:
• Operation with a ll TC-W3 outboard o ils in clud-
ing XD30, XD50, or XD100.
• Applications requiring maximum lubrication.
1. Lower to upper main bearing oiling circuit 005043 • Extreme applications (commercial or harsh con-
2. Idle oil circuit ditions, racing or other high performance opera-
3. Tee fitting
4. Cylinder recirculation circuit tion).
• Use this set ting with XD100 outb oard oil in
Crankcase / Main Bearing Recirculation extreme applications
The movement of oil through the main bearings is The XD100 setting provides an option to run the
controlled b y in ternal p assages, exter nal fitting s outboard at a reduced oil injection rate. This set-
and hoses, and an in-line check valve. ting REQUIRES the use of Evinrude XD100 ou t-
Both cent er ma in be arings receive oil throu gh board lubrican t and is not recommend ed for all
grooved passages in th e crankcase. Oil migrate s applications.
to the bearings from th e crankcase a reas of the IMPORTANT: The XD100 setting is not avail-
higher cylinders. able on all models.
The lower main bearin g receives oil thro ugh a Use the XD100 setting for:
grooved passage in the crankcase.
• Conventional use (runabouts, cruisers)
Lower to upper main bearing oil flow • Moderate applications
Oil moves from the lower main b earing cavi ty
through an internal cran kcase p assage to an
external fitting. Ext ernal hoses with an in-line
check valve connect to a f itting at the upper main 1
bearing, which leads to t he up per main bearing
through an internal crankcase passage.
1. Oil control setting 008571
168
OILING SYSTEM
NOTICE Running a n Evinrude E-TEC out- Install decals in a hig hly visible locatio n, such as
board on other grades of oil while s et to the one of the following:
XD100 oil ratio will res ult in increased engine • Dashboard/deck of boat, next to key switch
wear and shortened outboard life. • Deck of boat, next to the remote oil fill
• Deck of boat, next to oil tank assembly
Powerhead oil prog ramming la bels are provided • Oil tank cover
to ident ify EMM oil prog ramming. Inst all the cor- • Cover of oil tank compartment
rect label to alert user to specific oil requirements. • Attach to oil tank or oil fill cap.
IMPORTANT: Make sure the engine label an d
2 boat decals match EMM programming.
1
Break-In Oiling
IMPORTANT: DO NOT add oil in the fuel tank
on Evinrude E-TEC models.
The EMM automatically supp lies extra oil to the
engine as follows:
• 90° V6: First two hours above 2000 RPM
1. Evinrude/Johnson XD30 outboard lubricant (TC-W3) 004964 Follow these steps for outboard set-up:
YELLOW label
2. Evinrude/Johnson XD100 outboard lubricant (Premium)
BLUE label (Installed) Use Evinrude Diagnostics software to ma ke sure
the break-in pro gram has been started on a new
An XD100 Outb oard Oil De cal, P/N 352369, is outboard.
available to la bel b oats equ ipped with o utboards • Use th e diag nostics software to st art bre ak-in
that have been progra mmed for the redu ced oil oiling after a powerhead rebuild.
injection ratio. 8
1
NOTICE
This outboard has been programmed for
the use of Evinrude ® /Johnson® XD100™
outboard oil ONLY.
Failure to use Evinrude ®/Johnson®
XD100™ outboard oil may harm engine
355627
XD100 Outboard Oil Decal 355627 1. Break-in oil setting 008571
NOTICE The operator m ust mo nitor the oil

tank level to co nfirm oil cons umption. Th is
may require several hours of operation above
idle.
169
OILING SYSTEM
OIL SUPPLY PRIMING
OIL SUPPLY PRIMING 250 – 300 HP (3.4 L) MODELS

Start the outboard. Use the oil priming functions in
the sof tware to m ake sure t he sy stem is com -
A WARNING pletely primed.
Always use c aution while wo rking around
machinery with m oving p arts. The follow- IMPORTANT: The outbo ard sho uld be running
ing set-u p proce dures requ ire running during th e priming proce dure to avo id pumpin g
tests that are performed with the ou t- too much o il into the crankcase, which could
board’s motor cover removed. cause a hard-starting condition.
Prime the rear oil pump FIRST (cylinder oil pump).

Oil Hose Priming
Use the Prime Cylinder Oiler button o f t he
Insert the oil supply hose from the oil tank into a Dynamic Test screen to prime the rear oil pump.
suitable co ntainer. Squeeze the oil primer bu lb
until oil flows from the oil tank into the container.
Once oil supply hose from the oil tank is filled with
oil, conne ct t he ho se to the oil su pply fit ting on
outboard and secure with Oetiker clamp.
Oil Pump Priming

1
Squeeze the oil primer bulb until oil flows from the
oil supply hose, through the oil f ilter, and into the
crankcase oil pump (front oil pump).
IMPORTANT: Inspect oil filter to make sure it is

filled with oil. All air must be eliminated from the oil
filter during priming procedure. Dynamic Tests Screen 008570
1. Prime Cylinder Oiler button
Continue to sq ueeze the oil primer bulb until oil
flows through the front oil pump, into the oil distri- With the Prime Cylinder Oiler function activate d,
bution hoses, and to the crankcase fittings. continue t o squeeze the oil primer bulb un til oil
flows through the oil distribution hoses of the rear
Use Evinrude Diagnostics software to m ake sure
oil pump.
the EMM is pro grammed for the type of oil being
used.
NOTICE The software priming function must
be used along with the primer bulb for two rea-
sons:
• The primer bul b alone wi ll not move oil
through the rear pump assem bly unless the
pump is running.
170
OILING SYSTEM
OIL SUPPLY PRIMING
• The pump assembly cannot prime itself until Observe oil flo w through all oil distribution hoses.
it has been filled with oil. Air must be purged during the priming procedure.
2 2
1 1
1. Cylinder oil pump 008391 1. Crankcase oil pump 008392

2. Oil distribution hoses 2. Oil distribution hoses
Prime the front oil pump assembly LAST. Small bubbles are a cceptable. Larg e bu bbles
must be eliminated through continued priming.
Use the Prime Oil System button of the Dynamic
Test screen to prime the front oil pump.
1
3 2
1
1. Oil distribution hose
2. Small bubbles
3. Large bubbles
004398
8
Repair any fuel or oil leaks.
Dynamic Tests Screen 008570

1. Prime Oil System button
171
OILING SYSTEM
OIL SUPPLY PRIMING
200 – 250 HP (3.3 L) MODELS Make sure that oil flows through the rear oil distri-
Start the outboard. Use th e oil priming function in bution manifold to the cylinder block fittings.
the sof tware to mak e sure the s ystem i s co m-
pletely primed.
Use the Prime Oil System button of the Dynamic 1

Test screen to prime the oil pump.
1. Rear oil distribution manifold 008203

1
Small bubbles are accept able. Large bubbles
must be eliminated through continued priming.
1
Dynamic Tests Screen 008570A
1. Prime Oil System button
Observe oil flow through all oil distribution hoses.

Air must be purged during the priming procedure. 3 2
1. Oil distribution hose 004398
2. Small bubbles
3. Large bubbles
Repair any fuel or oil leaks.
The oiling system on the se mod els can also be

1 primed using the Self-Winterizing featu re if diag-
nostics software is not availa ble. Refer to STOR-
AGE on p. 44.
1. Oil distribution hoses 004224
172
OILING SYSTEM
OILING SYSTEM TESTS
OILING SYSTEM TESTS Oil Injection Pump Voltage Tests

Use a digital multimeter calibrated to a scale that
IMPORTANT: Always perform visual inspections reads 55 V (DC) to mea sure voltage between the
to identify oiling system le aks. Ma ke sure t he oil oil pump electrical connector and engine ground.
tank is filled and oil supply is not contaminated.
Acceptable Oil Injection Pump
Oil Injection Pump Static Test Test Readings
Key switch ON approximately 30 VDC
The EMM controls the pu mp by providing grou nd
Control signal approximately 10 Hz
through pin 23 (blue wire) of the J1-B connector
Engine running approximately 55 VDC
and pin 2 (blue wire) of the oil pump connector.
Use Evinrude Diagnostics software to activate the Connect negative meter lead to ground.
Oil Injector test. This test st arts the EMM control Use an appropriate test probe to connect positive
function for the oil injection pump. meter lead to pin 2 (blue wire) of oil injection pump
electrical connector.
1. Oil injection pump connector (pin 2) 004344

8
Static Tests Screen 008569 Turn th e key switch to the ON positio n. Ob serve
voltage at pin 2.
IMPORTANT: This test is op erating the pump • Voltage at pin 2 should be approximately 30 V.
with 30 V on the system voltage (55 V) circuit. The
start assist circuit (SAC) of the EMM converts bat-
tery voltage (12 V) to 30 V of system voltage. Bat-
tery must be fully cha rged and connections must
be clean and tight. Pump activation sho uld be
carefully confir med. Listen for an audible click
from the oil injection pump when it is activated.
Use an ind uctive timing lig ht to monitor cu rrent
flow throu gh the groun d circu it (blue wire) at the
oil pump connector (pin 2).
If the light flashes, the EMM and oil in jection cir-

cuits are not at fault.
Refer to Oil Inje ction Pump V oltage Tests on

p. 173.
173
OILING SYSTEM
OILING SYSTEM TESTS
Use the Oil Injector te st o f Evinrude Diagnostic Oil Injection Pump Circuit
software Static Test screen to activate the oil
pump.
Resistance Test
IMPORTANT: The complete oil injection pump
electrical circu it includes EMM alternator outp ut,
the engine wire harness, the injection pump wind-
ing and connectors, and the oil injector control cir-
cuit of the EMM. Check continuity of all wiring and
connections.
Disconnect J1-B connector from EMM. Use a digi-

tal mu ltimeter with appropriate adap ter leads to
measure the resist ance between pin 23 (blu e) of
the EMM J1-B connector a nd pin 1 (white/red) of
the oil inje ction p ump connector. Calibrate t he
meter to the LOW OHMS scale.
Oil Injection Pump Circuit Resistance
Observe voltage at pin 2. 2 to 3 Ω
• Voltage at pin 2 should drop as the oil pump
cycles.
1
Check the control signal while the Oil Injector test 2
is running. Set the digit al multimeter to the Hertz
(Hz) scale.
• Meter should read approximately 10 Hz.
Results:
• If volt age and co ntrol sign al rea dings at pin 2
are within range, the EMM and wiring are not at
fault.
• If voltage at pin 2 is not within range, check volt- 1. EMM J1-B connector (pin 23) 004343
age at pin 1 (white/red wire) of oil pump electri- 2. Oil injection pump connector (pin 1)
cal connector.
• An infinite reading (∞) indicates an open circuit.
Connect positive meter lead to pin 1 (white/red Isolate the fa ulty com ponent. Check continuity
wire) of oil injectio n pu mp electrical connector. of wiring, con nections, or inje ction pump win d-
Observe voltage at pin 1. ing. Repair faulty wiring or replace faulty pump.
• Voltage at pin 1 should be approximately 30 V. • For a higher t han expected reading, test resis-
tance of the inject ion pump. If injection pump
Start the engine. Observe voltage at pin 1.
resistance reading is within rang e, inje ction
• The volt age at pin 1 sh ould be appro ximately pump winding is good. Isolate faulty compo-
55 V. nent. Repair faulty wiring or replace faulty com-
• If voltage is not within range, refer to Oil Injec- ponent and retest.
tion Pump Circuit Resistance Test on p. 174.
• No volt age reading, refe r to System V oltage
Test on p. 81.
174
OILING SYSTEM
OILING SYSTEM TESTS
Cylinder Oil Pump Voltage Tests Use the Cylinder Oiler Test fu nction of Evinrude
Diagnostic software Static Test screen to activa te
The EMM controls the pu mp by providing grou nd
the cylinder oil pump.
through pin 4 (blue/red wire) of the J1-A connector
and pin A (blue/red wire) of the oil pump connec-
tor.
Use an appropriate test pro be and a digital multi-

meter calibrated to a scale that reads 12 V (DC).
Acceptable Cylinder Oil Pump
Test Readings
Key switch ON approximately 12 VDC
Control signal approximately 2 Hz
Engine running approximately 12 VDC
Connect negative meter lead to ground.
Connect p ositive me ter le ad to pin A (blue/red

wire) of oil injection pump electrical connector. Static Test Screen 008569
1. Cylinder oiler test
• Voltage at pin A should vary (drop), as the oil

pump cycles.
1 Check the control signal while the Oil Injector test

is running. Set th e digital multimeter to the Hertz
(Hz) scale.
• Meter should read approximately 2 Hz.
8
Results:
• If volt age and con trol signal readings (Hz) at
1. Oil injection pump connector 008445 pin A are within range, the EMM and wiring a re
not at fault.
Turn the key swit ch to th e ON position. Observe • If voltage at pin A is not within range, check volt-
voltage at pin A. age at pin B (re d/yellow wire) o f the oil pump
• Voltage at pin A should be approximately 12 V. electrical connector.
Connect p ositive me ter lead t o pin B (red/ yellow

wire) of oil injection pump electrical con nector.
Observe voltage at pin B.
• The volt age a t pin B sh ould be approximately
12 V.
Start the engine. Observe voltage at pin B.

• The volt age a t pin B sh ould be approximately
12 V.
• If voltage at pin B is within range, refer to Cylin-
der Oil Pump Resistance Test on p. 176.
• No volt age reading at pin B, che ck continuity
between pin B of oil pump electrical co nnector
and pin 24 of EMM J1-B connector.
175
OILING SYSTEM
OILING SYSTEM TESTS
Cylinder Oil Pump Resistance Oil Supply Vacuum Test

Test
A WARNING
Wear safety glasse s to avoid personal
Disconnect th e e lectrical connector f rom the oil injury, and set compressed air pressure to
injection pump. less than 25 psi (172 kPa).
Use a digital multimeter to measure the resistance
between the pins of the oil pump conn ector. Cali- Remove the oil pick-up assembly from the oil tank.
brate the meter to the LOW OHMS scale.
Carefully remove the pickup filter and flush with a
Oil Injection Pump Resistance mild solvent to re move any cont amination. Rein-
5–6 Ω stall filter.
Carefully remove the oil hose from the oil pickup

and remove the oil supply h ose from the oil injec-
tion pump.
Use low pressure air to purge oil from hose.

1
1
008446
1. Oil injection pump connector
3
Results:
2
An infinite reading ( ∞) indicates an open circuit of
the injection pump winding. Replace faulty pump.
1. Oil hose 12306
2. Oil pickup
3. Low pressure air
Use Plug/Holder, P/N 329661, and clamp to plug

the pickup end of the hose.
1. Plug/holder 12307
2. Oil hose
Attach a vacuum tester to the o utboard side of oil

supply hose an d draw 7 in. Hg (24 kPa) va cuum
176
OILING SYSTEM
OILING SYSTEM TESTS
on the hose for at least five min utes. Re pair or Static Test
replace any le aking components. Reinstall the oil Use the Evinrude Diagnostics software oil injector
hose. test to activate inje ctor. Confirm t hat a small
amount of oil is discharged while injection pump is
Check height of pickup assembly.
activated.
Pickup Assembly Height
6.84 to 6.96 in. Results:
1.8 gallon tank • Oil flows from distribution hose, comp are to oil
(174 to 177 mm)
8.74 to 8.86 in. flow at other distribution hoses.
3.0 gallon tank • If one or more hoses fail to discharge oil, check
(222 to 225 mm)
for a kinked or restricted hose before replacing
the oil injection pump assembly.
Oil Injection Fittings Flow Test

Make sure the oil injection fittings of the cylind er
and crankcase assembly allow fluid to move.
Remove oil distrib ution hose fro m cra nkcase fit-

ting. Temporarily install a length of oil hose.on the
fitting.
Use a Syringe, P/N 346936, filled with isop ropyl

alcohol to force fluid through hose and fitting.
LOW OIL Sending Unit Test

Height of Oil Pickup Assembly COB5657A Remove oil from the oil tank
Place a new seal on oil t ank and reinstall pickup Turn th e ke y switch ON. The d ash mounte d 8
with filter into oil tank. Install and tighten screws. Engine Monitor syst em should show a LOW OIL
warning.
Oil Injection Pump Function Test
Once the warning has been confirmed, refill the oil
Remove oil distribution h ose from fitting at crank-
tank. The LOW OIL warning should stop when the
case. Squeeze oil supply primer bulb to provide oil
oil level exceeds one-quarter of oil tank’s capacity.
to injection pump.
1. Crankcase fitting 004224
Running Test
Start the out board and observe oil flo w. Confirm
that a small amo unt of oil is discha rged while
injection pump is activated.
177
OILING SYSTEM
OIL COMPONENT SERVICING
OIL COMPONENT Once h ose is re moved from the manifold, make

sure hose support is in the end of the hose.
SERVICING
A WARNING
To preve nt acci dental s tarting while s er-
the battery.
Oil Distribution Hoses

The oil distribu tion hoses from each manifo ld 1
MUST be the same leng th. DO NOT alter the
1. Hose support 008070
length of any hoses.
Oil Distribution Hose Length Installation
Primary oil manifold to Cut Repla cement Oil Hose , P/N 778708, to the
12 in. (305 mm)
cylinder block fitting correct length. Insert hose support in manifold end
Rear oil manifold to of hose. (Primary manifo ld to rear manifo ld hose
32 in. (812 mm)
cylinder block fitting does not use a hose support.)
Primary oil manifold to
32 in. (812 mm) IMPORTANT: DO NOT insert distribution hoses
rear oil manifold*
*Primary oil manifold to rear oil manifold hose into manifold without a hose support.
has a 0.160 in. I.D. and does NOT use a hose Be sure the hose is full y in serted into man ifold.
support. Insertion depth is 5/8 in. (16 mm). Visually inspect
for hose supports.
Removal
Release the hose b y depressing the outer ring of
the hose retaining mechanism.
1. Retainer mechanism 004295
178
OILING SYSTEM
Oil Injection Pump Installation

Route oil d istribution h oses f rom the oil distrib u-
Removal tion manifold to the crankcase oil delivery fittings
Disconnect the battery cables at the battery. as they were before removal. Refer to OIL SUP-
PLY DIAGRAMS on p. 158.
Remove engine cover and air silencer.
Connect oil hoses to crankcase fittings and fasten
Remove the oil sup ply hose from the fitting (inlet)
with tie straps.
of the oil injection pump.
Disconnect the electrical connector.
IMPORTANT: Note oil distribu tion h ose rout-

ings b efore p roceeding with disassembly . Center
hose fro m pr imary oil manifo ld conne cts to oil to 1
inlet of rear oil manifold.
Remove oil distribution hoses from the crankcase

fittings.
Remove oil injection pump clamp screw.

1. Crankcase fitting 004224
Connect oil hose to rear oil manifold.
1. Clamp screw 004220

1
Remove the oil injection pump assembly.
1. Oil to rear manifold 007148
IMPORTANT: The oil injection pump and mani-
fold is an assembly and canno t be serviced a s
individual components.
179
OILING SYSTEM
Install oil pump o n bracket with clamp and retain- Rear Oil Pump
ing screw. Tighten to a torque of 24 to 36 in. lbs. (3
to 4 N·m). Removal
Remove engine cover.
Remove the oil supp ly hose from the fittin g (inlet)

of the oil pump.
1
Disconnect the electrical connector.
IMPORTANT: Note oil distribut ion ho se ro ut-

ings before proceeding with disassembly.
Remove oil distribution hoses from the crankcase

1. Clamp 004220 fittings.
Reconnect the electrical connector. Remove two mounting bracket screws.
IMPORTANT: Use oil primer bulb to purge air

from oil supply hose before reconnecting hose to
oil pump.
Reconnect oil sup ply hose to the inlet fitting of oil 2

pump. Fasten with Oetiker clamp.
2
1
1
1. Fitting (inlet) 008444

1. Oil supply hose 005519 2. Mounting bracket screws
2. Oetiker clamp
Remove the oil injection pump assembly.
Make sure oiling system is primed. Check oil flow
through o il d istribution ho ses. Check oil syste m IMPORTANT: The rear oil pump and manifold is
operation and rou ting o f oil h oses. Refer to OIL an assembly and cannot be serviced as individual
SUPPLY PRIMING on p. 170. components.
Run the outboard and check for leaks.
Repair any oil leaks an d any kinked or misrou ted

hoses.
180
OILING SYSTEM
Remove two screws to remove oil pump assembly Connect oil hoses to cylinder sleeve oil fittings on
from mounting bracket. the crankcase and fasten with tie straps.
1 1
1. Screws 008476 1. Cylinder sleeve oil fittings – port 008456
Installation
Clean threa ds o f screws an d apply Nut Lock to
threads. Inst all oil pump assemb ly into mounting
1
bracket with two scre ws. T ighten screws to a
torque of 24 to 36 in. lbs. (2.7 to 4 N·m).
Install the oil injection pump and bracket with two

mounting bra cket screws. T ighten to a torqu e of
60 to 84 in. lbs. (7 to 9.5 N·m).
1. Cylinder sleeve oil fittings – stbd 008457

8
Connect the electrical connector.
2 Reconnect the oil supply hose to the inlet fitting of
the oil pump. Faste n with Oetiker clamp. Orient
clamp as shown.
1 2
1. Fitting (inlet) 008444

2. Mounting bracket screws
008477
Route oil distribution hose s from the oil distribu- 1. Oil supply hose
2. Oetiker clamp
tion manifold to the crankcase oil delivery fittings
as they were before removal. Refer to OIL SUP- Connect the battery cables at the battery.
PLY DIAGRAMS on p. 158.
181
OILING SYSTEM
Make sure oiling system is primed. Check oil flow

through o il d istribution ho ses. Check oil syste m
operation and rou ting o f oil h oses. Refer to OIL
SUPPLY PRIMING on p. 170.
Run the outboard and check for leaks.
Repair any oil leaks an d any kinked or misrou ted

hoses.
Install engine cover.
182
COOLING SYSTEM
COOLING SYSTEM
TABLE OF CONTENTS
HOSE ROUTING AND WATER FLOW DIAGRAM 3.3 L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
HOSE ROUTING AND WATER FLOW DIAGRAM 3.4 L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
WATER PUMP AND INTAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
WATER SUPPLY TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
ADAPTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
THERMOSTATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
BLOCK VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
CYLINDER BLOCK / CYLINDER HEAD COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
EMM AND VAPOR SEPARATOR COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
ENGINE TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
SOFTWARE METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
PYROMETER METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
IDLE OPERATING TEMPERATURE TROUBLESHOOTING (BELOW RANGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
TEMPERATURE SENDER SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
THERMOSTAT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
PRESSURE RELIEF VALVE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
183
COOLING SYSTEM
HOSE ROUTING AND WATER FLOW DIAGRAM 3.3 L

10 12
6 9 11
7
7
8
5
8 13
5
5 4
PORT REAR
1. Water intake screens 13

2. Water pump
3. Water tube
4. Adapter housing
5. Water supply, adapter to cylinder block 3
(port and starboard)
6. Water supply to EMM (cylinder block vent)
7. Water supply, EMM to vapor separator
8. Vapor separator water outlet to adapter
9. Port thermostat tower to blow-off valve
10. Blow-off valve to port cylinder head
11. Starboard thermostat tower to blow-off valve
12. Blow-off valve to starboard cylinder head
13. Water supply to propeller hub cooling 2
Outgoing water (warm/hot) 1

Incoming water (cool)
004109
184
COOLING SYSTEM

10 12
6 9 11
7
7
8
5
8 5
5
4
PORT REAR
1. Water intake screens

2. Water pump
13
3. Water tube
4. Adapter housing 9
5. Water supply, adapter to cylinder block 3
(port and starboard)
6. Water supply to EMM (cylinder block vent)
7. Water supply, EMM to vapor separator
8. Vapor separator water outlet to adapter
9. Port thermostat tower to blow-off valve
10. Blow-off valve to port cylinder head
11. Starboard thermostat tower to blow-off valve
12. Blow-off valve to starboard cylinder head
13. Water supply to propeller hub cooling 2
1
Outgoing water (warm/hot)
Incoming water (cool) 008562
185
COOLING SYSTEM
COMPONENTS
COMPONENTS Water Supply Tube

The wa ter pump outlet co nnects with the wa ter
Water Pump and Intakes supply tube located in th e outboard’s midsection.
External water int akes mo unted in t he ge arcase Grommets seal the water tube to the water pump
housing collect water a nd must su pply the inlet housing and the inner exhaust housing.
side of the wa ter pu mp with a n un restricted an d
unaerated water su pply. W ater is drawn into the On 3.3 L mod els, the water tube faste ns to the
water pump throu gh a h ole in th e lower plate of inner exhaust hou sing with a water plate a nd
the water pump assembly. All cooling water to the screws.
powerhead is provided by the water pump. Water supplied to the water tube provides all cool-
• A nylon wedge (impeller key) is used to engage ing water to the adap ter housing and cylind er
the impeller bushing and driveshaft. block.
• The nylon impeller housing with lin er must seal
against a separate water pump plate. Adapter Housing
• The bottom plate MUST seal to gearcase. • Adapts the cylind er/crankcase assembly (pow-
• The pump opera tes as a p ositive displacement erhead) to the exha ust hou sing and the wa ter
pump at LOW speed s (below 1500 RPM) and tube.
as a centrifugal pump at HIGHER speeds. • Provides water passages which rout e incoming
and outgoing cooling water.
Refer to WATER PUMP SER VICE o n p. 292 for
• Provides exhaust p assages which connect to
water pump servicing.
the gearcase.
1
2
3
1. Adapter housing – 3.3 L models 000695
1
5
(Impeller key removed for clarity) 000697

1. Water inlet DSC02328
2. Water outlet
3. Seal
4. Plate
5. O-ring 1. Adapter housing – 3.4 L models 006991
186
COOLING SYSTEM
COMPONENTS
Pressure Relief Valve Thermostats

A pressu re relief valve is used to control water Thermostats control water flow and operating tem-
flow and operating temperature at higher speeds perature at lower speeds (below 1200 RPM).
(above approximately 1200 RPM) . Th e p ressure
relief valve op ens as wate r pressure incre ases. Overheating: A restricted or faulty thermostat typ-
Spring tension sets the opening pressure. ically results in LOW SPEED overheating.
Overheating: A restricted or faulty valve typically Overcooling: Debris may prevent the thermostat
results in HIGH SPEED overheating. from closing completely.
Overcooling: Debris may prevent the valve fro m

closing completely.
Thermostat DSC02335
Pressure Relief Valve Components DRC8113
Block Venting
A fitting and hose from the t op of the block allows
the const ant move ment of wate r an d/or air from
the block. Circulated water flows through the EMM
and V apor Sep arator befo re exitin g thro ugh th e
overboard indicator.
187
COOLING SYSTEM
OPERATION
OPERATION At low speed , th e pressure valve is against t he

seat and the thermostats are closed. Warm water
All models use a two-stage cooling system from the cylinder block gr adually migra tes to t he
design. The cooling system is dependent on water thermostat pocket at the to p of each cylind er
pump pressure and controlled by thermost at and head.
pressure valve operation.
The thermostat opens when the wa ter tempe ra-
NOTICE Restricted or inadequate water flow ture reaches approximately 143°F (62°C).
through the outboard reduces cooling system When th e th ermostat o pens, wate r flows down
performance and ma y lead to seve re power- through the cylinder head to a passage in the cyl-
head damage. inder block. Water flows throu gh the block to the
exhaust housing and then out of the outboard.
Cylinder Block / Cylinder Head
Cooling At higher sp eeds, wate r pressure op ens th e
pressure relief valve at approximately 1200 RPM.
The flow of water throu gh the cylinder block and
Water f lows th rough the va lve and byp asses t he
cylinder he ads is co ntrolled by two thermo stats
thermostats. Hoses route the wate r flow from the
and one external pre ssure va lve. The p ressure
pressure va lve to t he vertical wat er p assages
valve is connected by hoses to the top of each cyl-
below the thermostats. All water flows through the
inder head.
cylinder heads to the outlet passages of the block
1 2 1 and then exits through the adapter housing.
This pressure contro lled wa ter outlet cir cuit pro-

vides a “high flow” discharge of water during high
speed operation.
This cooling syste m configuration provides “bal-
anced cooling” at h igher RPM by using one pres-
sure valve to contro l the discha rge of water
through both cylinder heads.
Additional Cooling
Two external water supply hoses direct water flow
into th e exhaust (plenum) are a of the cylinder
1. Thermostats 004269 block. The water reduces exhaust runner temper-
2. Pressure valve assembly
atures and circulates through the cylinder block.
The thermost ats an d pressure valve control the The base ga sket limit s water flo w to th e ba se of
flow of water entering the vertical water passages the block and divert s water flo w to the rear port
of the cylinder heads. and rear starboard fittings of the adapter housing.
On 3.3 L mo dels, a t hird external wate r hose

directs water flow from the exhaust housing of the
cylinder block to a n exhaust passage a t t he
188
COOLING SYSTEM
ENGINE TEMPERATURE CHECK
adapter. The water reduces inner exhaust temper-

atures and cools the propeller hub.
ENGINE TEMPERATURE
CHECK
2 IMPORTANT: The e ngine te mperatures liste d
below are based o n an intake water temperature
of 70° ± 10°F (21° ± 3°C).
Install correct test propeller and place outboard in

a test tank or in the water. Start outboard and run
at 3000 RPM in FORWARD gear for at least five
3 minutes. Remember , r unning ou tboards at hig h
speeds in test t anks may disrupt wate r flo w to
gearcase wa ter int akes. Ma ke su re the outboa rd
1 1 has adequate water flow.
3.3 Liter Models 000698r

A CAUTION
1. External water supply hoses
2. Exhaust (plenum) When servicing the propeller, always shift
3. Inner exhaust cooling hose the outb oard to NEUTRAL, turn the key
switch OFF, and twi st and remove all
On 3.4 L mode ls, propeller hu b coo ling water spark plug le ads so the en gine cannot be
flows t hrough an internal passage of th e in ner started accidentally.
exhaust housing.
EMM and Vapor Separator Reduce sp eed to I DLE f or five minutes. Check
IDLE operating temperature.
Cooling
Cooling water is routed from the top of the cylinder Increase speed to 5000 RPM and check tempera-
block to the inlet fitting o f the EMM water cavity . ture.
Cooling of the EMM helps to stabilize the temper-
Check temperature on both sides of powerhead.
atures of internal components.
If engine temperature is not within range, trouble-
9
IMPORTANT: Improper EMM cooling will acti-
shoot cooling system.
vate se rvice co des 25 and 29 an d the Engine
Monitor warning system. Refer to the EMM Ser- If e ngine temperature test s within range , but th e
vice Code Chart at the back of th is manua l for engine monitor display indicates a “W ATER
specific service code information. TEMP” warning, refer to WATER TEMP/ HOT Cir-
cuit Test on p. 107.
Cooling water from the EMM is routed to the water
inlet fitting o f th e vapor sep arator wate r cavity .
Cooling the vapor se parator fuel chamber min i-
mizes fuel vaporization.
Cooling water from the vapor separator is rou ted

to the adapter/exhaust housing.
189
COOLING SYSTEM
Software Method Typical pyrometer readings at IDLE speed should

be 143°F ± 15°F (62°C ± 8°C)
Use Evinrude Diagnostics sof tware to read te m-
perature displays. IMPORTANT: If you get low or inaccurate read-
ings with a digital pyrometer, coat the probe loca-
tion with Thermal Joint Compound, P/N 322170.
Idle Operating Temperature

Troubleshooting (Below Range)
If en gine IDLE tempera ture is belo w op erating
range 160°F ± 10°F (7 1°C ± 6°C), ch eck thermo-
stat and pressure relief valve operation.
Pressure Relief Valve

The pressu re re lief valve should b e closed at
IDLE speed. W ater should no t flo w past t he
plunger and seal.
Engine Monitor Screen 008104
Plunger
Typical temp erature displays at IDL E spe ed
should be 160°F ± 10°F (71°C ± 6°C)
Typical temperature displays at WOT spe ed
should be 150°F ± 10°F (66°C ± 8°C)
Operating temperature must no t e xceed 194°F Seal

(90°C).
Pyrometer Method Pressure Relief Valve DRC8113

Use a Temperature Gun, P/N 772018, or a digital
pyrometer to mea sure the outboard’s operating Start the outboard and check IDLE operating tem-
temperatures. perature.
Measure temperature at the t op of cylinder b lock,
next to the thermostat housing and cylinder head.
Check temperature on both sides of powerhead.
1. Top of cylinder block (starboard side) 004339
190
COOLING SYSTEM
If IDLE temperature is too low, pinch off the water Start the outboard and check IDLE operating tem-
outlet hoses from p ressure relief valve to cylin der perature using Evinrude Diagnostics software pro-
heads. gram.
If IDLE temp erature increases to spe cific ope rat-

1 ing range, 160°F ± 10°F (71°C ± 6°C), after pinch-
ing of f h oses a nd e liminating water flow to th e
cylinder he ads, pressure relief valve is lea king.
Replace pressure relief valve.
2 2 If IDLE te mperature is st ill below operating range
with hoses pinche d off, inspect thermostats and
thermostat seals.
Thermostats
1. Outlet hoses DSC00827 Remove thermostat cover(s) and inspect thermo-
2. Pliers stat(s).
Use hose p inching pliers (acquired thro ugh local

tool source) to prevent hose damage.
004338
Hose Pinching Pliers DSC00830

Check po sition of thermost at seal a nd how th er-
mostat seals against cylinder head. Seal must be
9
properly fitted to flange of thermostat.
1. Seal, thermostat DSC02335
Check thermost at for cracks, hea t damage, or

signs of corrosion. Check for proper operation.
Thermostat opens at 143°F (62°C).
191
COOLING SYSTEM
TEMPERATURE SENDER SERVICING
TEMPERATURE SENDER THERMOSTAT

SERVICING SERVICING
Removal Disassembly
Loosen sensor and remove by hand. Use care to Remove the thermostat cover and O-ring from cyl-
avoid breaking threads. inder head.
007209 004338
Clean sensor threads, sensor, and sensor cavity. Remove spring, thermostat, and gasket.
Installation Inspection
Fill bottom of sensor cavity with 0.7 cc of Thermal Inspect all parts for cracks, heat damage, or signs
Joint Compound, P/N 322170. Sensor cavity of corrosion. Replace d amaged p arts. Cle an
should be filled to 1 in ch (25 mm) below the top debris from housing and parts.
edge of the cavity.
Install se nsor. DO NOT use gasket sealing com-

pound. SLOWLY tighten temperature sensor to a
torque of 50 to 70 in. lbs. (5.6 to 8.0 N·m).
1 in. 1 000757
(25 mm)
Assembly
Assembly is t he re verse of d isassembly. Pay
close attention when pe rforming the following
additional tasks.
3 2 Coat threa ds of each cylinder hea d thermostat
cover with Gasket Sealing Compound. Install and
1. Temperature sensor 007049 tighten the cover to a torque of 120 to 14 4 in. lbs.
2. Sensor cavity (13.5 to 16.5 N·m).
3. Thermal joint compound
Wait 10 minutes for trapped air to bleed from cav-

ity. Th ermal compo und may seep past threads.
Retighten sensor.
192
COOLING SYSTEM
PRESSURE RELIEF VALVE SERVICING
PRESSURE RELIEF Inspection

Inspect all parts for cracks, heat damage, or signs
VALVE SERVICING of corrosion. Rep lace d amaged p arts. Clea n
The pressure relief valve assembly should be ser- debris from housing and parts.
viced at the same time as the thermostats.
Assembly
Disassembly Assembly is th e re verse of d isassembly. Pay
Remove hose cla mps a nd hoses from p ressure close attention when per forming the followin g
valve. additional tasks.
Tighten bracket and cap screws to a torque of 60

1 1 to 84 in. lbs. (7 to 9.5 N·m).
Install valve on powerh ead. T ighten nut s to a

torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
Install hoses and secure with clamps.
1. Hoses 004269
Remove screws se curing the bracket to power-

head. Remove the pressure valve housing.
Remove the bracke t and the cap from the hou s-

ing. Remove the pressure valve assembly.
2 9
1. Bracket DRC8113
2. Cap
193
COOLING SYSTEM
NOTES
NOTES
Bulletins
Instruction Sheets
Other
194
EVINRUDE ICON REMOTE CONTROL SYSTEM
EVINRUDE ICON REMOTE

CONTROL SYSTEM
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
ELECTRONIC SERVO MODULE (ESM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
SHIFT ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
THROTTLE ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
ICON SYSTEM FAILSAFE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
ICON COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
ELECTRONIC SERVO MODULE (ESM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
SHIFT ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
THROTTLE ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
ICON SYSTEM SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
SET ENGINE IDENTITY (INSTANCE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
CALIBRATE ACTUATOR STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
ICON REMOTE CONTROL SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . 210
ICON REMOTE CONTROL SYSTEM FAULT MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
10
195
SERVICE CHART
SERVICE CHART
60 to 84 in. lbs.
(7 to 9.5 N·m)
60 to 84 in. lbs.
(7 to 9.5 N·m)
F
18 to 20 ft. lbs.
(24.5 to 27 N·m)
ESM to EMM
connector
ESM to engine harness

key switch connector
ESM to trim/tilt
connector
+
ICON buss
cable connector ESM power
supply harness
–
ESM to throttle
actuator connector
ESM to shift
actuator connector
F
60 to 84 in. lbs.
(7 to 9.5 N·m)
F Blue Nut Lock

008091
196
COMPONENTS
COMPONENTS Shift Actuator

The shift actuator converts electronic signals from
The ICON rem ote c ontrol sy stem consis ts of the
the ESM into the mechanical motion required to
following components:
shift the outboard into and out of gear.
• ICON remote control and boat network
• One, two, three, four or five outboards
• Electronic Servo Module (ESM)
• Shift Actuator
• Throttle Actuator
1
Electronic Servo Module (ESM)
The Electronic Servo Modu le (ESM) rece ives
shift, throttle and other con trol information from
the ICON remote control.
The ESM activates the shift and throttle actuators

Shift Actuator 008505
to t he positions command ed by the remote con-
trol.
If the shift actuator sensor cannot determine gear
position, all LED indica tors flash unt il contro l
levers and shift actuators are in NEUTRAL.
Then, the NEUTRAL indicator LED for the engine

that has a fault flashes. The EMM:
1 Activates S.A.F.E.
Stores service code 108 and 151
Engine Monitor display: RPM reduction, ICON
fault 151, see dealer
Electronic Servo Module (ESM) 007525

If the shif t act uator is unable to move to a com-
manded positio n, the FORWARD, NEUTRAL or
If the ICON remote contro l cannot commu nicate REVERSE indicator LED flashes to indicate which
with the ESM, all LED indicators flash until control gear position is affected. The EMM:
levers and shift actuators are in NEUTRAL. Activates S.A.F.E. 10
Then, the NEUTRAL indicator LED for the out-
board that has a fault flashes. The EMM:
Activates S.A.F.E.
197
COMPONENTS
Throttle Actuator If the throttle cann ot move toward op en positio n,

the FOR WARD or REVERSE indicator LED
The throttle actu ator c onverts electronic signals
flashes (dep ending on gear p osition whe n fault
from the ESM into the mechanical motion required
occurred).
to move the throttle of the outboard.
If the throttle cannot move toward closed position,
all L ED indicators flash until control levers a nd
shift actuators are in NEUTRAL.
1 Then, the NEUTRAL indicator LED for th e engine
that has a fault flashes. The EMM:
Activates S.A.F.E.
Throttle Actuator 007302

ICON System Failsafe Mode
If th e throttle actua tor sen sor cannot de termine Fault code 108 will appear with another code that
throttle position, all LED indicat ors flash until con- explains why the eng ine(s) entered RPM reduc-
trol levers an d shif t actuato rs are in NEUTRAL. tion. The EMM:
Then, the NEUTRAL indicator LED for the engine Activates S.A.F.E.
that has a fault flashes. The EMM: Stores service code 108
Activates S.A.F.E. Engine Monitor display: RPM reduction, ICON
Stores service code 108 and 149 fault 108, see dealer
198
ICON COMPONENT SERVICING
ICON COMPONENT Installation

Install grommets on ESM. Apply soapy water to
SERVICING grommets and push assembly on to studs.
A WARNING
the battery. 1
Electronic Servo Module (ESM)

Removal
Disconnect the: 1. Grommets 007500
• ICON buss cable from ESM
• ESM CANbus harness from EMM
• ESM throttle actuator harness
• ESM shift actuator harness
1
• ESM power su pply harness from solenoid and
ground stud
Remove the ESM from studs.
1 1. Studs 008506
Route the CANbus harness from the ESM to the

EMM as shown on the starboard side of outboard.
Install grommet in notch on the electrical bracket.
10
1. Retainer mechanism 008506
2
1. CANbus harness 007495

2. Grommet
199
Continue harness routing und er pressure relief NOTICE Make sure the oil recirculation hose
valve hoses to EMM connector. Clip conne ctor to is not pinched during assembly.
fuel rail. Make sure harness is not strained and
does not rub against EMM mounting boss.
1
1
2
1. Harness 007497
2. Hose
1. CANbus harness 007502
2. Connector clip Secure ESM to throttle a ctuator ha rness with tie
strap, P/N 320107.
Route ESM to actuator harnesses between actua-
tor plate and engine electrical bracket as shown. Route ESM to shift actuator harness behind throt-
tle actuator and over thrott le actuator harness.
Attach to clip on mounting plate.
1 Install clamp over a ctuator motor and secu re to
plate with screw. Tighten screw to a torque of 60 to
84 in. lbs. (7 to 9.5 N·m).
1. ESM to actuator harnesses 007496
Route the throttle actu ator harness behind and

over the oil recirculation hose as shown. Connect
to harness from ESM and attach to clip on mount-
ing plate.
1. Throttle harness tie strap 007498
200
Secure sh ift actua tor harne ss wit h tie st rap, Install cop per crush washer over ESM positive
P/N 317893. ring termina l. T hen, install star washer , battery
cable, and nut. Tighten nut to a torque of 60 to 84
in. lbs (7 to 9.5 N·m).
1
1
1. Shift harness tie strap 008514
Route ESM power sup ply harness beh ind trim 1. Copper washer 007508
relay harness. Route negative (– ) terminal to bat-
tery ground stud and positive (+) terminal to sole-
noid.
2
007526
Connect ESM ha rness to eng ine harness key

1. ESM Power supply harness 007499 switch and trim/tilt connectors.
2. Ground stud
3. Solenoid
Secure connectors in bracket as shown and install
Install ESM gro und, st ar wash er, ba ttery cable, connector cover. 10
and nut on main ground stud. Tighten to a torque
of 60 to 84 in. lbs. (7 to 9.5 N·m). 1
2
1
3
1. Key switch connector 008507

2. Trim/tilt connector
3. SystemCheck connector
1. ESM Ground 007507
201
Route all ESM harnesses as shown and secure to Shift Actuator

shift actuator with tie straps, P/N 907833.
Removal
1 Disconnect the battery cables at the battery.
1 Remove electrical bracket cover.
Observe and note all wire routings before disas-

sembling.
1. Large tie straps 008508
Install electrical bracket cover.
007525
Remove clip s and wash ers from the shift link.

Remove the shift link.
007525
IMPORTANT: Calibrate shif t a nd thrott le actua-

tors. Refer to Calibrate Actuator Stroke on
p. 207.
008509
202
Remove the shift actuator connector from the clip Installation

on the mounting plate. Disconnect the shift actua- Remove old adhesive from clamp retaining screw
tor harness. and shift actuator retaining screws.
Apply Nut Lock to the threads of the screws.
Install shift actuator o n mounting plate with thre e

long screws an d one short screw. Tighten screws
to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
1
2 1
1. Shift actuator connector 007498 1
Remove the clamp retaining screw.
1 1. Long screws 008505

2. Short screw
Place clamp o ver actuator motor . Install an d

tighten screw to a to rque of 60 to 84 in. lb s. (7 to
9.5 N·m).
1
1. Clamp retaining screw 007301
Remove the four shift actuator retaining screws.
10
1
1
1. Shift actuator retaining screws 008505
203
Connect the shif t actuator harne ss. Attach to clip Throttle Actuator
on mounting plate.
Removal
1 Remove the flywheel cover. Remove the electrical

bracket cover.
Observe and note all wire routings before disas-
sembling.
1. ESM to shift actuator harness 007498
Secure sh ift actua tor harne ss wit h tie st rap,

P/N 317893.
1 007525
Remove th e thrott le actuato r conn ector from t he

clip on the mounting plate. Disconnect the throttle
actuator harness.
1
1. Shift harness tie strap 007872
Route all ESM harnesses as shown and secure to

shift actuator with tie straps, P/N 907833.
1
1
1. Throttle actuator connector 007497
1. Large tie straps 008508
IMPORTANT: Do not install shif t link unt il the

calibration procedure has been completed. Refer
to Calibrate Actuator Stroke on p. 207.
204
Remove the clamp retaining screw. Installation

Remove old adhesive from clamp retaining screw
and shift actuator retaining screws.
Apply Nut Lock on the threads of the screws.
1
Install thro ttle actuator on mounting plat e with
three long screws and one short screw . T ighten
screws to a to rque o f 60 t o 84 in. lbs. (7 to 9 .5
N·m).
Do no t inst all clamp un til wiring h arnesses have

been secured.
Use Ba ll Socke t Re mover tool, P/N 342226 , to

1 1
remove throttle link from actuator arm.
1. Long screws 007302

2. Short screw
Use Ball Socke t In staller to ol, P/N 342225, to

snap throttle link onto actuator arm.
008034
Remove the four throttle act uator ret aining

screws.
10
1
007303
1. Throttle actuator retaining screws 007302
205
Secure ESM to throt tle actu ator harness with tie Route the thrott le actua tor harness behin d and
strap, P/N 320107. over the oil recirculation hose as shown. Connect
the throttle actu ator harness. Att ach to clip on
Route ESM to shift actuator harness behind throt- mounting plate.
tle actuator and over throttle actuator harness.
Place cla mp over actu ator motor. Install and

NOTICE Make sure the oil recirculation hose
is not pinched during assembly.
tighten screw to a t orque of 60 t o 84 in. lbs. (7 to
9.5 N·m). 1
2
1
2
1. Throttle actuator harness 007497

2. Oil recirculation hose
1. Tie strap 007498
2. ESM to shift actuator harness
3. Clamp retaining screw IMPORTANT: Calibrate actu ator. Refer t o Cali-
brate Actuator Stroke on p. 207.
206
ICON SYSTEM SETTINGS
ICON SYSTEM SETTINGS Calibrate Actuator Stroke

Set Engine Identity (Instance) A CAUTION
In a multi-engine application, the transom position After inst allation, dealer MUST us e
of the outboard must be identified on the network. Evinrude Diagnostics software, version 5.1
or higher, to calibrate the actuators for cor-
Engine identity is se t by a n Engin e Ident ity Plug
rect throttle and shift stroke.
installed in the ESM. Outboard s are identified as
Instance 0 through 4, from port to starboard, up to Failure to calibrate shift stroke will lead to
five engines. gearcase failure and possible loss of b oat
control not covered by warranty.
Each identity plug is stamped with it s inst ance
number. To calibrate the actuators, use the ICON tab of the
Evinrude Diagnostics Settings screen.
In a multi-engine application, all outboards can be

1 calibrated through one con nection. Use the
Engine Instance menu to sele ct the engin e
instance on the screen.
IMPORTANT: If the ICON t ab is not available,

make sure the engine management software has
been updated to the correct revision.
2
1. Engine Identity plug 007505
1
If the outb oard is a single eng ine or the port
engine in a multi-en gine applica tion, no change s 3
are required.
For all other outbo ards, engine identity must be

set by replacing th e original plug (0) with the plug
that corresponds to the outboard’s position on the
transom.
10
Identity Numbers 1. Settings 008578
2. ICON tab
Starboard
Starboard
Number of Out- 3. Engine instance menu

Center
Center
Center
Port
Port
boards
Throttle Actuator Stroke
To set th rottle stroke, click the Calibrate Throttle
1 0 button. Th e act uator a rm will move forward an d
back to find th e mecha nical limit s of the throttle
2 0 1
3 0 1 2
4 0 1 2 3
5 0 1 2 3 4
IMPORTANT: The Engin e Identity Plug over-

rides any previous EMM instance setting.
207
linkage. Evinrude Diagnostics report s when the • Select FOR WARD under Shift Position on t he
process is complete. ICON screen. The actu ator arm will move for-
ward.
• Use the Nudge butt ons to move the actuator
arm forward or backward until the shif t link
aligns with the actuator arm and shift lever pins.
• When the link and pins are exactly aligne d,
install the link a nd click th e Save button . The
actuator will move to the neutral position.
1 2
2
1. Calibrate Throttle button 008583
2. Process complete message
2
Shift Actuator Stroke
3
To set forward gear shift stroke:
• With the shift link disconnected, rotate the pro-
peller and manually shif t the outboa rd int o for-
1. Shift position 008579
ward gear with the shift lever. 2. Nudge buttons
3. Save button
1. Shift lever in forward 008510

008511
IMPORTANT: Make sure the ge ar is fully
engaged and the lever is all the way forward. To set reverse gear shift stroke:
• Remove shift link.
208
• With the shift link disconnected, rotate the pro- After forward and reverse strokes have been cali-
peller and manually shif t the outbo ard into brated, the ESM calculates neutral position.
reverse gear with the shift lever.
Install the shift link and secure with retainer clips
and washers.
1. Shift lever in reverse 008512
008509
IMPORTANT: Make sure the ge ar is fully
engaged and the lever is all the way to the rear.
Lock th e ret ainers b y moving the angled se ction
• Select REVERSE button under Shift Positoin on
behind the straight section.
the ICON screen. The actuato r arm will move
backward. Us e t he Nudge bu ttons to align the
shift link.
• When th e link an d pins are exactly align ed, 1
install th e link a nd click th e Save butto n. The
actuator will move to the neutral position.
Locked Retainer Clip DP0817a

1. Angled section behind straight section
NOTICE When installation is complete, shift

the ou tboard wi th control (while rot ating pro-
peller). Rot ate the propeller s haft b ack a nd
forth to ensure the face of the clutch dog con-
tacts the gear in both forward and reverse.
With the outboard in neutral, make sure the 10
propeller shaft turns free ly with no cont act
between the clutch dog and gears.
008513
209
ICON SYSTEM FAULTS
ICON System Faults

The ICON System exhibits two types of faults: Recoverable and Non-recoverable. ICON System faults
are visually indicated by the remote control, the swit ch panels, the gat eway, and the 6-po rt hub LED’s.
ICON System faults are also displayed on the Faults page of Evinrude Diagnostics and on the NMEA
2000 gauges.
Recoverable Faults
Recoverable faults are Motion or Over-Current errors which occur on a throttle or shift actuator. A motion
error occurs when the ESM is attempting to move an actuator from one position to another, but the actu-
ator does not move. An over-current error occurs when the ESM is moving an actuator and the actuator
draws too much current.
When recoverable fault s are dete cted the remote co ntrol continues to se nd shif t, th rottle, trim, a nd
start/stop commands as normal.
During a recoverable fault, the ICON System:
• Flashes a gear LED of the affected engine one time per second to indicate the gear position command
that caused the fault.
• Sends a fault message to the outboard EMM. The EMM then sends a “Check Engine” message to the
NMEA 2000 gauges.
• Stops shift or throttle actuator movement at the point where the fault occurred
• Will NOT activate S.A.F.E.
When all control levers are put in NEUTRAL, the ICON System
• Stops flashing the FORWARD and NEUTRAL gear LED’s
• Continues to flash the NEUTRAL LED of the faulty engine one time per second
• Allows shift or throttle actuator movement to continue up to the point where the fault occurred
CSM Remote Con-
Binnacle Control Control Lever
Fault Cause trol Switch Panel
LED’s (flashing) Position
LED (flashing)
Motion or over-cu rrent
Move control
error occu rred while mo v-
FWD Shift FWD NTL lever back to
ing shift actuator fro m NTL
NTL
to FWD
Motion or over-cu rrent
Move control
error occu rred while mo v-
REV Shift REV NTL lever back to
ing shift actuator fro m NTL
NTL
to REV
Motion or over-cu rrent Move control
error occu rred while mo v- lever to original
NTL Shift NTL NTL
ing shift actuator from FWD position (FWD or
or REV to NTL REV)
FWD LED if lever Move control
NTL
Motion or over-cu rrent is in FWD lever toward idle
Throttle error occu rred while mo v- and beyond the
Movement ing thro ttle act uator when REV LED if lever position where
NTL
in FWD or REV is in REV the fault
occurred
210
ICON SYSTEM FAULTS
Non-recoverable Faults
When a non-recoverable fault occurs, the ICON System:
• Flashes all gear position LED’s of the affected engine five times per second
• Sends a fault message to the outboard EMM, which in turn se nds a “Check Engin e” message to the
NMEA 2000 gauges
• Activates S.A.F.E.
• Moves throttle actuators to idle, and shift actuators to NEUTRAL, if they are functional
When all control levers are put in NEUTRAL and all engines are in NEUTRAL-idle, the ICON System:
• Stops flashing the FORWARD and NEUTRAL gear LED’s
• Flashes the NEUTRAL LED of the faulty engine five times per second if the condition is ESM or actu-
ator related
• Turns OFF all gear LED’s of the failed remote control lever, if the fault is lever-related
• Disables the faulty control lever or ESM
• Allows unaffected control levers and ESM’s to operate normally
• Retains SYNC function for non affected engines
If a port control lever has failed, starboard lever becomes the lead for SYNC.
If starboard control lever has failed, port lever becomes the lead for SYNC.
Station transfer is not allowed when a non-recoverable fault is present. The ICON System remains in this
state until power is reset.
Operation stops if the control lever fails on a single binnacle or concealed side mount remote control.
10
211
ICON SYSTEM FAULT CODE CHART
ICON System Fault Code Chart

Use this chart and Evinrude Diagnostics software to identify ICON Remote Control System fault codes.
Use the ICON System Troubleshooting Flowcharts to resolve a problem on an ICON Syste m. Refer to
the Evinrude ICON System Troubleshooting Guide.
Possible Causes and

Fault Code Description LED Indicators
Flowchart Reference
Remote control is not powered
ON.
107
The remote control buss cable is
Remote Control Communi- damaged or not connected.
Gear position LED’s flash five
cation Error
times per second. A remote control buss cable
The outboard’s EMM has not extension is damaged or not con-
With the remote control lever in
received a message from the nected.
NEUTRAL, the NEUTRAL LED
remote control for more than
of the affected engine continues 6-port hub LED is not ON
1.5 seconds.
to flash five times per second. 6-port hub connection port is
The fault message is gener-
damaged.
ated by the outboard’s EMM.
Remote Control Power Check
(Chart 5)
Remote control not communicat-
ing with ESM.
Remote control lever failure.
108
ESM not communicating with
RPM Reduction (S.A.F.E.) Gear position LED’s flash five remote control.
Code 108 always appears times per second.
Throttle actuator sensor failure
with fault codes 107, 109, 111, With the remote control lever in
149 and 151. NEUTRAL, the NEUTRAL LED Shift actuator sensor failure.
The fault message is sent of the affected engine continues See Evinrude Diagnostics or the
from the remote control to the to flash five times per second. service manual for other S.A.F.E.
outboard’s EMM. fault codes not caused by the
ICON System.
ICON System Fault Check
(Chart 11)
109
Remote Control Lever Fault Gear position LED’s flash five
The remote control lever times per second. Remote control lever potentiome-
potentiometer resistance is With the remote control lever in ter failure.
out of range. NEUTRAL, the NEUTRAL LED If this code is present, replace the
The fault message is sent of the affected engine continues remote control.
from the remote control to the to flash five times per second.
outboard’s EMM.
212
Possible Causes and

Flowchart Reference
Trim and tilt switch panel harness
is damaged or not connected to
110 the remote control.
Trim Switch Module Com- Trim and tilt switch panel harness
munication Fault is damaged or not connected to
Remote control cannot com- the switch panel.
municate with trim and tilt None Trim and tilt switch panel circuit
switch panel (3, 4, or 5 failure.
engines only).
Remote control is programmed
The fault message is sent with the wrong part number.
from the remote control to the
Trim Panel Check (Chart 12)
outboard’s EMM.
Remote Control Part Number
Check (Chart 4)
30A fuse for the ESM has failed.
The ESM buss cable is damaged
or not connected to the 6-port
111 hub.
ESM Communication Fault All gear position LED’s flash five The ESM buss cable extension is
Remote control has detected times per second. damaged or not connected to the
a communication fault mes- With the remote control lever in 6-port hub.
sage from the ESM. NEUTRAL, the NEUTRAL LED 6-port hub LED is not ON
The fault message is sent of the affected engine continues
to flash five times per second. 6-port hub connection port is
from the remote control to the damaged.
outboard’s EMM.
ESM instance plug numbers are
duplicated.
ESM Check (Chart 16)
RFI due to excessive spark plug 10
gap, damaged or worn spark
plugs.
149
All gear position LED’s flash five The actuator and the ESM are not
Throttle Actuator Sensor times per second. connected.
Fault
All gear position LED’s flash five The actuator and ESM connec-
The ESM has lost the throttle times per second. tors are damaged.
actuator position sensor sig-
With the remote control lever in The wiring of the actuator and
nal.
NEUTRAL, the NEUTRAL LED ESM connectors are in the wrong
The fault message is sent of the affected engine continues locations.
from the ESM to the out- to flash five times per second. Throttle actuator position sensor
board’s EMM.
failed.
Throttle Actuator Sensor
Check (Chart 17)
213
Possible Causes and

Flowchart Reference
150
Throttle link arm from ICON add-
Throttle Actuator Motion on kit is not assembled to the out-
Fault board.
The ESM tries to move the FORWARD or REVERSE LED Throttle linkage components are
throttle actuator, but it will not flashes (depending on gear damaged or their movement is
attain the commanded posi- position when fault occurred). blocked.
tion. With the remote control lever in Starter cable is not correctly
This is caused by a motion or NEUTRAL, the NEUTRAL LED routed behind the actuator
over-current error from the of the affected engine continues mounting plate.
actuator. to flash one time per second.
Throttle actuator has failed.
The fault message is sent
Throttle Actuator Motion Check
from the ESM to the out-
(Chart 17)
board’s EMM.
RFI due to excessive spark plug
gap, damaged or worn spark
plugs.
151 The actuator and the ESM are not
Shift Actuator Sensor Fault All gear position LED’s flash five connected.
The ESM has lost the shift times per second. The actuator and ESM connec-
actuator position sensor sig- With the remote control lever in tors are damaged.
nal. NEUTRAL, the NEUTRAL LED The wiring of the actuator and
The fault message is sent of the affected engine continues ESM connectors are in the wrong
from the ESM to the out- to flash five times per second. locations.
board’s EMM. Shift actuator position sensor
failed.
Shift Actuator Sensor Check
(Chart 18)
152
Shift Actuator Motion Fault ICON shift link is not assembled
to the outboard.
The ESM tries to move the FORWARD or REVERSE LED
shift actuator, but it will not Shift linkage components are
flashes (depending on gear damaged or their movement is
attain the commanded posi- position when fault occurred).
tion. blocked.
With the remote control lever in Shift stroke is not calibrated cor-
This is caused by a motion or NEUTRAL, the NEUTRAL LED
over-current error on the actu- rectly.
of the affected engine continues
ator itself. to flash one time per second. Shift actuator has failed.
The fault message is sent Shift Actuator Motion Check
from the ESM to the out- (Chart 20)
board’s EMM.
214
POWERHEAD
TABLE OF CONTENTS
POWERHEAD
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
COMPRESSION TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
POWERHEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
POWERHEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
SYSTEMS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
THROTTLE LINKAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
SHIFT LINKAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
CYLINDER BLOCK CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
POWERHEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
POWERHEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
CRANKSHAFT AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
SHIFT LINKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
THROTTLE LINKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
FINAL POWERHEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
POWERHEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
PRE-SERVICE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
POWERHEAD VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
PORT HOSE ROUTINGS – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
STARBOARD HOSE ROUTINGS – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
PORT HOSE ROUTINGS – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
STARBOARD HOSE ROUTINGS – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
11
PORT – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
STARBOARD – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
PORT – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
STARBOARD – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
FRONT – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
FRONT – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
REAR – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
REAR – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
STARBOARD – ICON MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
215
POWERHEAD
SERVICE CHART
SERVICE CHART
60-84 In. lbs. B Gasket Sealing Compound
(7-9.5 N·m)
D Moly Lube
60-84 In. lbs.

E Red Ultra Lock
(7-9.5 N·m) F Blue Nut Lock
30-42 In. lbs. J Thermal Grease
(3.5-5 N·m)
120-144 In. lbs.
L Pipe Thread Sealing Compound
(14-16 N·m) M RTV Sealant
60-84 In. lbs. P Permatex #2
(7-9.5 N·m)
Q Gel Seal II
B
T Liquid Neoprene
X See Service Manual Text
B
L B
X
H
A
Q
P, X
50-70 In. lbs.

(5.6-8 N·m) B
84-108 In. lbs.
(9.5-12 N·m)
J
E
38-42 Ft. lbs.
(52-57 N·m)
17-19 Ft. lbs. H
(23-26 N·m)
H
H
60-84 In. lbs.

(7-9.5 N·m)
L
F
H 48-53 Ft. lbs.
F (65-72 N·m)
F 120-144 In. lbs.

(13.5-16.5 N·m)
120-144 In. lbs.

(13.5-16.5 N·m)
60-84 In. lbs.
120-144 In. lbs.
(7-9.5 N·m)
E
(13.5-16.5 N·m) E A Install to .92 ± .05
60-84 In. lbs.
(7-9.5 N·m)
F
7-10 In. lbs.
(0.8-1.1 N·m)
144-168 In. lbs.

Apply Pipe Thread Sealant B, X (16.5-19 N·m)
to all pipe fitting threads.

008373
216
POWERHEAD
SERVICE CHART
96-120 In. lbs.

(11-13.5 N·m) F
B
60-65 Ft. lbs.
(81-88 N·m)
X
F
96-120 In. lbs.
(11-13.5 N·m)
F
96-120 In. lbs.
11
(11-13.5 N·m)
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
Y Extreme Pressure Grease
217
POWERHEAD
TAPER PIN TOOL
TAPER PIN TOOL
– Hole for Storage Scale: FULL SIZE
COMPRESSION TESTING
Start and run outboard until it achieves o perating If engine sh ows a variation greater than 15 psi
temperature, then shut OFF. (100 kPa) between cylinders, check for:
• damaged cylinder head
Disconnect crankshaft position sensor (CPS) con-
• damaged pistons
nector. Remove all spark plugs.
• broken or stuck piston rings
Advance throttle linkage to WOT. • scored cylinder walls
Install compression tester’s hose attachment into Return throttle to idle position and reconnect CPS
spark plug hole (14 mm threads). connector. Rep lace sp ark plugs. Refer to S park
Plug Indexing on p. 40.
While cranking outbo ard with st arter, note maxi-
mum pressure reading on gauge. Repeat proce-
dure for each cylinder.
218
POWERHEAD
POWERHEAD REMOVAL
POWERHEAD REMOVAL Remove water hoses and exhaust back pressure

hose from adapter.
A WARNING
Protect ag ainst hazardous fue l spray.
Before st arting any fuel syst em service,
carefully relieve fuel system pressu re.
Refer to Relie ving Fue l System Press ure
on p. 143. 1
2
vicing, twist and remove spark plug leads.
Remove l ower mo tor co vers. LOWER COV ER

Port Side 008443
SERVICE on p. 51. 1. Cooling hose (to exhaust plenum)
2. Cooling hose (from vapor separator)
Disconnect diag nostic connector fro m clip a nd
remove flywheel cover.
1
2
1
3
2
Starboard side 005042

1. Cooling hose (to exhaust plenum)
2. Exhaust back pressure hose (to EMM)
1. Diagnostic connector 004237 3. Cooling hose (from block) – 3.3 L models
2. Flywheel cover screw
Remove air temperature sensor from air silencer. Disconnect power trim connectors.
Remove the air silencer.
1 1
11
1
1. Trim/tilt connectors 004251
1. Air temperature sensor 004219
219
POWERHEAD
POWERHEAD REMOVAL
Remove trim/tilt harness from clamp. Fasten appropriate chain hook to eye of tool a nd
support weight of powerhead with hoist.
1. Trim harness 005041

2. Clamp
48758
Remove pin and wa sher from shif t rod lever to

release the lower shift rod. Remove all powerhead retaining screws and nuts.
1
1
1
1. Screws and nuts 004240

1. Shift rod pin 004241
Remove flywheel. Refer to Flywheel Removal on Remove the rear powerhead nut.
p. 109.
Securely fasten L ifting Fixture, P/N 3 96748, to
crankshaft threads.
1. Rear powerhead nut 004252
Use a suitable tool to carefully separate the pow-

erhead from exhaust housing.
IMPORTANT: Do not damage the powerhe ad

adapter mating surfaces when separating.
220
POWERHEAD
POWERHEAD DISASSEMBLY
POWERHEAD Throttle Linkage Removal

Remove throttle cam and throttle lever.
DISASSEMBLY
Systems Removal
To simplify reasse mbly and wiring inst allation, lay
out the various screws and clamp s in the order of 1 2
their proper location.
Remove the electric starter. Refer to Starter

Removal on p. 115.
Remove fuel pump assemblies, f uel manifold s,

and filter. Refer to FUEL COMPONENT SERVIC-
ING on p. 143. 1. Throttle cam screw 006866
2. Throttle lever screw
Remove EMM and electrical harness assemb ly.
Refer to EMM SERVICING on p. 70. Shift Linkage Removal
Remove stator. Refer to Stator Service on p. 109. Remove shoulder screw from shift arm and retain-
ing screw from shift rod lever
Remove oil pump, rear oil manifold, a nd oil circu-
lation hose s. Refer to OIL COMPONENT SER-
VICING on p. 178.
1
Remove ignition coils and fuel injectors. Refer to
Fuel Injector Service on p. 147.
IMPORTANT: Mark in jectors for cylinder loca-

tion before removal. All injectors must be installed
in their original location. Improper injector installa-
tion can result in powerhead failure. 2
Remove thro ttle linkag e. Re fer to Throttle Link-
008455
age Removal on p. 221. 1. Shift arm screw
2. Shift rod lever screw
Remove shif t linkage. Refer to Shift Link age

Removal on p. 221. Slide ent ire shif t linkag e assembly from crank-
case.
Remove the throttle body and reed plate asse m-
blies. Refer to Intake Manifold Service on p. 151. Remove Neutral/Shift Interrupt Switch from cylin-
der block.
11
Remove pressure valve assembly . Refer to
PRESSURE RE LIEF VALVE SER VICING on
p. 193.
221
POWERHEAD
Crankcase Disassembly Remove the upper crankcase head screws.

Use the TAPER PIN TOOL, or equivalent, to push
the crankcase taper pins toward th e front side of
the engine.
IMPORTANT: Do not use a t apered punch or

any oth er tool that could jam in or da mage the
taper bore when removing the pin.
004140
2
Remove the lower crankcase head screws.
1 IMPORTANT: DO NO T re move t he f our in side

retaining screws on the lower crankcase head.
1. Tool 49428
2. Taper pin
Remove crankcase flange screws.
004146
Loosen in stages, and re move the main bearing

screws and nuts.
004139
004136
222
POWERHEAD
Separate crankcase and cylinder block. It may be Connecting Rods and Pistons
necessary to tap on cranksha ft with a rawhide or
Use a permanent marker to identify each connect-
rubber mallet to loosen.
ing rod cap, connecting rod, and piston by cylinder
number. Number 1 is closest to the flywheel.
49429
000825
Carefully remove the crankcase fro m the cylinder
block to avoid damaging the crankshaft seal rings.
Use Torquing Socket, P/N 346187, to loosen in
stages the ro d cap ret aining screws. DO NOT
remove the screws.
004137
Cylinder Head Removal 000823

Loosen in st ages and remove cylinde r he ad
retaining screws. Remove the cylinder head.
11
49431
223
POWERHEAD
Use one hand to su pport the piston , and remove Remove wrist pin retaining rings. Discard retaining
the rod cap screws with your other hand. Remove rings.
each piston and rod assembly.
000689
49432 Use W rist Pin Pressing Tool, P/N 396747, to

remove wrist pin.
NOTICE Reattach each rod cap to its rod as
soon as the pi ston is remov ed. Each c ap is
unique and can only be installed on its mated
rod. Do not allow rod to contact inside surface
1
of cylinder or crankshaft.
IMPORTANT: Identify all intern al co mponents

so that if reu sed, they can be reinst alled in the ir
original positions.
Repeat steps for each remain ing piston and con-
necting rod.
1. Driver, P/N 396747 31806
Use an approp riate ring exp ander to remove all
piston rings from pistons. Discard the rings. Crankshaft Removal
A WARNING A WARNING
Wear safety glasses to avoid injury.
Carefully lif t crankshaf t straight u p a nd re move

from crankcase.
31809
46519
224
POWERHEAD
Use a punch to remove the upper crankshaft seal. Remove the O-ring from cr ankshaft sleeve an d
Remove and discard two crankcase head O-rings. inspect it. Repla ce the O-ring if it is not in goo d
condition.
0865
30057
If the lower crankcase head is to be resea led or
the lower main bearing replaced, remove the four Inspect the crankshaft sleeve and replace, if nec-
bearing retainer screws. While rot ating the crank- essary. To remove the sleeve, use Slide Hammer,
case h ead, g ently t ap on th e flan ge and remove P/N 432128, and Large Puller Jaws, P/N 432129.
the head.
30056
Remove the lower main bearing only if it needs to

1. Bearing retaining screws 000830 be replaced. Use externa l re taining ring pliers to
remove the lower main bearing retaining ring.
Use a punch to remove the lower crankshaft seal.
Remove and discard two crankcase head O-rings.
11
1
30069
1. Drift punch 30297
225
POWERHEAD
IMPORTANT: If the lower main bearing is Remove center ma in be arings an d sp lit sleeves
removed fro m the cranksha ft, it must be dis- for inspection. DO NOT mix parts. Note location of
carded. DO NOT reuse it. bearings for reassembly.
Use a b earing sep arator to suppo rt t he bearing,

and press off the crankshaft.
5195
30291
Remove and inspect crankcase seal rings. Iden-

tify each ring for installation in original location.
5198
226
POWERHEAD
CYLINDER BLOCK CLEANING
CYLINDER BLOCK Use Gel Seal and Gasket Remover to remove all
traces of ga skets, adhesives, and Gel-Seal II™
CLEANING sealant from the cylinder block and crankcase.
A WARNING
IMPORTANT: Before inspecting or assembling
powerhead, all internal components must be com- To avoid personal injury, wear eye protec-
pletely clean and free of contaminants. tion an d rub ber gloves when usin g Gel
Seal and Gasket Remover.
Remove any carbon accumula tion from exhau st
port areas.
Remove any carbon accumulation from cylin der

head combustion chambers.
If cylinder walls are glazed from extende d use,

use a rigid, medium grit cylinder hone to resurface
walls. Use slow RPM for best oil retention and ring
sealing. W hen finished, a cro ss hatch p attern of
22 to 32° sh ould be visible in the cylinder wall.
The pattern should be uniform in both directions.
IMPORTANT: To avo id piston or cylind er block

damage, restore the chamfer to all port edge s
TYPICAL 34861
using a ball hone or other suitable tool.
Carefully rem ove an y carbon ac cumulation from
the tops and ring groo ves of the piston usin g
Engine Tuner. A ring groove cleaning tool can b e
2 made by brea king an old ring and grind ing a n
angle on it s end. Do not damage ring grooves
while cleaning.
1
Thoroughly wash en tire cylinder block and crank-
case with warm, soapy water to remove all traces
of contaminants.
Air dry cylind er block and crankcase. Blow all

002067
1. Crosshatch pattern in cylinder wall
2. Chamfered port edge
holes and passageways with compressed air.
A WARNING 11
To avoid personal injury, wear eye protec-
tion and se t compres sed ai r p ressure at
less than 25 psi (172 kPa).
Cover the cylinder walls with a libera l amount of

outboard lubricant to prevent corrosion.
227
POWERHEAD
POWERHEAD INSPECTION
POWERHEAD Crankshaft
Measure the diame ter of ea ch crankpin and main
INSPECTION bearing journal. The lower main be aring journal
For d imensions, refer t o SERVICE SP ECIFICA- would only be measu red if the bearing was
TIONS on p. 10. removed for another reason.
IMPORTANT: Before any inspect ion pro cess

can begin, all internal components must be co m-
pletely clean and free of contaminants.
Visually inspect all p arts. Check for unusual wear

patterns, scuf fing, or det erioration o f aluminu m
parts, heat-related d iscoloration of be arings a nd
bearing surfaces, and broken components.
Cylinder Head 5220

Check for cylinder head warpage using a piece of
bar stock or mach inist’s straightedge and a feeler Visually inspect crankcase se al rin gs fo r we ar,
gauge set. grooves, or chipping. If rings appear worn, use a
micrometer to measure ring thickness.
Cylinder head warpage must not exceed 0.003 in.
(0.08 mm) per inch of me asurement. Replace Replace rin gs that are less than 0.154 in . (3.9
head if warpage exceeds this dimension. mm) thick.
Install seal rings in t heir original po sitions on

crankshaft after inspection.
49425
1936
228
POWERHEAD
POWERHEAD INSPECTION
Cylinder Bore Pistons

Use a Cylinder Bore Gauge to inspect each cylin- Visually inspect pisto ns for signs o f abn ormal
der bore for an out-of-round, oversize, or t apered wear, scuffing, cracks, or burning.
condition. Be sure the gauge is perfectly square in Piston Rings
the bore when measuring.
For new ring sets, place each ring separately in its
respective bore. Use a piston to square the ring in
the cylinder. Use a feeler ga uge to me asure the
ring end gap.
Measure as shown 49427
Measure each cylinder in at least two areas. Each

area should be measured twice. The dif ference
between th e two measurement s in each a rea is
the cylinder out-of-round dimension.
• The cylinder must not be out-of-round by more
than 0.004 in. (0.10 mm). 49433
The dimensional dif ference between the two Ring end gap should be:
areas is cylinder taper. • 0.022 to 0.028 in. (0.56 to 0.71 mm)
• The cylind er t aper must n ot exceed 0.002 in.
(0.05 mm). IMPORTANT: Ring end g ap increases ap proxi-
mately 0.003 in. (0. 076 mm) for e ach 0 .001 in.
(0.025 mm) incre ase in cylinder bor e diamete r.
DO NOT exceed cylinder oversize dimension.
1 Use a machinist’s straightedge to check for proper
ring clea rance. Position piston rings o n p iston.
Push rings into groove and hold straightedg e
against the side of the piston. Rings must be even
or just be low the surface of piston . Rings must
move freely in piston ring groove.
11
1. Cylinder taper DR1119
The difference between the measurement s and

standard bore is cylind er oversize. For dimen-
sions, refer to SERVICE S PECIFICATIONS on
p. 10.
• The cylinder must not be oversized by more
than 0.003 in. (0.08 mm).
31796
229
POWERHEAD
POWERHEAD ASSEMBLY
Bearings POWERHEAD
Inspect center main bearing and split sleeve s for
excess wear, nicks, or scratches. Replace if ne c- ASSEMBLY
essary.
IMPORTANT: Proceed slowly. Make no forced
assemblies u nless a pressing operation is called
for. All internal comp onents must be perfectly
clean and lightly coated with outboard lubricant.
IMPORTANT: Use new wrist pin ret aining rings,

gaskets, seals, and O-rings during assembly.
Crankshaft Assembly
Place be aring ret ainer plate, flat sid e down, o n
lower end of crankshaft.
24381
Inspect crankshaft rod be arings f or excess wear,

nicks, or scratches. Replace if necessary.
1. Bearing retainer plate 30077
24377
Oil the en d of the cran kshaft. Use Cra nkshaft
Bearing/Sleeve Installer, P/N 338649, and place a
new lower main bearing onto crankshaf t with let-
tered side fa cing the tool. Inst all b earing until it
seats on the crankshaft.
Oil the en d of the cran kshaft. Use Cra nkshaft

Bearing/Sleeve In staller, P/N 338649, to d rive a
230
POWERHEAD
POWERHEAD ASSEMBLY
new sleeve o nto the crankshaft u ntil the inst aller Use retaining ring pliers to install bearing retaining
contacts the lower main bearing. ring with sharp edge facing away from bearing.
30061
30074 Lubricate a new driveshaft O-ring and lightly lubri-

cate crankshaf t splines with Moly Lube. Inst all
If the inst aller sticks on the sleeve af ter installa- O-ring in sleeve.
tion, th read Slide Hamme r, P/N 3910 08, into
installer and pull it off.
30071
Lubricate the center main bea rings and split

sleeves with outboard lubricant and install them in
their original positio ns. The split sleeve ring
30072
grooves must face toward driveshaf t (lower) en d
of crankshaft when installed.
IMPORTANT: Inspect sleeve af ter inst allation.
Sleeve must not be used if surface is damaged. 11
000829
231
POWERHEAD
POWERHEAD ASSEMBLY
Lightly coat the outside edge of a new crankshaft Install new seals on th e fo ur be aring ret ainer
seal with Gasket Sealing Compound. Use Se al screws. Appl y Nut Lock t o th e threads o f t he
Installation T ool, P/N 3254 53, to install seal in screws and tighten to a torque of 96 to 120 in. lbs.
lower crankcase hea d with extended lip of se al (11 to 13.5 N·m).
facing down. Coat se al lip s with Triple-Guard
grease.
1
1. Seal, extended lip DRC5798
000827
Lightly coat two new O-rings with Gasket Sealing
Compound and inst all on lo wer crankca se he ad. Lightly coat the outside edge of a new uppe r seal
Keep sealer away from oil passage. with Gasket Sealing Compound. Use the fla t end
of Sea l Inst allation T ool, P/N 325 453, to inst all
seal flush in upp er cran kcase h ead with the lip
facing down. Coat the seal lip with Triple-Guard
1 grease.
1. Oil passage 004132
Use threaded rods or Guide Rods, P/N 383175, to

align retainer plate with crankcase hea d. Slide
crankcase head onto crankshaft u ntil sea ted 1. Seal installer, P/N 325453 49597
around lower main bearing.
000826
232
POWERHEAD
POWERHEAD ASSEMBLY
Lightly coat two new O-rings with Gasket Sealing Apply outboard lubricant to the wrist pin bearings.
Compound, and install on upper cra nkcase head. Install the bearings in the wrist pin bore.
Keep sealer away from oil passage.
Oil the wrist pin bore and wrist pin. Place connect-
ing rod with bear ing into the piston with the align-
ment dots facing the top of the piston.
1
1. Oil passage 004131
Pistons and Connecting Rods

3
NOTICE It is very import ant that the pistons
in this engine are installed in the correct loca-
tion and direction. Engine damage will occur if
installed incorrectly.
1. Alignment dots 004306
New pistons are stamped “PORT” or “STBD,” and 53628
“EXH.” These markings should be turned toward
the exhaust side (center) of the block. The splash Install wrist pin through piston and connecting rod.
bowl o n th e d ome of the piston will b e loca ted
toward the flywheel and opposite the exhaust port.
002057
11
1 Use W rist Pin Cone, P/N 33 1913, a nd Drive r,
1. Stamped markings 004305 P/N 396747, to install new wrist pin retaining rings
NOTICE It is als o very im portant tha t the

connecting rods are installed with the align-
ment dots and the dia gonal oil hole fac ing up,
toward the flywheel.
233
POWERHEAD
POWERHEAD ASSEMBLY
in each wrist pin hole. Gap of retaining ring faces NOTICE Before continuing, mak e sure that
away from notch in piston. all Gel-Seal II has been removed from the cyl-
inder blo ck and crank case ma ting flange s. If
traces of ha rdened Gel-Seal II are l eft, ma in
bearings could be misaligned. Refer to CYLIN-
DER BLOCK CLEANING on p. 227.
Coat pistons, rings, cylinder walls, and ring com-

pressor with outboard lubricant.
Center connecting rod in piston and locate piston
rings on dowel pins. Place appropriate ring com-
pressor on piston.
DR1641 Slide piston and rod assembly into the correct cyl-
inder, as marked du ring disassembly. Guide con-
necting rod through cylinder block to avoid
scratching cylinder wall.
2
1
1. Gap in retaining ring 000756
2. Notch in piston
Installing Pistons 49435
When all pistons and connecting rods are assem-

bled, inst all piston rin g set s. Be sure rings are Cylinder Head Installation
installed in the cylinder used to test ring end gap. Lightly coat bot h sides of a new cylinder he ad
Refer to POWERHEAD INSPECTION on p. 228. gasket with Gasket Sealing Compound. Place
gasket on cylin der blo ck fo llowing instructions
IMPORTANT: Be su re ga p of ring fit s sq uarely printed on gasket.
around dowel pin.
Apply soa py water to wa ter dam and insert in to
block.
002048
1. Water dam 006965
234
POWERHEAD
POWERHEAD ASSEMBLY
Install cylinder he ad wit h the thermostat toward Gently lower crankshaft into place.
the top. Apply Triple-Guard grease to threads and • Turn all crankcase seal ring gaps to face up.
install the cylinder head screws. DO NOT use any • Locate each main bea ring on it s dowel pin. A
sealant on threads mark place d on t he bea ring ra ce o pposite th e
dowel pin ho le will help in the alignment p ro-
Following seq uence st amped on cylinder he ad, cess.
tighten all screws in stages to a torque of 17 to 19 • Tap the crankshaft upward with a rawhide mallet
ft. lbs. (23 to 26 N·m). to seat crankshaft and lower crankcase head.
• Loosely secure uppe r and lower crankcase
heads with two screws.
004133
31828
Crankshaft and Connecting Lubricate ea ch crankpin and bearing assembly

Rods with outboard lubricant. Slowly pull connecting rod
Lightly co at the cylinde r block up per and lower up to crankshaft and install bearing halves.
crankcase head flange surfaces with a th in layer
of Gel-Seal II.
31827
11
004130
Check that main bearing alignment dowel pins are

seated in the block.
Push all pistons to the to p of cylinders. Remove

the numbered connecting rod cap s and hold the
connecting rods to the outside with rubber bands.
235
POWERHEAD
POWERHEAD ASSEMBLY
Lubricate rod cap screw threads and under screw Install Rod Cap Alignme nt Fixture, P/N 39674 9,
head matin g su rface with a light coat of Triple- before tighten ing rod cap screws. Align the flat
Guard gre ase. App ly ou tboard lubricant to screw marked “SET” on the rod adjustment stop with the
hole threads in rod, and to screw head mating sur- arrow on the frame. Positio n the stop at t he high-
face on cap. est setting (two lines showing). Rotate adjustment
knob 180° to lock the stop in position.
Align do t on rod cap with dot on the conn ecting
rod.
Install rod cap screws finger tight (NO MORE than

6 in. lbs. (1 N·m) maximum).
1. Adjustment stop, highest setting 2287
Secure restraining jaw “A” and forcing jaw “B” to

frame.
31826
IMPORTANT: Be sure alignment dot on rod cap

matches dot o n rod and that both dot s face fly-
wheel.
1 Restraining Jaw “A” 21591
1. Alignment dots 53628
NOTICE Tightening rod cap sc rews without

Alignment Fixture, P/N 396749, o r us ing an
incorrect procedure c ould ca use perma nent
damage to the connecting rod and crankshaft.
Forcing Jaw “B” 21594
To maint ain accurate torque values, keep
torque wrench extension length to a minimum.
236
POWERHEAD
POWERHEAD ASSEMBLY
Apply a light coat of outboard lubricant to the cor- Loosen both rod cap screws one-quarter turn.
ners of the con necting rod and rod cap. Place
frame on connecting rod using the followin g pro- Use Torquing Socket, P/N 346187, to tighten rod
cedure: cap screws in three stages:
• Position f rame onto th e conne cting ro d so the • Apply first torque of 40 to 60 in. lbs. (5 to 7 N·m)
contact area of the jaw is ce ntered on the side to both rod cap screws.
of the rod. • Tighten screws to a torque of 20 to 22 ft. lbs. (27
• Tighten forcing screw u ntil jaws con tact con- to 30 N·m).
necting rod. • Apply final torqu e of 60 to 65 ft. lbs. (81 to 8 8
• Slide frame down until adjustment stop contacts N·m).
the rod cap. The groove lines on the jaws mu st
be centered on the rod/crankpin diameter.
21605
1. Adjustment stop 21589

IMPORTANT: If a new screw is used, it must be
2. Groove line installed as above. Then, it must be removed, re-
lubricated, and installed again.
• Tighten the forcing screw t o a torq ue of 2 3 in.
lbs. (2.5 N·m). Loosen forcing screw and remove the frame.
Test at least three corners of the rod and cap joint

with a pick. Joint must be smooth with no step.
11
21587
IMPORTANT: Make sure th at frame is squarely 004129

in position and that rod and cap are aligned.
237
POWERHEAD
POWERHEAD ASSEMBLY
Crankcase Assembly IMPORTANT: The use of Locquic Primer is NOT

recommended. If primer is used, crankcase
Thoroughly clean an d deg rease the mating
halves must be assemble d an d tig htened within
flanges of the crankcase and cylinder block with a
ten minutes after the Gel-Seal II has been applied.
non-petroleum based so lvent, such as iso propyl
alcohol or acetone, and let air dry. Lower the crankcase into place.
IMPORTANT: DO NOT allow solvent to get on Install main bearing screws an d n uts finger tight,
internal componen ts. Clean on ly th e mating no more than 60 in. lbs. (7 N·m).
flanges.
When the crankcase is se ated, inst all and firmly
Use a small brush with a tapping motion to apply a seat both crankcase taper pins.
thin, even coat of Gel-Seal II sealant to the crank-
case mating fla nge. Th e sea ler must no t come
within 1/4 in. (6.4 mm) of bearings.
004135
Tighten main bearing screws a nd nuts in stages

004127 to a final torque of:
• Screws – 48 to 53 ft. lbs. (65 to 72 N·m)
Lightly coat th e upper and lower crankcase head • Nuts – 38 to 42 ft. lbs. (52 to 57 N·m)
flange surfaces with a thin layer of Gel-Seal II.
Start in the center an d work outward in a spira l
pattern.
004134
IMPORTANT: Gel-Seal II h as a shelf life of at 004141

least one year when stored at roo m 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.
238
POWERHEAD
POWERHEAD ASSEMBLY
Apply Permatex No. 2 to crankcase flange screws Shift Linkage Installation

where thre aded hole is op en t o crankcase .Install
Install Neut ral/Shift In terrupt switch. Apply Nut
screws and tighten to a torque of 84 to 108 in. lbs.
Lock to screw threads and tighten to a torque of 7
(9.5 to 12 N·m).
to 10 in. lbs. (0.8 to 1.1 N·m).
004138
1. Neutral/Shift Interrupt switch 008451
Test that the crankshaft spins freely without bind-

If removed , install cam on shif t arm. Apply Ultra
ing.
Lock to screw threa ds an d tighte n to a torqu e of
Apply Nut Lock to the upper and lower crankcase 60 to 84 in. lbs. (7 to 9.5 N·m).
head screws. Install and tight en screws t o a
Lubricate sh ift linkage bosses a t the base of th e
crankcase with Triple-Guard gre ase. Inse rt bush-
ings into bosses.
Apply Triple-Guard grease to the shaft of the shift

lever assembly. Guide shaft through bushings in
crankcase.
Install shif t rod le ver an d tight en ret aining screw

60 to 84 in. lbs. (7 to 9.5 N·m).
Apply Triple-Guard grease to shoulder of shift arm

screw and Nut Lock to threads. Install arm, screw,
and washer a nd tighten screw to a torque of 120
004142 to 144 in. lbs. (13.5 to 16.5 N·m).
IMPORTANT: After powerhead ha s be en

assembled, allow at least two hours for Gel-Seal II 11
to cure before running outboard. 1
1. Shoulder screw 008455

2. Shift rod lever retaining screw
239
POWERHEAD
POWERHEAD ASSEMBLY
Throttle Linkage Installation Final Powerhead Assembly

Apply Nut Lock to threads of throttle lever screw. Install the reed plate and throttle body assemblies.
Refer to Intake Manifold Service on p. 151.
Insert spring into cavity of throttle lever.
Install oil recirculatin g hoses and che ck valves.
Install lever, screw, and washer on crankcase and Refer to OIL RECIRC ULATION DIAGRAMS on
hook sprin g on r ib as sh own. Tighten screw t o a p. 162, or POWERHEAD VIEWS on p. 244.
torque of 120 to 144 in. lbs. (13.5 to 16.5 N·m).
Install pressure valve assemb ly. Re fer to PRES-
SURE RELIEF VALVE SERVICING on p. 193.
Install shift linkage. Refer to Shift Linkage Instal-

1 lation on p. 239.
Install throttle linkage. Refer to Throttle Linkage

Installation on p. 240.
Install fue l injecto rs and ignition coils. Ref er to

Fuel Injector Installation on p. 149.
IMPORTANT: All injectors must be reinstalled in

006966
1. Throttle lever spring
their original location. Improper injector installation
can result in powerhead failure.
Apply Nut Lock to threa ds of throttle cam screw.
Install cam, scre w, and washer on cylinder b lock Install oil pump, rear oil manifold, and oil injection
and tighten screw to a torque of 120 to 144 in. lbs. hoses. Ref er to OIL COMPONENT SER VICING
(13.5 to 16.5 N·m). on p. 178.
Install stator. Refer to Stator Service on p. 109.
Install electrical harness and EMM. Refer to EMM

1 SERVICING on p. 70.
Install fuel pump assemblies, fuel man ifolds, and
filter. Refer to FUEL COMPONENT SER VICING
on p. 143.
Install the electric starter. Refer to Starter Instal-

lation on p. 121.
1. Throttle cam screw 006866 A WARNING

IMPORTANT: Do not lubricate throttle levers or To preve nt fire an d expl osion hazard,
shoulder screws. make sure all electrical and ignition wiring
is routed and clampe d in original posi-
tions.
240
POWERHEAD
POWERHEAD INSTALLATION
POWERHEAD Apply Gasket Sealing Compound to the threads of

all powerhead screws.
INSTALLATION Loosely install all fasteners before tightening.
Apply Permatex No. 2 to both sides of a new base
Tighten the 3/8 in. diameter powerhead screws to
gasket around the exhaust port only. Install gasket
a torque of 20 to 22 ft. lbs. (27 to 30 N·m) in the
on adapter. To ensure proper sealing, mating sur-
sequence shown.
faces must be clean and dry.
Tighten t he 5/1 6 in. diamet er powerh ead screws
to a torque of 144 to 168 in. lbs. (16.5 to 19 N·m)
in the sequence shown.
1 2
3
Crankcase to Adaptor Gaskets 008324
1. Exhaust port area – 3.3 L models
2. Exhaust port area – 3.4 L models
3. Identification tab (3.4 L models only)
Coat the driveshaft splines with Moly Lube. Do not

apply lubricant to end of driveshaft.
Use Lif ting F ixture, P/N 396748, an d hoist to
004261
slowly lower p owerhead onto exhaust h ousing. If
necessary, rotate flywheel in a clockwise direction
to align crankshaft and driveshaft splines.
IMPORTANT: Retighten powerhea d mo unting
screws after outboard has been run at full operat-
ing temperature and allowed to cool.
Install two fro nt and o ne rear po werhead nu ts.

Tighten nuts 144 to 168 in. lbs. (16.5 to 19 N·m).
11
1
48758
1. Front powerhead nut (2) 004262
241
POWERHEAD
Install wa ter hoses and exha ust back pressure

hose.
1. Rear powerhead nut 004252 3 2
Place the shift rod in the shift rod lever. Install the
retaining pin an d washer. Tighten pin to a torque
Port side 008443
of 60 to 84 in. lbs. (7 to 9.5 N·m). 1. Cooling hose (from exhaust plenum)
2. Cooling hose (from vapor separator)
3. Speedometer hose
1
1
3
1. Shift rod pin 004241
IMPORTANT: Make sure th e gea rcase shif ts Starboard side

1. Cooling hose (to exhaust plenum)
005042
solidly into both forward and reverse and that pro- 2. Exhaust back pressure hose (to EMM)
peller shaft spins freely in neutral. 3. Cooling hose (from block) – 3.3 L models
Route power trim harness through clamp and con-

nect to engine harness.
1. Trim harness 006992

2. Clamp
242
POWERHEAD
Pre-Service Adjustments
NOTICE After installing a new or reb uilt
powerhead, perform the follo wing procedures
1 1
before returning outboard to service:
• Adjust timing pointer.

• Index all spark plugs. Refer to Spark Plu g
Indexing on p. 40.
• Use Evinrude Diagnostics software to start pow-
erhead b reak-in o iling. Ref er to Powerhead
1. Trim/tilt connectors 004251
Break-In on p. 67.
• Use Evinrude Diagnostics software to set TPS
Install flywheel. Refer to Flywheel Installation on calibration. Refe r to TPS CALIBRA TION on
p. 110. p. 113.
• Use Evinrude Diagnostics so ftware to mak e
Install air temperature sensor, air silencer, and fly- sure engine ma nagement software version an d
wheel co ver. T ighten f lywheel co ver screws to a revision are current. Update as required.
torque of 30 to 42 in. lbs. (3.5 to 5 N·m). • Prime fuel system.
• Prime oilin g syste m. Refer to OIL SUPPL Y
PRIMING on p. 170.
• Use Evinrude Diagnostics software to check
engine timing. Ref er t o TIMING ADJUST -
MENTS on p. 112.
1
• Run outb oard and check for water , fu el, or oil
leaks.
• Make sure en gine reaches correct op erating
temperature and does not overheat.
1. Air temperature sensor 004219
Install the lower engine covers. Re fer to LOWER

COVER SERVICE on p. 51.
11
243
POWERHEAD
POWERHEAD VIEWS
POWERHEAD VIEWS
Port Hose Routings – 3.3 L models
007153
244
POWERHEAD
POWERHEAD VIEWS
Starboard Hose Routings – 3.3 L models
11
007154
245
POWERHEAD
POWERHEAD VIEWS
Port Hose Routings – 3.4 L models
008503
246
POWERHEAD
POWERHEAD VIEWS
Starboard Hose Routings – 3.4 L models
11
008502
247
POWERHEAD
POWERHEAD VIEWS
Port – 3.3 L models
008448
248
POWERHEAD
POWERHEAD VIEWS
Starboard – 3.3 L models
11
008449
249
POWERHEAD
POWERHEAD VIEWS
Port – 3.4 L models
008441
250
POWERHEAD
POWERHEAD VIEWS
Starboard – 3.4 L models
11
008442
251
POWERHEAD
POWERHEAD VIEWS
Front – 3.3 L models
008450
252
POWERHEAD
POWERHEAD VIEWS
Front – 3.4 L models
11
008439
253
POWERHEAD
POWERHEAD VIEWS
Rear – 3.3 L models
007142
254
POWERHEAD
POWERHEAD VIEWS
Rear – 3.4 L models
11
008440
255
POWERHEAD
POWERHEAD VIEWS
Top
008438
256
POWERHEAD
POWERHEAD VIEWS
Starboard – ICON models
11
008504
257
POWERHEAD
NOTES
NOTES
Bulletins
Instruction Sheets
Other
258
MIDSECTION
MIDSECTION
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
STERN BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
EXHAUST HOUSING – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
EXHAUST HOUSING – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
EXHAUST HOUSING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
EXHAUST HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
LOWER MOUNT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
EXHAUST HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
EXHAUST HOUSING DISASSEMBLY – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
EXHAUST HOUSING DISASSEMBLY – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
EXHAUST HOUSING ASSEMBLY – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
EXHAUST HOUSING ASSEMBLY – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
STERN BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
STERN BRACKET DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
STERN BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
EXHAUST RELIEF MUFFLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
12
259
MIDSECTION
SERVICE CHART
SERVICE CHART
Stern Bracket
40-50 In. lbs.
(4.5-5.5 N·m)
64-72 Ft. lbs.

(87-98 N·m)
8-12 In. lbs.

10-16 In. lbs.
(0.9-1.4 N·m)
A (1.1-1.8 N·m)
A
30-50 In. lbs.

U (3.3-5.5 N·m)
60-84 In. lbs. A 40-50 In. lbs.

(7-9.5 N·m) (4.5-5.5 N·m)
28-30 Ft. lbs.

A
(38-41 N·m) 40-50 In. lbs.
(4.5-5.5 N·m)
45-50 Ft. lbs.
(68-73 N·m) 216-240 In. lbs.
(25-27 N·m)
IMPORTANT
Use Triple-Guard grease
on all pivot points
40-50 In. lbs.
(4.5-5.7 N·m)
216-240 In. lbs.

8-12 In. lbs. (25-27 N·m)
(0.9-1.4 N·m)
170-190 In. lbs.

(19-22 N·m) 38-45 Ft. lbs.
(52-61 N·m)
40 Ft. lbs. (54 N·m)

Marine Sealant
120-144 In. lbs.
See "Installation &
(13.5-16.5 N·m)
Predelivery" in manual
A B A Triple-Guard Grease
130-150 Ft. lbs.
(176-204 N·m) B Gasket Sealing Compound
E Red Ultra Lock
004105
U Instant Bonding Adhesive
260
MIDSECTION
SERVICE CHART
Exhaust Housing – 3.3 L models

22-24 Ft. lbs.
(30-33 N·m)
F
P
See Assembly
Instructions
B
F 60-84 In. lbs.
120-144 In. lbs. (7-9.5 N·m)
(14-16 N·m)
L
B B
60-84 In. lbs. 144-168 In. lbs.
(7-9.5 N·m) (16-19 N·m)
Q
9-12 Ft. lbs.
(12-16 N·m)
B
60-84 In. lbs. C
(7-9.5 N·m)
40-42 Ft. lbs. 144-168 In. lbs.

(54-57 N·m) (16-19 N·m)
E B F
60-84 In. lbs.
(7-9.5 N·m)
B
Q
C
B See Assembly
60-84 In. lbs. Instructions
(7-9.5 N·m)
B
60-84 In. lbs.
(7-9.5 N·m)
B
B
20-22 Ft. lbs.

B C (27-30 N·m)
60-84 In. lbs.
(7-9.5 N·m)
C
C
A A
A
12
156-180 In. lbs.
Triple-Guard Grease (18-20 N·m) C
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
L Pipe Thread Sealing Compound C
P Permatex #2
A 004107
Q Gel Seal II
261
MIDSECTION
SERVICE CHART
Exhaust Housing – 3.4 L models

F
22-24 Ft. lbs.
(30-33 N·m)
P
144-168 In. lbs.
(16.5-19 N·m)
B
144-168 In. lbs.
Q (16.5-19 N·m)
9-12 Ft. lbs.
(12-16 N·m)
B C
60-84 In. lbs.
(7-9.5 N·m)
40-42 Ft. lbs.

144-168 In. lbs.
(54-57 N·m)
(16.5-19 N·m)
E B
C F
60-84 In. lbs.
(7-9.5 N·m
A
Q
20-22 Ft. lbs.

(27-30 N·m)
A
A
156-180 In. lbs.
Triple-Guard Grease (18-20 N·m)
C
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
L Pipe Thread Sealing Compound C
P Permatex #2
004107BT
Q Gel Seal II A
262
MIDSECTION
SERVICE CHART
Muffler
007117
12
263
MIDSECTION
TILT TUBE
TILT TUBE Remove the nut from the starboard side.
The tilt tube may be serviced without major disas-

sembly of the outboard using Tilt Tube Service Kit,
P/N 434523.
Removal
A WARNING
Support the outboard with a suitable hoist.
Pull the locking tabs on the tilt limit cam loose from
30747
the collar.
Thread the spacer f rom Tilt T ube Service Kit,
P/N 434523, on to the st arboard end of th e tilt
tube.
1. Locking tabs 30749
Remove the cam and collar from the tilt tube.

30746
Remove steerin g cab le wiper nut from tilt tub e.

Thread the adap ter from T ilt T ube Service Kit,
P/N 434523, onto the port end of the tilt tube.
30748
30745
264
MIDSECTION
TILT TUBE
Thread Slide Hammer, P/N 432128, into the Install the starboard locknut.
adapter until at least 2 in. (51 mm) of threa d are
engaged. A WARNING
Replace locknut if definite resistance is
not felt.
Tighten starboard tilt tube nut to a torque of 45 to

50 ft. lbs. (61 to 68 N·m).
30744
Pull tilt tube from stern bracket with the slide ham-
mer. When tilt tube clears the port stern b racket,
remove tilt tube from the spacer.
Installation
Thread starboard end of tilt tube into the spacer.
Thread the adapter onto port end of tilt tube.
30741
Use a wood or leather ma llet to t ap the tilt tube
into position. Replace steering cable wiper nut on port end of tilt
tube.
Apply one drop of instant bond ing adhesive in

receiving chann els of tilt limit switch collar an d
install collar and tilt cam on tilt tube. Be sure locat-
ing tab on collar fits in hole on tilt tube.
30743
Make sure the lock tab is in correct position.
12
1
30750
1. Lock tab 30742
265
MIDSECTION
EXHAUST HOUSING SERVICE
EXHAUST HOUSING Remove the exhaust housing.
SERVICE
Exhaust Housing Removal
Before removing the exhaust housing:
• Remove th e gearcase . Re fer to Ge arcase
GEARCASE RE MOVAL AND INSTALLATION
on p. 289.
• Remove the p owerhead. Refer to POWER-
HEAD REMOVAL on p. 219.
Remove and discard four lower mount screws.
006979
Lower Mount Service

Remove lower mount covers and inspect the
lower mounts.
If replacement is necessary, lubricate mount with

soapy water a nd carefully pry at b oth en ds to
remove.
32590
Remove the steering arm ground lead and screw.

Remove two upper mount screws.
32578
1. Ground lead (removed) 32589
266
MIDSECTION
If re moved, coat the lower mount s with soap y Exhaust Housing Installation
water and press into the exhaust housing with the
Bring the exhaust housing into position with th e
“OUTSIDE” mark facing outward.
stern bracket.
Install four new lower mount screws with lock-

patch. Tighten screws to a torque of 38 to 45 ft.
lbs. (51 to 61 N·m).
1
23033
Install t he mou nt covers. Ap ply Nut Lock to

screws, install washers and screws, and tighten to
a torque of 156 to 180 in. lbs. (18 to 20 N·m). 1. Lower mount screws 32590
Apply Ultra Lock to upper mount screws an d

tighten t o a to rque of 64 to 72 f t. lbs. ( 87 to 9 8
N·m).
32579
7716
12
267
MIDSECTION
Attach the ground lead and lockwasher to the star- Exhaust Housing Disassembly –
board side of the steering arm.
3.3 L models
Remove two f ront adapter to o uter exhaust hous-
ing screws. Remo ve thre e nut s at rear of the
adapter.
32586
If necessary, replace the exhaust adapter to lower

engine cover seal. Attach with Adhesive 847.
32580
Loosen and remove the upper mount plate screws

and remove the mount plate.
32585
Install gearcase. Refer to Gearcase GEARCASE

REMOVAL AND INSTALLATION on p. 289.
32588
Install powerhead. Refe r to POWERHEAD
INSTALLATION on p. 241. Lubricate the upp er mou nt with so apy water a nd
pry up to remove it from the adapter housing.
Lift the ad apter/inner e xhaust h ousing ou t of t he

exhaust housing.
268
MIDSECTION
Mark the water tube for correct reassembly loca- Exhaust Housing Disassembly –
tion. Remove six inner exhaust ho using screws.
Remove the inner exhaust housing.
3.4 L models
Remove two fr ont adapter to o uter exhaust hous-
ing screws.
13638
Remove the water tube and grommet from the

inner exhaust housing. Discard the grommet.
Loosen ret aining screws an d remove the cover 006980
from water plate.

Remove three nuts at rear of the adapter.
Loosen retaining screws a nd remove wa ter plate
.
from the adapter.
006978
1. Cover 13641
2. Water plate
12
269
MIDSECTION
Loosen and remove the upper mount plate screws Cleaning and Inspection
and remove the mount plate.
A WARNING
injury, and set compressed air to less than
25 psi (172 kPa).
Clean all parts with parts cleaning solvent and dry

with comp ressed air . All nut a nd screw threads
coated with thread locking material must be thor-
oughly cle aned b efore assembly . When u sing a
thread locking pro duct, be su re to prime t he
threads with Locquic Primer.
32588
Examine the upper and lower thrust mounts, and

Lubricate the up per mou nt with soapy water and replace if deteriorated or damaged.
pry up to remove it from the adapter housing.
Before checking the ex haust housing fo r distor-
Lift the a dapter/inner exhaust housing o ut of the tion, thoroughly clean the top and bottom mating
exhaust housing. surfaces and remove all sealer and corrosion.
.
Check the e xhaust hou sing for distortio n. Place

the housing on a surface plate. Using a dial indi-
cator, check flatness by measuring the run-out on
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.
IMPORTANT: A d istorted exhaust ho using will

cause the upper driveshaft splines to wear exces-
006981 sively and will damage the crankshaft splines.
DR2223
270
MIDSECTION
Inspect the wa ter tube fo r obstructions or kinks, Coat the outside diameter o f a n ew water tub e
which may restrict water flow. grommet with Adhesive 847. Install grommet in
the inner exhaust housing. Install the water tube.
Exhaust Housing Assembly –
3.3 L models
Lightly coat both sides of a n ew gasket with Gas-
ket Sealing Compound and install the gasket and
water plate.
Apply Gasket Sealing Compound to threads of the
water plate retaining screws. Inst all with washe rs
and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5
7715
N·m).
Lightly coa t both sides of a ne w inner exhaust
housing ga sket wit h Gasket Sealing Compound
and install it.
Install th e inn er exhaust housing. Co at inn er

exhaust housing screws with Gasket Sealing
Compound and tighten to a torqu e of 60 to 84 in.
lbs. (7 to 9.5 N·m).
13644
Apply Adhesive 847 to the water p late surface,

then place the cover on the water plate.
Apply Gasket Sealing Compound to thread s of
cover retaining sc rews. Ins tall with washers and
tighten to a torque of 60 to 84 in. lbs. (7 to 9.5
N·m).
13639
Apply Adhesive 847 to t he b ottom fla nge of th e

inner exhaust hou sing. Inst all a new seal. Apply
Triple-Guard grease to outer seal surface.
12
13642
7713
271
MIDSECTION
Install a new inne r exha ust ho using sea l. Apply Lubricate the upp er mou nt with so apy water a nd
Adhesive 847 to the seal groove. push into place in the adapter housing. The mount
radius must face af t with the “T OP” mark facing
up.
Apply Locquic Primer a nd Nut Lock to the upp er

mount plate screws and inst all the plate a nd
screws loosely. In stall th e g round lead a nd star
washer under the forward starboard screw.
Align the oute r exhaust housing an d adapter by

placing two powerhe ad mounting screws through
their holes.
13640
Clean and degrea se the adapte r housing and

outer exhaust h ousing mating surfaces with
Cleaning Solvent. Apply Gel-Seal II sealant to the 1
adapter flange of the exhaust housing.
1. Powerhead mounting screws 13689
Install four mount plate screws and washers a nd

tighten t o a to rque o f 22 to 24 f t. lbs. (30 to 33
N·m).
13692
Place the adapte r/inner exha ust ho using into the

exhaust housing. Align the water tube.
Loosely inst all the small r etaining screws, n uts,

and washers.
13690
32580
272
MIDSECTION
Tighten th e small a dapter to exha ust ho using Install gro mmet and wate r tube in the inn er
screws and nuts to a torque of 60 to 84 in. lbs. (7 exhaust housing.
to 9.5 N·m).
1. Water tube grommet 006982

13691
Clean an d d egrease t he a dapter hou sing an d
Exhaust Housing Assembly – outer exhaust ho using matin g surface s with
Cleaning Solvent. Apply Gel-Seal II sealant to the
3.4 L models adapter flange of the exhaust housing.
Apply Adhesive 847 to the bottom flange of the
inner e xhaust ho using. In stall a ne w seal. Apply
Triple-Guard grease to outer seal surface.
13692
Place the a dapter/inner e xhaust hou sing into th e

006984 exhaust housing. Guide the water tube throug h
the hole in the outer housing.
12
006981
273
MIDSECTION
Loosely inst all the small r etaining screws, n uts, Install four mount plate screws and washers a nd
and washers. tighten t o a to rque o f 22 to 24 f t. lbs. (30 to 33
N·m).
32580
006986
Lubricate the up per mou nt with soapy water and
push into place in the adapter housing. The mount Tighten the small ad apter to exhaust ho using
radius mu st face aft with the “TOP” mark facing screws and nuts to a torque of 60 to 84 in. lbs. (7
up. to 9.5 N·m).
Apply Locquic Primer and Nut Lock to the up per
mount p late scre ws and inst all the p late a nd
screws loosely. Inst all the ground le ad and st ar
washer under the forward starboard screw.
Align the out er exhaust housing and adapte r by

placing two powerh ead mounting screws throu gh
their holes.
13691
1. Powerhead mounting screws 006985
274
MIDSECTION
STERN BRACKET
STERN BRACKET Remove the steering shaf t an d thru st washer . It

may be necessary to t ap the ste ering shaf t out
Stern Bracket Disassembly using a wood dowel and mallet.
Before servicing the stern bracket:
• Remove gearcase. Refe r to Gearcase
GEARCASE RE MOVAL AND INSTALLATION
on p. 289.
• Remove powerhead. Refe r t o POWERHEAD
REMOVAL on p. 219.
• Remove exhaust housing. Re fer to Exhaust
Housing Removal on p. 266.
• The power trim/tilt unit must be removed. Refer
to TRIM AND TILT SERVICE on p. 349.
Remove and discard steering shaft locknut. 30735
Pry out upp er and lower stee ring shaft seals and
discard. Remove the upper and lower steering
shaft bushings.
30738
Remove the lower mount bracket and keeper.

30765 / 30764
Remove th e tilt tube. Refe r to TILT TUBE on

p. 264.
Remove the two tilt tube washers.
12
30736
30763
275
MIDSECTION
STERN BRACKET
Remove the anode. Remove the tilt limit swi tch and retainer from t he
swivel bracket.
2
1. Anode 30762
1. Tilt limit switch 30758
Remove the swivel bracket. Inspect and, if neces- 2. Retainer
sary, replace the tilt tube bushings.

Disconnect the trail lock spring and remove it from
the swivel bracket. Remove trail arm retainer.
2
1
1. Tilt tube bushing 30761
Remove the trim se nder unit from the port stern 1. Trail lock spring 30756
2. Trail arm retainer
bracket and pull its wires throu gh the braid ed
tube. Remove the trail lock arm and bushings from the
swivel bracket.
30760
1. Trail lock bushing 30755
276
MIDSECTION
STERN BRACKET
Remove th e two trim rod rollers from th e swivel Stern Bracket Assembly
bracket.
IMPORTANT: Before proceeding, make sure all
components ha ve be en thoro ughly cleane d.
Replace any seals th at h ave been remove d.
Inspect all thrust washe rs and bushin gs for evi-
dence of deterioration.
Install the detent roller and spring and the tilt sup-
1 port with bush ing in the swivel bra cket. T ighten
bushing to a torque of 28 to 30 f t. lbs. (38 to 41
N·m).
1. Trim rod roller 30754
Remove the tilt support and bushin g fro m the

swivel bracket and in spect the dete nt roller and
spring.
1
30752
1. Tilt support bushing 30753

1
1. Tilt support bushing 30753
12
277
MIDSECTION
STERN BRACKET
Install the two trim rod rollers on the swivel Install the tilt limit switch and retainer on the swivel
bracket. Tighten to a torque of 216 to 240 in. lbs. bracket. Tighten screws to a torque of 40 to 50 in.
(25 to 27 N·m). lbs. (4.5 to 5.5 N·m).
1. Trim rod roller 30754 1. Tilt limit switch 30758

2. Retainer
Install the trail lock and bushings in the swivel

bracket. Tighten to a torque of 216 to 240 in. lbs. Route the trim sender wires through the braid ed
(25 to 27 N·m). tube, and install the send er unit in the port ste rn
bracket.
1. Trail lock bushing 30755

30760
Install th e trail lock sp ring in the swivel bracket

and connect the spring to the trail lock. Install the upper and lower steering shaft bushings
and new seals in the swivel bracket. Both seal lips
face out.
• Coat the outside surfaces of seals with Gasket
Sealing Compound.
2
1
1. Trail lock spring 30756

2. Trail arm retainer
278
MIDSECTION
STERN BRACKET
• Coat the bushings and se al lip s with Triple- Install the steering shaf t keepe r. App ly Locquic
Guard grease. Primer and Nut Lock to the splines of the steering
shaft and lower mount bracket.
30765 / 30764
Coat tilt t ube bu shings with Triple-Guard grease

and, if removed, install them in the swivel bracket.
30736
Install the lower mount bracket and a new locking

nut with it s u nstaked side f acing the mount
bracket. Align the bracket with the ste ering arm
and tighten the nut to a torque of 130 to 150 ft. lbs.
(176 to 204 N·m).
30761
Place the swivel bracket between the stern brack-

ets and install the anode.
Install the tilt tube and tilt limit cam. Refer to TILT
TUBE on p. 264.
Install the steering shaft and thrust washer.

30767
Fill th e swivel b racket with Triple-Guard grease

through the grea se fitting on the bracke t’s port
side. Lu bricate the tilt tube, swivel bracket, an d
stern brackets through the two f orward grease fit-
tings.
12
Install the exhaust housing. Refer to Exhaust
Housing Installation on p. 267.
30735
279
MIDSECTION
EXHAUST RELIEF MUFFLER ASSEMBLY
EXHAUST RELIEF The overboard indicato r and flush port in the

exhaust re lief gro mmet conne ct to the adaptor
MUFFLER ASSEMBLY housing assembly with a hose. This ho se is n ot
connected to the muffler assembly.
The exhaust relief muffler is located at the rear of
the adaptor housing and con cealed by the lower
motor co vers. The exha ust relief grommet con-
nects directly to the muffler assembly.
1
1
1. Overboard indicator and flush port 004225
Periodically in spect ho ses and connections for

condition. Replace muffler or hoses as needed.
1. Exhaust relief grommet 004122
The muf fler assembly connects to th e e xhaust

relief hoses from the adaptor housing assembly.
1. Exhaust relief grommet 004226

2. Exhaust relief hoses
280
GEARCASE
GEARCASE
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
GEARCASE TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
PROPELLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
GEARCASE LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
GEARCASE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
SHIFT ROD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
GEARCASE – STANDARD ROTATION
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
PROPELLER SHAFT BEARING HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
PINION GEAR AND DRIVESHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
DRIVESHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
SHIFT HOUSING, GEAR, AND PROPELLER SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
GEARCASE HOUSING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
SHIFTER, BEARING AND SEAL SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
PINION BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
SHIFT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
DRIVESHAFT BEARING HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
PROPELLER SHAFT BEARING HOUSING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
DRIVESHAFT SHIMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
SHIFT HOUSING, GEAR, AND PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
PINION GEAR AND DRIVESHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION – “L2” TYPE . . . . . . . . . . . . . . . . . . . . . 315
PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION – “M2” TYPE . . . . . . . . . . . . . . . . . . . . . 316
FINAL ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
GEARCASE – COUNTER ROTATION
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
PROPELLER SHAFT BEARING HOUSING REMOVAL – “M2” TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
PINION GEAR REMOVAL AND DRIVESHAFT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
SHIFT HOUSING, GEAR AND PROPELLER SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
GEARCASE HOUSING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
SHIFTER, BEARING AND SEAL SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
SHIFT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
PINION BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
PROPELLER SHAFT BEARING HOUSING AND FORWARD GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
DRIVESHAFT SHIMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
SHIFT HOUSING, GEAR, AND PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
PINION GEAR AND DRIVESHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
13
PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION – “M2” TYPE . . . . . . . . . . . . . . . . . . . . . 329
FINAL ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
281
GEARCASE
SERVICE CHART
SERVICE CHART
V6 PERFORMANCE MODELS “L2”–TYPE GEARCASE
C 60-84 In. lbs. B

24-36 In. lbs. (7-9.5 N·m) A
(3-4 N·m) B B 120-144 In. lbs.
(13.5-16.5 N·m)
A
60-84 In. lbs.
A D B (7-9.5 N·m)
A B
C
B B
A
A
A 45-50 Ft. lbs.
A (61-68 N·m)
C A
A 18-20 Ft. lbs. A
X (24-27 N·m)
26-28 Ft. lbs.
(35-38 N·m) 60-84 in. lbs.
(6.8-9.5 N·m)
G A
B
B 26-28 Ft. lbs.
60-84 In. lbs. 14-18 In. lbs. (35-38 N·m)
(7-9.5 N·m) (1.5-2 N·m)
100-110 Ft. lbs.
J (136-149 N·m)
A A
35-40 Ft. lbs.
(47-54 N·m)
60-84 In. lbs.

18-20 Ft. lbs. (7-9.5 N·m)
(24-27 N·m)
E
B G
B
B
A
B
108-132 In. lbs.

(12-15 N·m)
70-80 Ft. lbs.
(95-109 N·m)
C Adhesive 847
D Moly Lube
A E Red Ultra Lock
F Blue Nut Lock
J Gearcase Lubricant
282
GEARCASE
SERVICE CHART
V6 STANDARD ROTATION “M2”–TYPE GEARCASE
C 60-84 In. lbs.

24-36 In. lbs. (7-9.5 N·m) B
(3-4 N·m) B A
A B
120-144 In. lbs.
(13.5-16.5 N·m)
D
A B
60-84 In. lbs.
(7-9.5 N·m)
B
A
C
B
C
A
A 26-28 Ft. lbs.
(35-38 N·m)
A A A 45-50 Ft. lbs.
(61-68 N·m)
C
A X A
18-20 Ft. lbs.
(24-27 N·m) 60-84 in. lbs.
G (6.8-9.5 N·m)
B A
14-18 In. lbs. 26-28 Ft. lbs.
(1.5-2 N·m) (35-38 N·m)
J B
60-84 In. lbs.
100-110 Ft. lbs. (7-9.5 N·m)
A (136-149 N·m)
A
35-40 Ft. lbs. 60-84 In. lbs.
(47-54 N·m) (7-9.5 N·m)
18-20 Ft. lbs.

B E (24-27 N·m)
G
A 30-34 Ft. lbs.
A A (41-46 N·m)
J
A
108-132 In. lbs.

(12-15 N·m)
70-80 Ft. lbs.

(95-109 N·m)
A B Gasket Sealing Compound
C Adhesive 847
D
E
Moly Lube
Red Ultra Lock
13
F Blue Nut Lock
283
GEARCASE
SERVICE CHART
V6 COUNTER ROTATION “M2”–TYPE GEARCASE
C A
60-84 In. lbs.
24-36 In. lbs. (7-9.5 N·m)
(3-4 N·m) B B A
A
120-144 In. lbs.
B (13.5-16.5 N·m)
A D
B 60-84 In. lbs.
(7-9.5 N·m)
B
A
C
B
C
A
A
26-28 Ft. lbs.
A (35-38 N·m)
A 45-50 Ft. lbs.
C A (61-68 N·m)
A
X A
18-20 Ft. lbs. 60-84 in. lbs.
(6.8-9.5 N·m)
B G (24-27 N·m)
A
26-28 Ft. lbs.
14-18 In. lbs.
(35-38 N·m)
(1.5-2 N·m)
100-110 Ft. lbs. B
100 Ft. lbs. J (136-149 N·m) 60-84 In. lbs.
(136 N·m) J (7-9.5 N·m)
A 60-84 In. lbs.

35-40 Ft. lbs.
(47-54 N·m) (7-9.5 N·m)
18-20 Ft. lbs.

B E (24-27 N·m)
A G
A
A A
A 30-34 Ft. lbs.

(41-46 N·m) J
108-132 In. lbs.

(12-15 N·m)
70-80 Ft. lbs.
(95-109 N·m)
A C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
284
GEARCASE
GEARCASE TYPES
GEARCASE TYPES
Housing
Outboard Model Description of Features Gear Ratio
Type
high speed profile, external water screens, pressed in
90°V6 20 in. “L2” 14:26 (.538)
propeller bearing housing, performance gearset (V6).
90°V6 20 in. front water inlets and straight leading edge, pressed in
90°V6 25 in. propeller shaft bearing housing with retaining flange, 13:24 (.542)
90°V6 30 in. heavy duty standard gearset (V6)
“M2”
front water inlets and straight leading edge, pressed in
90°V6 25 in. / 30 in. propeller shaft bearing housing with retaining flange“ 13:24 (.542)
Counter Rotation
CR” shafts, bearings and heavy duty gearset (V6)
Housing Identification
Remove the trim tab retaining screw, gasket and Make note of identificatio n markings. Refer to
trim tab from the gearcase. Housing Profiles on p. 285.
1
1
2. Trim tab COA3663 1. Identification markings COA3139
Housing Profiles
V6 “L2” Type V6 “M2” Type
19.20 19.20
13
006976 4.918
5.082
285
GEARCASE
PROPELLER SERVICE
PROPELLER SERVICE Propeller Selection

Inspection A CAUTION
Carefully examine p ropeller and o utboard f or the Selection of the wro ng propell er could
following: reduce engine service l ife, affect boat pe r-
• Damaged blades and sign s of pro peller cavita- formance, or cause serious damage to the
tion (burned paint, etc.) powerhead.
• Spun or overheated inner hub
• Worn or twisted spline s an d ina dequate lub ri- Water testing with various propeller designs and
cant sizes is the best method of propeller selection.
• Damaged or missing converging ring (if applica-
ble) The co rrect propeller, und er no rmal lo ad cond i-
• Damage to outer hub area tions, will allow the engine to run near the mid-
• Worn, missing, or incorrect thrust washer and point of the RPM oper ating range at full throttle.
spacer Refer to SERVICE SPECIFICATIONS on p. 10.
• Correct size and style Operating Range
• Check for ben t or damaged propeller shaft and Peak HP
twisted splines. H 100%
o 90%
Refer to Propeller Hardware Installation on r
p. 287. s 80%
e 70%
A WARNING p 60%
o 50%
w 40%
When servicing the propeller, always shift e 30%
the outboard to NEUTRAL, turn the key r
switch OFF, and d isconnect the batte ry 2000 3000 4000 5000 6000
positive (+) ca ble so the ou tboard cannot RPM
be started accidentally. 008329
NOTICE If the propeller blade s have too

much pitch, th e engine will operate be low i ts
normal range at full throttle. Power will be lost,
and powerhead damage coul d occ ur. If the
propeller blades have too little pitch, the
engine will operate above its normal range and
damage from overspeeding could occur.
286
GEARCASE
PROPELLER SERVICE
When selecting a propeller, consider the following: Propeller Hardware Installation

• Use an accurat e t achometer t o determine the
engine’s full-throttle RPM. A WARNING
• The outboard should be trimmed for top speed.
• Select a prop eller that suits the customer’s To prevent accidental starting while servic-
application an d allows the engine to run n ear ing, twist and remove all spark plug leads.
the midpoint of th e full-throttle opera ting ran ge
when the boat has a normal load. IMPORTANT: Depending on propeller style, dif-
• Occasionally, one propeller will not cover a wide ferent thrust bushings, sp acers, and cotter pin
range of boat application s — water skiing to keepers are used. See the Evinrude/Johnson
high speed performance boating. In such cases,
Genuine Parts and Accessories Catalog for cor-
it might be necessary to have a p ropeller for
each situation. rect propeller hardware.
• Refer to the Evinrude/Johnson Genuine Parts Apply Triple Guard grease t o the entire pro peller
and Accessories Catalog for p ropeller style s shaft before installing the propeller.
and sizes.
• Right-hand p ropellers a re considered standard Install thrust bushing onto prop eller shaft with
rotation propellers. When propelling a boa t for- taper of bushing matching taper of shaft.
ward, the propeller rot ates in a right-hand
(clockwise) direction as viewed from the rear. If inst alling a p ropeller with an interchangeable
• Left-hand pro pellers are considered cou nter- hub, assemble the propeller following instructions
rotation propellers. When propelling a boa t for- provided with the propeller.
ward, the propeller rotates in a left-hand (coun-
terclockwise) direction as viewed from the rear. Align splines of propeller and shaft. Push propeller
until seated on the thrust bushing.
Install the spacer over the propeller shaft splines.
Wedge a block of wood between propeller blad e

and the anti-ventilation plate.
2 1
1. Right-hand rotation (clockwise) 000033
2. Left-hand rotation (counterclockwise)
A WARNING 001992
For dual-o utboard inst allations, always

Install the propeller nut and tighten to a torque of:
check to be sure propellers are installed
• With Keeper – 70 to 80 ft. lbs. (95 to 109 N·m)
on the correct e ngines b efore aggres -
• Without Ke eper – 120 t o 144 in. lbs. (13.6 to
sively operating the boat.
16.3 N·m) 13
287
GEARCASE
GEARCASE LEAK TEST
If cotter pin holes in t he nut (without keeper) and

shaft do not align, tighten further. Do not loosen.
GEARCASE LEAK TEST
Drain lubricant before testing.
Install keeper (if applicable). Install new cotter pin.
Use Gearcase Pressure Tester, P/N 507977.
Aluminum or stainless steel
Small diameter hub
Install lubricant drain/fill p lug and seal, thre ad
1 2 pressure test g auge fitting a nd seal in lubricant
Without keeper
120 to 144 in. lbs level hole.
3
Pressurize 3 to 6 psi (21 to 42 kPa).
If pressure gauge indicates lea kage, submerge

Aluminum or stainless steel
Large diameter hub
the gearcase in water to determine source of leak.
1 2 4 With keeper
70 to 80 ft. lbs If th e gauge does not in dicate le akage, increase
3 pressure to 16 to 18 psi (110 to 124 kPa). Check
for leaks.
Make necessary repairs and repeat test.

Aluminum interchangeable hub
Small diameter hub
1 2 Without keeper Install Gearca se V acuum T ester, P/N 507982.
120 to 144 in. lbs Apply 3 to 5 in. of vacuum (76 to 127 mm) Hg.
with pump.
If vacuu m gaug e indicat es le akage, apply oil

around suspect ed seal. If lea k stop s or oil is
Aluminum interchangeable hub drawn in, seal is defective.
Large diameter hub
1 2 4 With keeper
70 to 80 ft. lbs
Repeat test, g earcase must ho ld minimum o f 15
in. vacuum (381 mm) Hg.
3
Stainless steel TBX hub

4 Large diameter hub
1 With keeper
70 to 80 ft. lbs
3
1. Thrust bushing 008057

2. Spacer
3. Propeller nut
4. Keeper
002388
IMPORTANT: After inst allation, make sure out-

board is in NEUTRAL and carefully spin propeller.
Propeller must turn freely and sh ould not spin off
center. If propeller app ears to wobble, check for
possible bent propeller shaft.
288
GEARCASE
GEARCASE REMOVAL AND INSTALLATION
GEARCASE REMOVAL Remove the 3/8-16 x 3.5 in . scr ew and washe r,

and remove 7/16-14 x 3.5 in. screw and washer.
AND INSTALLATION
1
Gearcase Removal
A WARNING
vicing, twis t and remove all sp ark plug
leads.
During service, the outboard may drop 2
unexpectedly. A void perso nal inju ry;
always support the outboard’s weight with
1. 3/8-16 x 3.5 in. screw 006869
a suitable hoist or the tilt support bracket 2. 7/16-14 x 3.5 in. screw
during service.
Remove the four 3/8-16 x 1.75 in. gearcase retain-
Remove pin and wa sher from shif t rod lever to ing screws and washers.
release the lower shift rod.
1
1. Shift rod screw 004241
1. Gearcase retaining screws (4) 001990
Note where the index mark on the gearcase aligns
with the index number of the adjustable trim tab so Remove the gearcase assembly from the exhaust
the trim tab can be installed in the same position. housing, being careful not to bend the shift rod.
Remove the trim tab retaining screw, gasket and
trim tab from the gearcase.
2
1 13
1. Index mark COA3663
2. Trim tab retaining screw
289
GEARCASE
Gearcase Installation Slide the gearcase into place, making sure:

• Driveshaft engages the crankshaft.
A WARNING • Water tube enters the water pump.
• Lower inner exhaust housing installs correctly.
During service, the outboard may drop
unexpectedly. A void perso nal inju ry; • Shift ro d does not turn an d is positio ned pro p-
always support the outboard’s weight with erly in the shift rod lever below the crankcase.
a suitable hoist or the tilt support bracket
Some outboa rd mode ls inclu de hollow alignme nt
during service.
pins between the exhaust housing and gearcase.
NOTICE Before installing gearcase, shift rod If o utboard is not equipped with alignment pins,
adjustment MUST be checked. Refer t o SHIFT use Gea rcase Alig nment Kit, P/N 5 007231, to
ROD ADJUSTMENT on p. 295. accurately align gearcase h ousing to exhaust
housing. Position alignment bolts (2) as indicated.
Coat th e drivesh aft splines with Moly Lube. DO
NOT co at top su rface of th e driveshaf t be cause
lubricant may prevent seat ing of the driveshaf t in
the crankshaft.
Alignment Bolt(s) 005401
30385
Apply Adhesive 847 to the lo wer exhaust housing 1

seals’ inner surfaces. Place two new seals on the
housing. Apply Triple-Guard grease to the seals’ 1. Position of alignment bolts (2) 005402
outer surfaces and pla ce the housing on the
gearcase. IMPORTANT: Replace alignment b olts with
mounting scre ws af ter all othe r gearcase mou nt-
ing screws are installed.
A WARNING
1 Failure to properly tighte n gearcase
screws with a torque wrench could lead to
gearcase damage or loss, resulting in loss
of control and possible personal injury.
Screw torque should be checke d regu-
larly, e specially in high-speed a pplica-
1. Lower exhaust seals 001985 tions, or any t ime p ropeller d amage has
occurred.
290
GEARCASE
IMPORTANT: New gearcase screws are treated ft. lbs. (47 to 54 N· m). For adjustme nt, refer to
with a thread-locking material. Apply Triple-Guard Trim Tab Adjustment on p. 30.
grease to thre ads t o ensure th at the correct
clamping force is ach ieved when tig htening—If a
previously inst alled screw is re-used, use a wire
brush to remove any old thread-locking material or
corrosion and lubricate threads with Triple-Guard
grease.
1
Install screws and washers and tighten to a torque
of:
• 3/8 in. screws – 26 to 28 ft. lbs. (35 to 38 N·m)
• 7/16 in. screw – 45 to 50 ft. lbs. (61 to 68 N·m) 2
1. Trim tab screw COA3663
2. Index mark
NOTICE Standard rotation and counter rota-

tion trim t abs must not be inte rchanged. This
would result in inad equate cooling water sup-
2
ply to the propeller hub.
Place the shift rod in the shift rod lever. Install the
1 retaining pin and washer. Tighten pin to a torque
of 60 to 84 in. lbs. (7 to 9.5 N·m).
1. Alignment bolt 005403
2. 3/8-16 x 1.75 in. screw
1
1
2 1. Shift rod screw 004241
006869
A WARNING
1. 3/8-16 x 3.5 in. screw
2. 7/16-14 x 3.5 in. screw
To prevent loss of operator control, check

Apply Triple-Guard gre ase to threads o f the trim
for proper shifting operation and adjust, if
tab screw . Install gasket on “M”-type gearcase s.
necessary.
Install an d align the trim t ab (cover on “L”-type)
with the inde x ma rks noted prior to disassemb ly.
Tighten the trim tab screw to a torque of 35 to 40 IMPORTANT: During break-in pe riod of a reas- 13
sembled gearcase, change the gearcase lubricant
between 10 to 20 hours of operation.
291
GEARCASE
WATER PUMP SERVICE
WATER PUMP SERVICE Assembly

Apply a drop o f Adhesive 847 in the seal ring
Disassembly groove at each of the four ribs.
Rotate the driveshaf t coun terclockwise to unlock
the impeller key . Remove the four impeller hou s- IMPORTANT: Do not allow any sealer to get into
ing screws. the air bleed groove in the impeller housing. If this
groove is blocked by adhe sive, the pump will lose
1 its prime and will not pump water.
1
3
1. Screws 31998
2
Slide the wa ter pump of f the driveshaft. Remove
the impeller key, O-ring, impe ller plate, an d ga s- 1. Seal ring groove 2311
ket. Discard the gasket. 2. Ribs DR1185
3. Air bleed groove
Install the O-ring in groove in the impeller housing.

1
1. Gasket surface 006876
Remove all the parts from the housing.

1. O-ring 34814
Inspection Lightly coa t the exterio r rim o f the impeller cup

Check impeller fo r overh eating, hub sep aration, with Gasket Sealing Compound. Install the cup in
and other wear or damage. the impeller housing. The cup locks in place in the
housing with a square index tab.
Check liner and wear plate for scoring, distortion,
and impeller material transfer. Make sure vent hole in impeller cup is open.
Inspect the housing for cracks or melting.
Make sure gasket surface is clean and smooth.
292
GEARCASE
WATER PUMP SERVICE
On outb oard models with 1/2 in. diamete r water Guard grease to the o-rings and install water tube
tube, install the water tube grommet with the in exhaust housing.
inside taper facing up.
1
1
1
1. O-rings 007152
1. Water tube grommet 32000
Apply Triple-Guard grease to screw threads and
On outb oard models with 5/8 in. diamete r water install the impeller housing cover. Tighten screws
tube, apply a light coat of Triple-Guard grease to to a torque of 24 to 36 in. lbs. (3 to 4 N·m).
the inside of the impeller housing water tube cav-
ity and to the water tube o-rings. Apply Adhesive 847 to flat side of th e impeller
housing grommet. I nstall the gro mmet, fla t sid e
IMPORTANT: Impeller Housing, P/N 5007968, down.
can be identified by a chamfer on the inside edge
of the water tube cavity. 1
1
2
1
1. Impeller housing cover 32001

2. Impeller housing grommet
1. Chamfer 007170
Lightly coat th e inside of the liner with Triple-
Guard grease. With a cou nterclockwise rot ation,
On outb oard models with 5/8 in. diamete r water
install the impeller into the liner with the slot for the
tube, re move wate r tube from exhaust ho using
impeller key facing out.
and replace o-rin gs. Apply a lig ht coat of Triple-
13
293
GEARCASE
WATER PUMP SERVICE
Apply a thin bea d of Adhesive 847 in the s eal Slide the water pump down the driveshaft. Alig n
groove, and install the special shaped O-ring seal. impeller slot with th e impeller key . Rot ate t he
driveshaft to engage the key with the impeller, and
slide water pump down over key. Be sure impeller
key does not fall out of position.
1 2
1
1. O-ring 34815
1. Sharp edge of drive key CO2995
Apply Gasket Sealing Compound to both sid es of 2. Direction of driveshaft rotation
a new impeller plate gasket. Install the gasket and

impeller plate. NOTICE Make sure the impeller engages the
impeller key. Serious powerhead dama ge will
Apply Triple-Guard g rease to a new impeller O- result if impeller key is not in place.
ring. Slide the O-ring down the driveshaft and half
way over installed impeller key to temporarily hold Align the impeller housing with the gear case.
key in place. Apply Gasket Sealing Compound to threads of the
four impeller ho using screws. Inst all the screws
and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5
N·m).
3 On 20 in. out board models, place Gro mmet,

P/N 349354, on housing cover.
1
2
4
1
1. Impeller plate gasket 006871
2. Impeller plate
3. O-ring
4. Drive key
The sharp edge o f the ke y is the leadin g edge in

clockwise rotation.
1. Grommet 007150
294
GEARCASE
SHIFT ROD ADJUSTMENT
On 25 in. and 30 in. models, place the appropriate

water tube sp acer and grommet on the impeller
SHIFT ROD
housing cover. ADJUSTMENT
Check the shift rod height from the shift rod hole to
the surface of the gea rcase using Universa l Shift
2 Rod Height Gauge, P/N 389997.
1. Spacer 32728
2. Grommet
After water pump is assemble d completely, rotate

driveshaft cou nter clockwise 1/4 turn to un lock
and release impeller and key from driveshaft.
Next, pull up on d riveshaft a nd tu rn clockwise to COA6166

lock impe ller to shaf t. This process increases
pump ef ficiency by lockin g the impeller lower on With the gea rcase in NEUTRAL , rot ate the shif t
the driveshaft. rod up or d own as necessary fo r cor rect a djust-
ment. Once correct height is achieved, rotate rod
one half turn or less to direct offset forward.
IMPORTANT: The NEUTRAL dete nt is a two-

step design. Make sure the NEUTRAL detent ball
is in the ce nter step before ch ecking sh ift rod
height.
Shift Rod Heights

Model Type Height
21 29/32 in.
“L2”
007078 20 in. (L) (21.906 in./ 556 mm)
“M2”
± 1/2 Half Turn
NOTICE Before installing gearcase, shift rod 26 29/32 in.
adjustment MUST be checked. Refer t o SHIFT “L2”
25 in. (X) (26.906 in./ 683 mm)
ROD ADJUSTMENT on p. 295. “M2”
± 1/2 Turn
31 29/32 in.
30 in. (Z) “M2” (31.906 in./ 810 mm)
± 1/2 Turn
13
295
GEARCASE DISASSEMBLY
GEARCASE • Hydrostatic Seal Grooves — Must be in go od

condition to help prevent propeller ventilation.

DISASSEMBLY
Pre-Disassembly Inspection
A WARNING 1
Wear safety glass es to avoid persona l
injury, and set compressed air pressure to
less than 25 psi (172 kPa).
IMPORTANT: Clean and inspect all parts during

disassembly. Replace an y damaged parts, seals,
1. Hydrostatic seal grooves 4557
O-rings, and gaskets.
Remove the propeller and mounting hardware. • Gearcase Anodes — If anodes have eroded to
two-thirds their origina l size, t hey must be
Drain a nd inspect o il as d escribed in Gearcase replaced.
Lubricant on p. 37.
Remove gearcase as de scribed in GEARCASE

REMOVAL AND INSTALLATION on p. 289.
Remove water pu mp as d escribed in WATER 1

PUMP SERVICE on p. 292.
Before disassembling the gearcase, exa mine the

following:
• Gearcase Housing — Check for visible da m-
age to skeg, strut, an ti-ventilation plate , bullet,
14161
and mating surface. Check seal areas for visible 1. Gearcase anode
signs of lubricant leakage.

• Propeller Shaft — Check for bent or d amaged • Drive Shaf t — Check splin es for visible dam-
shaft. Check for t wisted sp lines a nd d amaged age, twisting and wear. Severe spline wear indi-
threads. cates th e exh aust h ousing or ge arcase has
been distorted, possibly by impact damage.
• Shift Rod — Check fo r misad justed, bent, or
binding rod. A misadju sted shift rod height can • Water Intake Screen s — Check for damage
cause shift difficulty, loss o f boat an d outboard and blo ckage. If screens ca nnot b e cleane d,
control, and gearcase damage. they mu st be re placed. Dif ferent scre ens a re
available and should not be mixed. Refer to cor-
rect model parts manual for listing an d descrip-
tion.
296
Propeller Shaft Bearing Housing Remove the propeller shaft bearing ho using from
the gearcase using:
Removal • Propeller Shaf t Bearing Housing Puller Kit,
IMPORTANT: Identify gearcase type before dis- P/N 354060.
assembly. For counter rotation gearcases, refer to DO NOT use tools designed to push on the pro-
GEARCASE DISASSEMBLY on p. 319. peller sha ft. Push ing force against the propeller
The p ropeller shaft bearing housing o n “L 2” a nd shaft could damage the forward gear thrust bear-
“M2” models is PRESSED into gearcase housing. ing or thrust washer.
“L2” TYPE GEARCASES IMPORTANT: The L2 type g earcase uses th e

adaptor ring included with puller kit.
Remove the t wo screws, washers, and ret ainers
holding the propeller shaft bearing housing. Install the threaded adaptor from th e puller kit on
to the propeller shaft until seated.
1. Retainer tab screws 001989
“M2” Type Gearcase 006833

“M2” TYPE GEARCASES
Remove t he two screws ho lding the p ropeller Assemble puller kit co mponents. Hold adap tor
shaft bearing housing. with wrench and turn nut clockwise to pull bearing
housing.
1. Retainer screws 006835

006874
13
297
Pull propeller shaf t and bearing housing far Pinion Gear and Driveshaft
enough to loosen t he PRESSED bear ing housing
from the gearcase housing.
Removal
Adjust the sh ift rod to move the clutch dog as far
forward as possible. This will help ease removal of
the pinion nut.
Use Driveshaft Holding Socket, P/N 311875, Pin-

ion Nut Holde r, P/N 334455, and W rench
Retainer, P/N 341438 to loo sen and remove t he
pinion nut from the bottom of the driveshaft. Pad
handle of holder to prevent damage to gearcase.
1
“L2” Type Gearcase 006836
1. Holding socket 006875

2. Pinion holder
“M2” Type Gearcase 006837 3. Retainer
Remove the bearing hou sing, thrust wash er, Remove th e four driveshaf t bearing ho using
thrust bearing, and reverse gear from gearcase. screws.
1
1
006838 1. Driveshaft bearing housing screws 006876
298
Remove t he drivesh aft from th e gearcase . The Locked Driveshaft Removal

bearing housing, shims, thrust bearing, and thrust The driveshaft to pinion taper is a locking taper. If
washer will come out with the driveshaft. necessary, use Driveshaft Puller, P/N 390706, and
Backing Plate , P/N 325867, to break the lock.
Install the too ls as shown by clamp ing them
around t he d riveshaft. Alternately tighten the two
1
vertical screws aga inst the backing plate inserted
between th e p uller an d th e g earcase until th e
driveshaft pops loose from the pinion.
2
4
1
3
2
1. Bearing housing COA3558
2.
3.
Shims
Thrust bearing 3
4. Thrust washer
If driveshaft cannot be remove d, refer to Locked

Driveshaft Removal on p. 299.
Remove the pinion gear from the gearcase. 1. Drive shaft 006879
2. Puller
3. Backing plate
If upper driveshaft becomes separated from lower

driveshaft, use Lower Driveshaf t Pulle r,
P/N 342681, t o remove . Inst all puller into lower
driveshaft and turn 90° to position hook under pin
in driveshaft. Thread Slide Hammer, P/N 391008,
into puller and remove driveshaft.
006878
006880
13
299
Driveshaft Service Install the roll pin to the specified dimension.

To separate the uppe r driveshaft (if ne eded) from
the lower d riveshaft, remove the roll pin. Replace
the damaged component.
0.125 in.
1 (3.2 mm)
1. Roll pin DR4610
Shift Housing, Gear, and

Propeller Shaft Removal
006881 Push d own o n t he shift rod. This will move t he
detent leve r downward to clear the inside of t he
To assemble the driveshaft, install new driveshaft gearcase when th e sha ft a ssembly is pulled ou t.
retainer into the groove of the upper driveshaft. Unscrew the sh ift rod from the deten t lever .
Remove screws, cover , and shif t ro d from t he
gearcase.
Discard the cover gasket. Remove and disca rd

the shift rod O-ring from inside of cover.
006882
Install the upp er driveshaf t into the lower drive-

shaft, aligning the holes in the d riveshaft retainer 1
and the lower driveshaft.
1. Cover gasket 006884
006883
300
GEARCASE HOUSING INSPECTION
Remove propeller shaft assembly from gearcase.

GEARCASE HOUSING
INSPECTION
Thoroughly clean gearcase housing to remove all
dirt and deb ris p rior to inspe ction. Inspect pinion
bearing an d forward thrust surfa ce of gea rcase
housing.
Use Gearcase Alignment Gauge Kit, P/N 5006349

to check the condition o f gearcase h ousing prior
to reassembly. Refer to instructions p rovided with
kit. Use additional Gauging Head as follows:
006839 • P/N 5007750, for “L2” Type gearcase housings
• P/N 5007749, for “M2” Type gearcase housings
Remove and clean water intake screens. Replace
if damaged.
006787
1. Water intake screen 006886
13
301
SHIFTER, BEARING AND SEAL SERVICING
NOTICE Use Alignment Ga uge Puller , SHIFTER, BEARING AND

P/N 354718, to install and remove press fit pro-
peller shaft bearing housing in L2 and M2 Type SEAL SERVICING
gearcase housings.
Failure to follow this procedure will result in Pinion Bearing Removal
inability to remove gaugin g head, forward Remove pinion bearing retaining screw.
thrust bearing an d forward b earing hou sing
from gearcase housing.
2
3
Alignment Gauge Puller, P/N 354718 354718
1. Pinion bearing retaining screw 006892
IMPORTANT: DO NOT force g auging shaft into 2. Water screen pocket DRC7416
3. Seal 006893
alignment hole. Sh aft MUST slide easily into hole
of gauging head. If shaft does not slide into hole,
Assemble Pinion Bearin g Remo ver a nd In staller,
gearcase housing is damaged and must be
P/N 5005927, in the gearcase as follows:
replaced.
Use a 7/8 in. wrench to hold the remover in place.
Use a 3/4 in. wrench to turn flange nut clockwise.
Draw the bearing up from the housing.
1
1 2
1. Gauging shaft 004347
1. Flange nut, P/N 326586 DR3419

2. Plate, P/N 391260
3. Rod, P/N 326582
4. Remover, P/N 326579
302
Pinion Bearing Installation Position new O-ring on the pinion bearing retain-
ing screw. Apply Gasket Sealing Compound to O-
Assemble the following compone nts of Pinion
ring. Apply Nut Lock to screw thre ads. Install the
Bearing Remover and Inst aller, P/N 5005927, a s
screw and tighten to a torque of 60 to 84 in. lbs. (7
shown:
to 9.5 N·m).
1
2
3 1
4
6
1. O-ring DRC7416
7
Shift Housing Disassembly
1. 1/4-20 X 1/2 in. Hex head screw 824182
2. 1 in. O.D. Flat washer
3. Spacer; P/N 350932 “M” and “M2” A WARNING
P/N 326584 “L” and “L2”
4. Plate and Bearing P/N 391260 Wear safety glasses to avoid injury.
5. Rod P/N 326582
6. Installer/Remover, P/N 350958
7. 1/4-20 X 1 1/4 in. Hex head screw
IMPORTANT: The shift housing and bearing are
serviced as an assembly . If e ither are wo rn or
IMPORTANT: Spacers are dif ferent sizes a nd damaged, replace the complete assembly.
cannot be interchanged.
Insert a suit able tool under one end of the clutch
Apply Needle Bearing grease to the needle bear- dog spring an d remove it from it s g roove by
ings and insert them into the bearing case. unwrapping it from aro und the clut ch dog. Dis-
Place the bearing on the installer tool with the let- card the spring.
tered side of the b earing facing the top of t he
gearcase. Use Needle Bearing grease to hold the
bearing on the tool. 1
IMPORTANT: The pinion bear ing is tapered so
that, when inst alled co rrectly, it s sh ape comp en-
sates for stresses in the gearcase and allows full
bearing con tact. Wh enever a g earcase is d isas-
sembled, the pinion bearing should be checked to
ensure that it has bee n installed with the lettering
facing up.
Insert the to ol with the be aring into the gea rcase.

Drive the bearing into the gearcase until the
1. Clutch dog spring 006887
13
washer on the tool contacts the spacer.
Remove the tool.
303
Push the pin out of the clutch dog . Remove all shifter detent as needed to help ease re moval of
parts. parts.
5 4
3
1
2
1
1. Pin 006888 1. Shift lever pin 006890

2. Shift shaft
3. Cradle
Remove the gear, thrust bearing, and thru st 4. Shift lever
washer from the shift housing. 5. Shifter detent
1 A WARNING
injury. Th e dete nt ball and s pring and
2 3 come out with great force.
Wrap the housing with a shop cloth to ca tch ball

and spring. Rotate the sh ifter detent 90° in either
direction, then pull the detent out of the housing.
1. Gear 006889
2. Thrust bearing
3. Thrust washer
2
Remove th e shif t lever pin from the ho using. 1

Remove shif t shaf t, crad le an d shif t leve r. Move
1. Shifter detent 006891

2. Ball and spring
Remove the detent ball and spring.
Remove needle bearings from bearing housing for

cleaning and inspection.
304
Shift Housing Assembly Thoroughly grease 25 needle bearings wit h Nee-

dle Bearing grease and place in the bearing case.
IMPORTANT: Clean and inspect all parts before
beginning assembly procedures. Replace any
damaged parts.
Lightly coat the detent ball and spring with Needle

Bearing grease. In sert the spring in th e ho using,
then the ball.
006901
With shif ter detent in NEUTRAL, in stall arms of

shift le ver into dete nt slot s. Align the pivot holes
and insert th e re taining p in. Push shif ter detent
down.
006899
1
Insert shifter detent at 90° a ngle into the housing
as shown, while depressing t he ba ll and spring
with a suitable tool. Once the shifter detent is past
the ball, remove th e too l an d po sition d etent to 3
engage NEUTRAL position.
1. Shifter detent 006902

2. Shift lever
3. Pin, shift lever
Rest the cradle on the shift shaft.
006900
1
13
1. Cradle 004512
2. Shift shaft
305
Place the shift lever arms into the recesses of the Align holes in the clutch dog with slot in the pro-
shift cradle. Pull shifter dete nt back up to NEU- peller shaft. Install the clutch dog on the shaft with
TRAL position to ho ld the cradle and sh aft in “PROP END” facing rear of the shaft.
place.
NOTICE The clutch dog is not symmetrical.
If inst alled ba ckward, it will no t fully enga ge
and will immediately damage itself and the
gears.
001219
Coat thrust bearing and thrust washer with Needle

Bearing grease. Place the be aring on the b ack of 1
the gear. Set the washer on top of the thrust bear- 1. “PROP END” 006906
ing. Insert the g ear, bearing, and wash er into the
bearing housing. Slide the prop eller shaft onto the shift shaft, align
the hole in the shaft with t he ho le in th e clutch
NOTICE Bearing and washer must be dog, inst all the pin and th en, a new cl utch d og
installed in the correct order. retaining spring. Place three coils over each end
of the pin, MAKING SURE NONE OF THE COILS
OVERLAP OR ARE LOOSE.
2
1
1. Thrust bearing 006905 1

2. Thrust washer
1. Retaining spring 006907
306
Driveshaft Bearing Housing NOTICE Do not install the O-ring in the bear-
Service ing h ousing’s b ottom groove . The bot tom
groove is an oil p assage. Gearcase dama ge
The driveshaft bearing is not serviceable. Replace
could result.
the b earing ho using assembly if the be aring is
worn or da maged. Also, inspect the driveshaft
bearing surface if the bearing is damaged.
1
Seal Removal
Remove the drivesha ft bearing housing seals
using Puller Bridge, P/N 432127, and Large Puller 2
Jaws, P/N 432129. Discard the seals.
1. O-ring (top groove) 006908

2. Oil passage
Apply Gasket Sealing Compound to metal casings

of new seals before installing.
Use Seal Inst allation Tool, P/N 330268 to install

new seals back to back in bearing housing. Install
006894 inner seal with lip facing toward bea ring housing,
then the outer seal with lip facing away from bear-
Remove and discard the O-ring from the bearing ing housing . Apply Triple-Guard grea se to sea l
housing. lips.
Clean the bearing ho using in so lvent to remove

sealer from the seal bore and the O-ring groove.
Seal Installation
Lightly apply Gasket Sealing Compound to a new
O-ring. Install the O-ring in top groove of the bear-
ing housing. Do not allow sealant in oil passage. 1
2
13
1. Inner seal DR2061
2. Outer seal DR2062
307
Propeller Shaft Bearing Housing Inspect th e b earing h ousing anode. Replace

anode if it is reduced to two-thirds of original size.
Service Tighten screws to a torque of 108 to 13 2 in . lbs.
Rear Seal Removal (12 to 15 N·m).
Remove se als using Puller Bridge, P/N 432127,
and Small Pulle r Jaws, P/N 432131. Positio n the
1
plate on top of the housing to support the brid ge,
and tighten jaws securely behind the inner seal.
1. Anode 006897
Discard the bearing housing O-rings. Clean the

housing and be arings in solvent an d dry th or-
oughly. I f bearings were no t replaced , rot ate t he
006895 needles to check for freedom of movement.
Bearing Removal Inspect O-ring grooves. Sand off any sharp edges
that might cut O-r ing. Remove any nicks or burrs
IMPORTANT: Inspect bea rings in place . If a on front of bearing housing.
bearing is removed for any reason, it must be dis-
carded. 1
Remove either bear ing u sing Puller Brid ge,

P/N 432127, and Large Puller Ja ws, P/N 432129.
Rest the puller plate on top of the housing to sup-
port the bridge, and tighten t he ja ws securely
behind the bearing.
1. O-ring groove 006898
006896
308
Bearing Installation COUNTER ROTATION HOUSING

Oil, then install new bearings in bearing housing. Bearing Installation Tool:
• P/N 432401 – front bearing
Place the lettered end of the bearing case on the • P/N 354139 – rear bearing
bearing inst aller, then press th e bea ring into the
housing u ntil the too l seat s. When in stalled, the
lettered end of the bearing should be visible.
1
STANDARD ROTATION HOUSING
Bearing Installation Tool:
• P/N 354139 – front and rear bearings
Front Bearing 006945

1. Bearing installation tool
Front Bearing 006909

Rear Bearing 006910

Rear Bearing 006910

13
309
DRIVESHAFT SHIMMING
Rear Seal Installation DRIVESHAFT SHIMMING

Apply Gasket Sealing Compound to metal casings
of the seals before installing.
NOTICE If a ne w p inion gear is needed,
Use Seal Installation Tool to install new seals back replace gear set before shimming.
to back in bearing housing.
Pinion gear ba cklash is achieved by using sh ims
Seal Installation Tool: between the drivesha ft bea ring housing and the
• P/N 354056 – “L2”, “M2” thrust washer. When installing a new thrust bear-
ing or washer, bearing housing, pin ion, or drive-
Install inner seal with lip facing toward the bearing shaft, it is ne cessary to pro perly sh im th e
housing, then outer seal with lip facing away fro m assembly to restore factory clearance.
the bearing housing.
Use Driveshaft Shimming Tool, P/N 5005925.
Shim gauge bars are precision made and should

be han dled carefully. The leng th of each bar is
stamped near the p art number. This dimension is
0.020 in. (0 .508 mm) sh orter t han the a ctual
shimmed length of the driveshaft.
1 IMPORTANT: Clean pinion and driveshaf t

before assembly. Replace any damaged parts.
Assemble th e drivesh aft bearing hou sing, thrust

washer, thrust bearing, and pinion onto the drive-
shaft. Use Driveshaft Seal Protector, P/N 318674,
when installing or removing the bearing housing.
Lightly coat the threads of the pinion nut with out-

board lubricant and tight en to a torque of 100 to
110 ft. lbs. (136 to 149 N·m).
2
1 3
1. Inner seal DR2061
2. Outer seal DR2062
Apply Triple-Guard grease to seal lips.
2 4
1. Driveshaft bearing housing 006911

2. Thrust washer
3. Thrust bearing
4. Pinion gear
IMPORTANT: The original pinion nut may be

used for shimming, but must NOT be used in final
assembly.
310
DRIVESHAFT SHIMMING
Select collar, P/N 341440, and th e co rrect shim Check squareness of the be aring housing mount-
gauge bar: ing surface by holding the shim gauge bar against
• “M2”: Shim gauge bar, P/N 349957 the pinion while rot ating just th e be aring ho us-
• “L2”: Shim gauge bar, P/N 328367 ing. Use a fe eler g auge to me asure cle arance
between the g auge b ar and th e bearing ho using
Slide the collar onto the driveshaft with large e nd between each p air of screw hole s. Re place the
in contact with the bearing housing. bearing housing a nd rep eat check if var iance is
greater than 0.004 in. (0.101 mm).
Insert the assembled driveshaft into the tool base
and t ighten p reload screw against the driveshaf t Check squareness of t he pinion to th e driveshaft.
until groove on the sp ring-loaded plunger is flush Hold the shim ga uge b ar aga inst the bearing
with end of thread s. Tighten locking ring on pre- housing (between the screw holes) wh ile rotating
load screw. just the drive shaft and pinio n assembly. Mea-
sure clear ance betwee n th e ga uge bar a nd th e
3 pinion a t several location s. If varian ce is grea ter
than 0.002 in. (0.0 50 mm) replace the pinion or
driveshaft, as necessary, and repeat check.
1 Subtract th e average clearance measureme nt

from 0.020 in . (0.508 mm) to determine the cor-
rect shim thickn ess requ ired. Select th e fewest
number of shims to achieve the correct thickness.
2 Remove the driveshaft from the tool and add the
required shims be tween the b earing housing an d
1. Collar 006912 the thrust washer.
2. Tool base 006913
IMPORTANT: Use extreme care when removing
3. Groove
Rotate the driveshaft se veral revolutio ns to seat bearing housing to avoid damaging the seals. Use
bearings. Driveshaft Seal Protector, P/N 318674.
Lay th e tool base on it s side. Position the shim Check cleara nce a gain. The measureme nt
gauge bar against guide pins of the tool base. between the gaug e bar and pinion should be
0.020 in. (0.508 mm).
006914
13
1. Shim gauge bar
005417
Remove th e nut and pinion from the driveshaf t.

Discard the nut.
311
GEARCASE ASSEMBLY
GEARCASE ASSEMBLY Shift Rod Housing Installation

Lubricate a new shift rod cover O-ring with Triple-
Water Intake Screens Guard grease. Install the O-ring into th e shift rod
Install water in take screens. Tighten screws to a cover.
IMPORTANT: Make sure O-ring is fully seated
in groove.
Shift Housing, Gear, and 1. O-ring 006916
Propeller Shaft Installation Install the shift rod spacer on the sh ift rod (25 in.
Push shif ter de tent into farthest downward posi- models). On 30 in. mode ls, inst all the exte nsion
tion. T ip the rear of the gearcase slightly down- (not shown).
ward to assist in t he inst allation of t he shaf t
Place the shift rod grommet on the shift rod.
assembly.
Be sure the thrust bearing and the thrust washer
1
are in the proper position. Insert the shaft assem-
bly fully into the ge arcase while alig ning shift
housing pin with hole in forward end of ge arcase
housing.
1
1. Grommet 006917
2. Shift rod spacer
Apply Triple-Guard grease to the thread ed end of

the shift rod and insert it thro ugh the cover. Turn
the shift rod while p ushing it through the cover to
avoid damaging the O-ring.
1. Pin 006885
312
GEARCASE ASSEMBLY
“L2” TYPE GEARCASES Apply Gasket Sealing Compound to the threads of

Apply Gasket Sealing Compound to both sid es of the shift rod cover screws. Tighten the screws to a
a new shift rod cover gasket. Place the gasket on torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
the gearcase.
006919
1. Cover gasket COA3141
Refer to SHIFT ROD ADJUSTMENT on p. 295.
“M2” Type Gearcases
Apply Adhesive 847 to seal groo ve of shif t rod
Pinion Gear and Driveshaft
cover. Place a new shift rod cover seal in groove. Installation
Refer to DRIVESHAFT SHIMMING on p. 310.
Install new se als in driveshaft b earing hou sing.
Refer to Driveshaft Bearing Housing Service on
p. 307.
Place the driveshaft thrust bearing, thrust washer,
1
and correct shim(s) on the driveshaft as shown.
2
1
1. Cover seal 006918
ALL GEARCASES
Thread the shift rod into the shifter dete nt about
four turns.
3
Move shift rod from side to side while pushing on
the pro peller shaft to ensure proper alignment of
006920
the bearing housing locator pin into the pin hole in 1. Thrust bearing
2. Thrust washer
the gearcase. 3. Shim(s)
13
313
GEARCASE ASSEMBLY
Using Drivesh aft Sea l Protector , P/N 318674, Lightly coat the thre ads of a new pinion nut with
slide th e driveshaf t b earing ho using o nto the outboard lubricant. Use Pinion Nut Starting Tool,
driveshaft and into position in the gearcase. P/N 342216, to install nut on the driveshaft. Turn
the driveshaft by han d to thread the nut on to
shaft.
1
1. Seal protector 006921
Adjust shift rod to mo ve clutch dog as far forward

006923
as possible. Be sure excess grea se is re moved
from the pinion bearing.
Apply Gasket Sealing Compound to the threads of
Washer must be snapped into recess of pinion the driveshaf t bea ring housing screws. Tighten
gear. screws in stages to a torque of 120 to 144 in. lbs.
(13.5 to 16.5 N·m).
1
1 1
1. Washer 006922
IMPORTANT: The inside t aper of the pinion

006876
gear an d the driveshaf t t aper MUST be co m- 1. Driveshaft bearing housing screws
pletely free of grease. Clean the tapers with

Use Driveshaft Holding Socket, P/N 311875, Pin-
Cleaning Solvent. Use a shop towel free of grease
ion Nut Holde r, P/N 334455, and W rench
and lint.
Retainer, P/N 341438, to tight en the pinion nu t to
Place the pinion gear into the gearcase. Insert the a torque of 100 to 110 f t. lbs. (1 36 to 1 49 N·m).
driveshaft into the gearcase and thro ugh the pin-
ion gear.
314
GEARCASE ASSEMBLY
Pad handle of holde r to prevent damage to gear- Slide the gear a ssembly on to the propeller shaf t
case. until it engages the pinion gear.
2 1. Thrust bearing and thrust washer 006843
Lightly apply Triple Guard Grease to a new be ar-

006875
1. Holding socket
2. Pinion holder
ing housing O-ring. Install O-ring in groo ve in the
3. Retainer housing. G rease t he m achined s ide s urfaces o f
bearing housing.
Propeller Shaft Bearing Housing Install hou sing into ge arcase. Align screw holes
and Gear Installation – “L2” Type with retainer slots in gearcase.
IMPORTANT: The propeller shaft bearing hous-
ing on the “L2” type gearcases is PRESSED into
the gearcase housing.
Oil and install thrust bearing and thrust washer on
hub of reverse gear.
2 1
006836
Use Installer Handle, P/N 345822, Propeller Shaft

Bearing Housing Inst aller, P/N 354058, Gearcase
Fixture, P/N 354059 and a n a ppropriate floor
press (10 ton o r grea ter) to in stall housing in to
1. Thrust bearing 006905
2. Thrust washer
13
315
GEARCASE ASSEMBLY
gearcase. Alig n and level gearcase assembly in Propeller Shaft Bearing Housing
fixture as shown. Secure fixture to floor press.
and Gear Installation – “M2” Type
ing on the “M2” type gear cases is PRE SSED into
the gearcase housing.
Oil and install thrust bearing and thrust washer on

hub of reverse gear. Slide the gear assembly onto
the propeller shaft until it engages the pinion gear.
2
006844
Housing must be completely se ated in ge arcase

to install ret ainer t abs. Depth to ret ainer t ab sur- 1
face on bearing housing is appro ximately
1 in. (25.4 mm).
1. Thrust bearing 006925

2. Thrust washer
Lightly apply Triple Guard Grease to new bearing

housing O-rings. In stall O-rings in grooves in the
housing. G rease t he m achined s ide s urfaces o f
bearing housing.
006845
Install two ret ainers, washers and screws. Apply

Ultra Lock to threads and tigh ten screws to a
torque of 18 to 20 ft. lbs. (24 to 27 N·m).
1
006924
1. Retainer tab screws 001989
316
GEARCASE ASSEMBLY
Place bearing housing in gearcase. gearcase. Align and level gearcase assembly in
2
3
006846
1
Align ret aining holes in bearing housing with
screw holes in gearcase . Thread Alignment Pins,
P/N 354140, into gearcase.
1. Gearcase fixture, P/N 354059 006927

1 1 2. Vertical alignment screws
3. Handle P/N 345822
4. Housing installer P/N 354057
Housing must be completely sea ted in gea rcase

to inst all ret ainer screws. Bearing housing is
approximately level with gearcase.
1. Alignment pins 006926

Bearing Housing In staller, P/N 354057, Gearcase
Fixture, P/N 354059 an d an approp riate floor
press (10 ton or gre ater) t o inst all hou sing into
006928
13
317
GEARCASE ASSEMBLY
Apply Ultra Lock to threads and inst all two retain-

ing screws. Tighten screws to a torque of 18 to 20
ft. lbs. (24 to 27 N·m).
Final Assembly and Adjustment

To complete gearcase assembly, refer to:
• GEARCASE LEAK TEST on p. 288
• WATER PUMP SERVICE on p. 292
• SHIFT ROD ADJUSTMENT on p. 295
• GEARCASE RE MOVAL AND INSTALLATION
on p. 289
• Gearcase Lubricant on p. 37
• Propeller Hardware Installation on p. 287
• Trim Tab Adjustment on p. 30.
During bre ak-in period o f a re assembled g ear-
case, change the gearcase lubricant between 10
to 20 hours of operation.
318
GEARCASE Install the threaded adaptor from th e puller kit on

to the propeller shaft until seated.

DISASSEMBLY
IMPORTANT: Counter rot ation (CR) gearcase s
use unique components and require different ser-
vice proce dures. Use care when working on
counter rotation gearcases. DO NOT interchange
parts between standard and counter rotation mod-
els. Iden tify gearcase type prior to disassemb ly.
Make sure the “CR” marking is o n the end of the
propeller shaft.
Pre-Disassembly Inspection 006833

Refer to Pre-Disassembly Inspection on p. 296.
Assemble puller kit co mponents. Hold adap tor
Propeller Shaft Bearing Housing with wrench and turn nut clockwise to pull bearing
housing.
Removal – “M2” Type
ing on “M2 ” type ge arcases is PRESSED into
gearcase housing.
Remove the two retaining screws holding the pro-

peller shaft bearing housing.
1
2
006834
Pull pro peller shaf t a nd bearing h ousing far

enough to loosen the PR ESSED bearing housing
from the gearcase housing.
1. “CR” marking 006835

2. Retainer screws
Remove the propeller shaft bearing h ousing from

the gearcase using:
• Propeller Shaf t Bearing Housing Puller Kit,
P/N 354060.
DO NOT use tools designe d to push on the pro- 13

peller sha ft. Pushing against the propeller shaft
could damage the forward gear thrust be aring or “M2” Type Gearcase 006837
thrust washer.
319
GEARCASE HOUSING INSPECTION
Remove propeller shaft, forward gear and bearing Use an app ropriate tool to apply downward pres-
housing assembly from gearcase. sure on the dete nt wh ile pulling on the pro peller
shaft assembly. Remove propeller shaft assembly
from the gearcase.
006850
Pinion Gear Removal and

Driveshaft Servicing
Refer to Pinion Gear and Dri veshaft Removal
on p. 298.
Shift Housing, Gear and Counter Rotation Models 006929

Propeller Shaft Removal 1. Tool
Push down on the shif t rod. This will move the

detent lever downward to clear the inside of the
gearcase when t he sh aft assembly is pulled o ut. Remove and clean water intake screens. Replace
Unscrew the shif t rod from the dete nt lever . if damaged.
Remove scre ws, cover , an d shif t rod from the
gearcase.
Discard the cover gasket. Remove the shift rod O-
ring from inside of cover and discard. 1
1
GEARCASE HOUSING
1. Cover gasket 006884
INSPECTION
Refer to GEARCASE HOUSING INSPECTION on
p. 301.
320
SHIFTER, BEARING AND Remove the ge ar, thrust bearing, and thrust
washer from the shift housing.
SEAL SERVICING
Shift Housing Disassembly
1
A WARNING
Wear safety glasses to avoid injury. 2 3
IMPORTANT: The shift housing and bearing are

serviced a s an assembly . If eithe r are worn or
damaged, replace the complete assembly.
Insert a suitable tool under one end o f the clutch 1. Gear 006931
2. Thrust bearing
dog spring and remo ve it from its groove by 3. Thrust washer
unwrapping it from ar ound the clutch dog. Dis-
card the spring. IMPORTANT: The shif t h ousing support s th e
reverse gear on counter rotation gearcases.
Remove the shif t lever p in from the hou sing.

1 Remove shif t sh aft, cradle and shif t lever . Move
shifter detent as needed to help ease re moval of
parts.
1. Clutch dog spring 006887
Push the pin o ut of the clutch dog . Remove all

parts.
1. Pin 006861
A WARNING
Wear sa fety glasses t o av oid personal
injury. Th e dete nt ball and s pring and
come out with great force.
1
1. Pin 006930 13
321
Wrap the housing with a sho p cloth to catch ball able tool. Once the detent is past the ball, remove
and sp ring. Pull the shif ter de tent straig ht ou t of the tool and position detent to engage NEUTRAL.
the housing.
1
2
1
1. Punch 006934
1. Ball and spring 006932
2. Shifter detent Thoroughly grease 25 needle bearings wit h Nee-
dle Bearing grease and place in the bearing case.
Remove the detent ball and spring.
Remove needle bearings from bearing housing for

cleaning and inspection.
Shift Housing Assembly

IMPORTANT: Clean and inspect all parts before
beginning assembly p rocedures. Replace an y
damaged parts.
Lightly coat the detent ball and spring with Needle
Bearing grease. In sert the spring in th e ho using,
then the ball. 006901
Rest the cradle a nd shif t lever on t he shif t shaf t

and insert through the front side of the shift hous-
ing.
006933
1
Insert shif ter de tent into the housing a s shown,
while depressing the ball and spring with a suit-
1. Cradle 006860
2. Shift lever
322
Install a rms of shif t lever into de tent slot s. Align Coat thrust bearing and thrust washer with Needle
the pivot holes and insert the retaining pin. Push Bearing grease. Place t he bearing on the ba ck of
shifter detent down. the gear. Set the washer on top of the thrust bear-
ing. Insert the ge ar, bearing, and washer into th e
1 bearing housing.
NOTICE Bearing and washer must be

installed in the correct order.
2 1
1. Pin, shift lever 006861
Inspect clu tch shaf t detent balls, ret ainer and

spring. These p arts should no t require removal
under normal servicing. 1. Thrust bearing 006905
2. Thrust washer
A WARNING
Align holes in the clutch dog with slot in the pro-
peller shaft. Install the clutch dog on the shaft with
"PROP END" facing rear of the shaft.
If the se p arts are dama ged or removed, a new
service kit should be installed. Refer to parts cata- NOTICE The clutch dog is not symmetrical.
log for kit part number. If inst alled ba ckward, it will no t fully enga ge
and will immediately damage itself and the
gears.
1
1. Clutch Shaft Retainer Kit 0000

2. Clutch Shaft 1
1. “PROP END” 006906
13
323
Slide the pro peller shaft onto the shif t shaft, align
the hole in the sh aft with the h ole in the clutch
dog, inst all the pin and then, a new cl utch dog
retaining sp ring. Place th ree coils over each e nd
of the pin, MAKING SURE NONE OF THE COILS
OVERLAP OR ARE LOOSE.
006937
Remove the shim(s).
1
1. Retaining spring 006935
Pinion Bearing
Refer to Pinion Bearing Installation on p. 303.
Propeller Shaft Bearing Housing

and Forward Gear
Disassembly 006852
Remove and discard the bearing housing O-ring.
Inspect the f orward ge ar and bearing ho using
Remove the anode and discard if mo re than two- assembly for excessive wear or damage.
thirds deteriorated.
Clamp the propeller shaft bearing housing by the

anode b osses in a vise, as sh own. Remove the
forward gear bearing housing assembly from pro-
peller sha ft bearing ho using. Use S panner
Wrench, P/N 43240 0, to unscrew in a cou nter-
clockwise direction.
006853
006936
324
Push propeller shaft out of the bearing housing. Assembly

Position the forward gear bearing housing assem-
bly on a flat, level surface. (Mirror or glass can b e
used.) Use depth gauge to measure distance from
flange of housing to flat surface as shown.
1
006939
Remove the thrust washer and thrust bearing.
1 1. Flange 006855
Add the appropriate shims to create a d imension

of 0.140 in. (3.556 mm).
2 To determine thickness of shims; use the following
example:
1.389 in. reading on the gauge
+ 0.011 in. shims required
= 1.400 in. required dimension
006940
1. Thrust washer
2. Thrust bearing
Apply Needle Bearing grease to the thrust bear-
ing. Position bearing around shoulder on the pro-
For se al a nd be aring se rvice re fer to Propeller peller shaft.
Shaft Bearing Housing Service on p. 308.
Apply Needle Bearing grease to the thrust washer.
Place washer in recess of bearing housing.
1. Thrust bearing 006941 13

2. Thrust washer
325
Coat bearing surfaces of propeller shaft with gear- Use Spanner Wrench, P/N 4324 00, to tighten t he
case lu bricant. Slide the prop eller housing onto gear assembly t o a torque o f 10 0 f t. lbs. (1 36
the propeller shaft. N·m).
006942 006943
IMPORTANT: Use caution when assembling the Inspect th e b earing h ousing anode. Replace
propeller shaf t in the b earing hou sing. Thru st anode if it is reduced to two-thirds of original size.
bearing must rema in around shoulder on the pro- Tighten screws to a torque of 108 to 13 2 in . lbs.
peller shaft. (12 to 15 N·m).
Apply gearcase lubricant to the threads of the for- 1

ward gear bearing housing.
Install forward g ear assembly with correct shims

in bearing housing.
1. Anode 006897
1. Shim(s) 006937
IMPORTANT: To prevent da mage to thread s,

install forward gear bearing housing assembly by
hand until fu lly seated aga inst pro peller shaf t
bearing housing.
326
DRIVESHAFT SHIMMING
DRIVESHAFT SHIMMING Select collar, P/N 341440, and shim gauge bar:
• “M2”: Shim gauge bar, P/N 349957
NOTICE If a new pinion gear is needed, Slide the collar o nto the driveshaft with large en d
replace gear set before shimming. in contact with the bearing housing.
Pinion gear backlash is achieved by using shims Insert the assembled driveshaft into the tool base
between the drivesh aft bearing hou sing and the and tighten pre load screw against the driveshaft
thrust washer. When in stalling a new thrust bear- until groove on the spr ing-loaded plunger is flush
ing o r washer, bearing housing, pinion, or drive- with end of threads. Tighten locking ring on pre-
shaft, it is n ecessary to p roperly sh im the load screw.
assembly to restore factory clearance.
3
Use Driveshaft Shimming Tool, P/N 5005925.
Shim gauge bars are precision made and shou ld

be handled carefully. The len gth of each bar is
1
stamped near the p art number. This dimension is
0.020 in. (0.508 mm) shorter than the actu al
shimmed length of the driveshaft.
IMPORTANT: Clean pinion and driveshaf t 2

before assembly. Replace any damaged parts.
1. Collar 006912
Assemble th e driveshaf t bearing ho using, thru st 2. Tool base 006913
washer, thrust bearing, and pinion onto the drive- 3. Groove
shaft. Use Driveshaft Seal Protector, P/N 318674,
when installing or removing the bearing housing. Rotate the driveshaf t several revolutions to se at
bearings.
Lightly coat the threads of the pinion nut with out-
board lubrican t and tigh ten to a torque of 100 to Lay the tool base on its side . Position the shim
110 ft. lbs. (136 to 149 N·m). gauge bar against guide pins of the tool base.
IMPORTANT: The origina l pinion nut may be

used for shimming, but must NOT be used in final
assembly.
1
1 3
1. Shim gauge bar 006914
2 4
13
1. Driveshaft bearing housing 006911
2. Thrust washer
3. Thrust bearing
4. Pinion gear
327
DRIVESHAFT SHIMMING
Check squareness of the bearing housing mount- Remove the driveshaft from the tool and add the
ing surface by holding the shim gauge bar against required shims be tween the b earing housing a nd
the pinion while ro tating just the b earing h ous- the thrust washer.
ing. Use a feeler gauge to measu re clearance
between the gauge bar and the bea ring h ousing IMPORTANT: Use extreme care when removing
between each pair of scre w holes. Replace the bearing housing to avoid damaging the seals. Use
bearing housing and re peat check if va riance is Driveshaft Seal Protector, P/N 318674.
greater than 0.004 in. (0.101 mm).
Check cleara nce a gain. The measureme nt
Check squareness of the pinion to the driveshaft. between the gaug e bar and pinion should be
Hold the shim g auge bar ag ainst the bearing 0.020 in. (0.508 mm).
housing (between the scre w holes) while rotating
just the driveshaft and pinion assembly. Mea-
sure clea rance between the gauge bar and the
pinion at se veral locatio ns. If varia nce is gre ater
than 0.002 in . (0.050 mm) replace the pinion or
driveshaft, as necessary, and repeat check.
Subtract the averag e clearan ce measurement
from 0.020 in. (0.508 mm) to determine the cor-
rect shim thickness req uired. Sele ct t he fe west
number of shims to achieve the correct thickness.
005417
Remove th e nut and pinion from the driveshaf t.

Discard the nut.
328
GEARCASE ASSEMBLY
GEARCASE ASSEMBLY Shift Rod Cover

Refer to Shift Rod Housi ng I nstallation on
Water Intake Screens p. 312
Install water in take screens. Tighten screws to a
torque of 60 to 84 in. lbs. (7 to 9.5 N·m). Pinion Gear and Driveshaft
Installation
Refer to Pinion Gear and Driveshaft Installation
on p. 313.
1
Propeller Shaft Bearing
Housing and Gear Installation –
“M2” Type
ing on “M2” type gearcases is PRESSED into th e
gearcase housing.
Lightly apply Triple Guard Grease to new bearin g
Shift Housing, Gear, and housing O-rings. In stall O-rings in grooves in the
housing. G rease t he m achined s ide s urfaces o f
Propeller Shaft Installation bearing housing.
Push shif ter de tent into farthest downward posi-
tion. T ip the rear of the gearcase slightly down- Place bearing housing in gearcase.
ward to assist in t he inst allation of t he shaf t
assembly.
Be sure the thrust bearing and the thrust washer
are in the proper position. Insert the shaft assem-
bly fully into the ge arcase while alig ning shift
housing pin with hole in forward end of ge arcase
housing.
006846
13
1. Pin 006929
329
GEARCASE ASSEMBLY
Align ret aining holes in bearing housing with Housing must be completely sea ted in gea rcase
screw holes in gearcase . Thread Alignment Pins, to inst all ret ainer screws. Bearing housing is
P/N 354140, into gearcase. approximately level with gearcase.
1 1
1. Alignment pins 006926

006928
IMPORTANT: Pinion, clutch dog an d forward
gears must align properly for bearing housing to Apply Ultra Lock to threads and install two retain-
seat properly. ing screws. Tighten screws to a torque of 18 to 20
ft. lbs. (24 to 27 N·m).
Bearing Housing In staller, P/N 354057, Gearcase
Fixture, P/N 354059 an d an approp riate floor
press (10 ton or gre ater) t o inst all hou sing into
gearcase. Alig n and level gearcase assembly in 1
2
3
4
Final Assembly and Adjustment
To complete gearcase assembly, refer to:
• GEARCASE LEAK TEST on p. 288
1 • WATER PUMP SERVICE on p. 292
• SHIFT ROD ADJUSTMENT on p. 295
• GEARCASE R EMOVAL AND IN STALLATION
on p. 289
• Gearcase Lubricant on p. 37
• Propeller Hardware Installation on p. 287
• Trim Tab Adjustment on p. 30
During brea k-in period of a rea ssembled ge ar-
1. Gearcase fixture, P/N 354059 006927
case, change the gea rcase lubricant between 10
2. Vertical alignment screws to 20 hours of operation.
3. Handle P/N 345822
4. Housing installer P/N 354057
330
TRIM AND TILT
TRIM AND TILT

TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
TRIM-OUT / TILT-UP MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
TILT-DOWN / TRIM-IN MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
IMPACT RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
SHALLOW WATER DRIVE TILT RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
THERMAL EXPANSION RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
MANUAL RELEASE – UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
MANUAL RELEASE – DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
ROUTINE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
RESERVOIR FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
MANUAL RELEASE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
STERN BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
SYMPTOMS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
PRESSURE LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
ELECTRICAL CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
RELAY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
TRIM AND TILT MOTOR CURRENT DRAW TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
TRIM AND TILT MOTOR NO LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
TRIM GAUGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
TRIM SENDER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
TRIM AND TILT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
TRIM AND TILT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
TILT PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
TILT PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
TILT PISTON ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
TILT ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
TRIM ROD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
TRIM ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
MANIFOLD AND RESERVOIR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
TRIM ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
TILT ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
14
331
TRIM AND TILT
SERVICE CHART
SERVICE CHART
35-52 In. lbs.

(4.0-5.9 N·m)
12-24 In. lbs.

(1.4-2.7 N·m)
84-108 In. lbs. 58-87 Ft. lbs.

(9.5-12 N·m) (79-118 N·m)
60-84 In. lbs.

(7-9.5 N·m)
60-70 Ft. lbs.
(81-95 N·m)
DO NOT OVER TIGHTEN

45-55 In. lbs.
58-87 Ft. lbs.
F (79-118 N·m)
(5.1-6.2 N·m)
60-84 In. lbs.

(7-9.5 N·m)
A
35-52 In. lbs.

(4.0-5.9 N·m)
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
004106 G Needle Bearing Grease
332
TRIM AND TILT
SYSTEM DESCRIPTION
SYSTEM DESCRIPTION Trailering Bracket and Tilt

The power tr im/tilt hydraulic system is completely
Support
contained between the outboard's stern brackets. Use the trailering bracket to support the outboard
when trailering in th e tilted position . This bracket
The system consists of: protects the hydraulic system from damage.
• Electric motor
• Oil reservoir Tilt the outboard up fully, engage the bracket, then
tilt the ou tboard down until the b racket is firmly in
• Pump manifold assembly
position.
• Cylinder body assembly
Optimal boat and outboa rd performance can be
achieved b y adjusting (trimming) th e dire ction of
outboard propeller thrust. The trim range (first 21°)
is primarily made by the trim cylinders. 1
Outboard mo vement be yond the trim ra nge is

considered tilting . Tilting of the outboard may be
desired in sh allow water d rive app lications a nd
trailering/storage. The tilt cylind er moves th e out-
board through the tilt range (final 54°).
A tilt relief valve limits the propeller thrust load that 1. Trailering Bracket 001987
will be supported by the unit in tilt range. As pres-
sure in creases, the out board will tilt down to the For mooring or storing the boa t with the outboard
top of the trim range. tilted, a tilt suppo rt is provided to support the o ut-
board.
IMPORTANT: When in tilt range , make sure
water is available to gearcase water pickups.
Manual Adjustment
The outboard can be ma nually raised or lo wered 1
through the en tire trim and tilt range by opening
the manual release valve a minimum of th ree
turns. The manu al release valve mu st be closed
and torqued 45 to 55 in. lbs. (5 to 6 N·m) to hold
the outboard in position and before normal opera-
tion can be resumed.
1. Tilt support 002279
IMPORTANT: The tilt su pport must not b e used

to support the outboard while trailering.
1
1. Manual release valve 001988

14
333
TRIM AND TILT
MODES OF OPERATION
MODES OF OPERATION
The trim/tilt hydraulic assembly achieves trim and
tilt moveme nt through the following mod es of
operation.
2
Trim-OUT / Tilt-UP Mode 1
When the UP switch is pressed, the trim/tilt motor 3
rotates clockwise (as viewed from pump end) and
turns the pump gears. 7
Fluid pressure pushes the UP che ck valve off its
seat, and fluid passes through the valve to the
bottom of all cylinders, pushing the pistons UP. 4
Fluid is pushed fr om the top of the tilt cylinder by
the pisto n a nd returns to the pu mp through the
open DOWN check valve.
In the trim ran ge, flu id is pushed from th e top of 5

the trim cylinders by the pistons and returns to the
reservoir.
Only f luid f rom the top o f t he tilt cylinder is

returned to the pump. Because the cylind er rod
displaces some fluid, t hat volume is less than the
volume of th e bottom of th e tilt cylind er. So, add i-
tional fluid is drawn into the pump from the reser-
voir. 6
When all the cylinder s are comp letely extend ed,
the pressure in creases until the UP relief valve
opens at th e tilt-up stall pressure (approximately
1500 psi (10342 kPa)). 1. Up shuttle valve DRC3462
2. Down shuttle valve
3. Down check valve
4. Up check valve
5. Tilt cylinder
6. Trim cylinders
7. Up relief valve
334
TRIM AND TILT
MODES OF OPERATION
Tilt-DOWN / Trim-IN Mode

When the DOWN switch is pressed, t he trim/tilt
motor rot ates counterclockwise (as viewed from
pump end) and turns the pump gears.
Fluid pressure passes through the DOWN shuttle

valve to the UP shuttle valve, which mechanically
opens the UP check valve. 1 2
Fluid pressure pushes t he DOWN check valve o ff
its seat and fluid passes through the valve to the
5
top of the tilt cylind er, mo ving the tilt piston 4
DOWN.
3
When the swivel bracket con tacts the top of the
trim rods, the mecha nical force of the tilt cylin der
pulling th e ou tboard down also pu shes th e trim
pistons down. Fluid is pulled from the reservoir to
the top of the trim cylinders.
Fluid from the bottom of the cylin ders return s

through the open UP check valve to the pump.
In the tilt rang e, all of th e fluid from the b ottom of

the tilt cylinder returns through the UP check valve
to the pump. Since more fluid is returning to the
pump than is required to fill the top of the cylinder,
the excess fluid is vent ed through the DOWN
relief orifice to the reservoir.
In th e trim ra nge, flu id from the botto m of all the
cylinders is r outed to the pump, which fe eds only
the top of the tilt cylinder. All of the excess flu id
vents through the DOWN relief orifice to the reser- 1. Down shuttle valve DRC3463
voir. 2.
3.
Up shuttle valve
Up check valve
4. Down check valve
When all cylinders are completely retracted, all of 5. Down relief orifice
the pump outp ut vent s thro ugh the DOWN relief
orifice to the reservoir a t st all pressure (a pproxi-
mately 800 psi (5516 kPa)).
14
335
TRIM AND TILT
MODES OF OPERATION
Impact Relief
Should the gearcase hit an underwater object and
the ou tboard suddenly tilts u p, th e t ilt cylinder
extends. The fluid abo ve the piston is co m-
pressed, producing high pressure.
This h igh pressure f luid p asses th rough the

impact relie f valves in t he tilt piston, dissipating
much of the energy of the impact.
To return the outboard to its original po sition, the
hydraulic unit mu st be op erated in the DOWN
direction.
1 1
1. Impact relief valves DRC3467
336
TRIM AND TILT
MODES OF OPERATION
Shallow Water Drive Tilt Relief

If the outboard exceeds idle RPM while operating
in shallow water d rive mode (tilted up be yond the
trim range ), increase d pressure ben eath the tilt
piston forces fluid through the tilt relief valve built
into the manual release valve.
Fluid flows from below the tilt piston, throu gh the

tilt relief valve, and to the reservoir.
2
As the tilt p iston mo ves down, the filter valve
opens and allows fluid to flow from the reservoir to
the top of the tilt cylinder.
The outboard will tilt down to the top of the trim

range. 3
Thermal Expansion Relief
Ambient air temperature increase can cause fluid
1
expansion within the hydra ulic assemb ly. If the
fluid expands when stored in the tilt ran ge, the
fluid under all of the pistons (and above the tilt pis-
ton) cannot expand, so its pressure increases.
If the pressure gets high en ough to push th e ball

of the tilt relief valve off its seat, the excess pres-
sure is vented to the reservoir.
1. Tilt relief valve DRC3465

2. Manual release valve
3. Filter valve
14
337
TRIM AND TILT
MODES OF OPERATION
Manual Release – UP
The outboard can be positio ned manually by fir st 2
opening (loosening) the manual release valve.
Open the manu al relea se valve (turn it slowly

counterclockwise) with a screwdriver, about 3 1/2
turns, until it lightly contacts its retaining ring.
When the manual release valve is opened and the

outboard is manually raised, flu id flo ws from the
top of the tilt cylinder to the manual release valve.
The fluid may p ass th rough the manual r elease
valve to the bottom of the tilt cylinder, or return to
the reservoir. Additional fluid may be drawn from
the bottom of the trim cylinders, which retract and
draw additional fluid from the rese rvoir to the tops
of the cylinders.
DRC3464
Trimming Outboard OUT 1. Manual release valve
2. Reservoir
Pull gearcase out farth er than the desired fin al
position (up into the tilt range, if necessary). Tilting Outboard UP
Close the manual release valve. Tilt outboard up and hold it with a suitable hoist or
engage either its tilt support or trailering bracket.
Manually, push the gearcase in (or down) until it is
supported by the trim system. A WARNING
Open the manual release valve only enough to let Do not attempt to hold the outboard up by
the outboard trim in to desired position. closing the manual release valve. The out-
board must be held manually, and lowered
to the trim range manua lly, af ter it has
been tilted up manually. The outboard can
drop to the trim range if the sup port is
removed.
Close the ma nual release valve firmly. The ma n-

ual re lease valve must b e closed to enable t he
trim/tilt unit to function.
338
TRIM AND TILT
MODES OF OPERATION
Manual Release – DOWN

When the manual release valve is opened and the
outboard is ma nually tilted do wn or trimmed in,
fluid f lows f rom th e botto m of the tilt cylinder ( in
the tilt range), or from the bottom of all of the cylin-
ders (in the t rim range), and p ast the manu al
release valve.
Fluid flows from the bot tom of th e tilt cylinder (in 1

the tilt range) to the top of the tilt cylinder. The
excess fluid, equal to the volume of the piston rod,
is vented to the reservoir.
In th e trim ra nge, the fluid fro m the bot tom of all

three cylinder s is vented to the reservo ir, e xcept
for the amount required to fill the top of the tilt cyl-
inder.
After open ing the manual release valve, close it

firmly. The manual re lease valve must be closed
to enable the trim/tilt unit to function.
1. Manual release valve DRC3465
14
339
TRIM AND TILT
ROUTINE INSPECTIONS
ROUTINE INSPECTIONS TROUBLESHOOTING

General If the power trim/tilt system has malfunctioned and
the cause h as not been d etermined, th e Symp-
Check for exte rnal signs of fluid leakage. Correct
toms Chart on p. 341 should help locate the
causes as necessary.
problem.
Check the b attery and make sure it is in go od
Keep a manual release valve and a valve body in
operating condition.
stock for troublesho oting. Use these p arts whe n
the Service Proce dures on p. 341 call fo r t he
Reservoir Fluid substitution of known good parts.
Check reservo ir fluid level every th ree yea rs or
every 300 opera ting ho urs. System cap acity is If the trim/tilt does not work, and its motor neither
approximately 21 fl. oz. (620 ml). runs nor hums, troubleshoot the problem by refer-
ring to TILT/TRIM RELAY TEST on p. 105.
Refer to Trim and T ilt on p. 39 for filling proce-
dure. If the outboard tilts part way up but not smoothly,
or with a const ant sound, there is probably air in
Manual Release Valve the s ystem du e t o l ow fluid. Fi ll re servoir an d
Check the manual release valve with a torq ue bleed (purge air from) the system.
wrench. To test fo r mechanical binding, op en the manua l
IMPORTANT: Tighten valve to a torque of 45 to release valve and manually tilt the motor up and
55 in. lbs. (5 to 6 N·m). down. If parts are binding, refer to MIDSECTION
section.
Stern Brackets If the outboard will not st ay in shallow water drive
Inspect the stern brackets for binding. and drops down at fast idle, the wrong manual
release valve may be inst alled. Check f or th e
Tighten starboard tilt tube nut to a torque of 45 to identification groove in the face of the valve.
50 ft. lbs. (61 to 68 N·m).
2
1. Grooves (V4 Models) 30959
2. No grooves (V6 Models)
340
TRIM AND TILT
TROUBLESHOOTING
If th e outboa rd does not tilt as hig h as it should, STEP 3

and the tilt mot or TURNS OF F at maximum tilt Go to TILT/TRIM RELA Y TEST on p. 105 to
(does not sound like it is st alled at the maximum determine if problem is power supply.
tilt position), adjust the tilt limit switch higher a nd
retest. Refer to Tilt Limit Switch Adju stment on STEP 4
p. 28. Remove trim mo tor a nd c heck condition of drive
coupling. If coupling is damaged, replace it.
Symptoms Chart
If any of these symptoms describe the unit, follow STEP 5
the ind icated Service Proce dures, in the o rder Temporarily inst all a known go od pump ma nifold
listed, to locate and correct the problem. assembly and retest. If symptoms remain, original
assembly is n ot the prob lem. Rein stall origina l
Service assembly.
Symptom Procedures
Unit will not move in either direction. 1, 2, 3, 4, 6 If symptoms d isappear, the o riginal p ump mani-
Unit runs slowly in one direction, 1, 2, 6 fold assembly was faulty . Remove temporary
normal speed in other direction. assembly and replace it with correct one.
Unit runs slowly. (if low hours) 1, 2, 7 STEP 6
(if high hours) 1, 2, 5, 7 Install replacement pump manifold assembly and
Unit leaks DOWN and/or will not 1, 2, 6 retest. If all symp toms are not corrected, reco n-
hold trim position against thrust in sider the problem using the new symptoms.
forward.
STEP 7
Unit leaks both UP and DOWN – 1, 2, 7
Leaks down in tilt range and/or will Install O-ring kit. Loo k for any cylinder damage.
not hold trim position against thrust Look for chip s in fluid or imp act valves. L ook for
in forward or reverse. other abnormal conditions. If all symptoms are not
corrected, reconsider th e prob lem using the new
Unit will not trim/tilt one way, but 2, 3, 6
symptoms.
works the other way. Unit will not run
DOWN, but runs UP; or it runs
DOWN, but will not run UP.
Pressure Leakdown Test
Before servicin g a hydraulic unit, it should b e
pressure te sted to de termine the unit's malfunc-
Service Procedures tion. This test must be performed with the hydrau-
lic unit remo ved from the outbo ard and mounted
STEP 1 in a vise or holding fixture.
Be sure the manu al relea se valve is clo sed. If
NOT, torque to 45 to 55 in. lbs. (5.1 to 6.2 N·m). Power T rim/Tilt Service Kit, P/N 434524, allo ws
testing of trim/tilt operation and component condi-
STEP 2 tion.
Temporarily install a known good manual release • The “A” adapter, P/N 336658, checks operation
valve and r etest. If sympt oms rema in, origin al of the UP circuit.
valve is not the problem. Reinstall original valve.
If symptoms disap pear, t he origina l va lve wa s

faulty. Remove temp orary valve and replace with
correct new valve.
14
341
TRIM AND TILT
TROUBLESHOOTING
• The “B” adapter, P/N 336659, checks operation bypass the reservoir cap. These steps will relieve
of the DOWN circuit. the pressure in the unit.
1 2 1
1. A Adapter 27340 1. Manual release valve 41739

2. B Adapter 2. Reservoir cap
This kit do es no t includ e a gau ge and collar Remove the manu al release valve ret aining ring
assembly. Gauge and collar assembly shipp ed using retaining ring pliers.
with Power T rim/Tilt Service Kit, P/N 390 010, will
work. Gauge and Collar Assembly, P/N 983975, is
also available.
Be sure to use a fully charged battery.

STEP 1
Screw the man ual rele ase valve in the hyd raulic
unit unt il it is seate d. Place a la rge drain p an
under the unit to catch hydraulic fluid.
41754
1 Remove the manual release valve. Inst all pres-

sure gauge and a dapter “A” to check pr oblems in
the UP circuit.
IMPORTANT: Torque gauge and ad apter lightly

to 5 to 10 in. lbs. (0.6 to 1.2 N·m). Excessive
torque might damage adapter or O-rings.

Cycle the unit down and up several times to purge
air. With all rods fully extended, run the unit down
Operate the unit to the full UP po sition, the n run momentarily to reduce pressure. Che ck fluid level
the unit down momentarily to reduce pre ssure. again, and add flu id if nece ssary. Remember that
Loosen the reservoir cap one full turn. Loosen the
manual release valve three turns. Some fluid will
342
TRIM AND TILT
TROUBLESHOOTING
all rods mu st be complete ly e xtended to check Remove the manual release valve. Inst all pres-
fluid level. sure gauge and a dapter “B” to check pr oblems in
the DOWN circuit. Cycle the unit down and up
several times to p urge a ir. With all ro ds f ully
extended, run the un it down mome ntarily to
reduce pressure. Check fluid level again, and ad d
fluid if necessary. Remember that all rods must be
completely extended to check fluid level.
Starting with the tilt cylinder fully extended, run the

unit DOWN.
• The gauge should show 0 to 200 psi (0 to 1379
kPa) as the tilt cylinder is retracting.
• The gauge should sh ow approximately 800 p si
41757
(5516 kPa) as the unit stalls.
• Release th e switch and watch for a pre ssure
Starting with the tilt cylinder fully retracted, run the
drop. The stall pressure reading must not drop
unit UP.
more than 200 psi (1379 kPa) after motor stops.
• The gauge should show 0 to 200 psi (0 to 1379
kPa) as the tilt cylinder is extending. If result s vary from the abo ve limit s, there is a
• The gauge should show 1400 to 1600 psi (9653 problem in the DOWN cir cuit. Refer to MODES
to 11032 kPa) as the unit stalls. OF OPERATION on p. 334 for circuit description.
• Release the switch and watch for a p ressure
drop. The stall pressure reading must not drop A CAUTION
more than 200 psi (1379 kPa) after motor stops. After tes ts are c omplete, run the unit up,
If result s vary fro m the ab ove limit s, there is a then down moment arily. Cycle the unit
problem in the UP circuit. Refer to MODES OF down and up seve ral times to purge air .
OPERATION on p. 334 for circuit description. With all rods fully e xtended, ru n the unit
down momentarily to reduce pressure.
STEP 2
Remove th e man ual release valve ret aining ring Check fluid level again and add fluid, if necessary.
using retaining ring pliers.
41754
14
343
TRIM AND TILT
ELECTRICAL CIRCUIT TESTS
ELECTRICAL CIRCUIT Connect a 0 to 100 A DC ammete r in series

between the ba ttery side of the st arter solenoid
TESTS and the red lead to the trim/tilt relay module.
1
Relay Testing
When the trim-UP button is pressed, the UP relay
is energized and connects the blue trim motor wire
to the battery positive (+) terminal. The green trim
motor wire remains grounded. When the button is
released, the blue trim mot or wire returns to a
grounded position.
When the trim-DOWN butto n is pressed, the

DOWN relay is energized and connects the green
trim motor wire to the battery positive (+) terminal. 1. Red lead 005441
The blue motor wire remains grounded. When the
button is re leased, the gre en trim motor wire Observe ammeter and a stopwatch while running
returns to a grounded position. hydraulic unit through several complete cycles.
Refer to TILT/TRIM RELAY TEST on p. 105 for Compare test results to the values listed.
relay testing procedure.
Normal Time in
Trim and Tilt Motor Current Draw Mode Current Draw Seconds
Tests Trim-OUT (Trim range) 22 A 14
Careful an alysis of t he electric motor's cu rrent Tilt-UP Stall 80 A N/A
draw and trim/tilt unit operating speed aids evalu- Trim-IN (Trim range) 16 A 7
ation of the electric motor a nd certain mechanical
Trim-IN Stall 35 to 45 A N/A
components.
Use a battery rated at 360 CCA (50 Ah) or higher Test results include three basic possibilities:
that is in good condition and fully charged to per-
form this test. A. Low current draw – Check for:
• Valves leaking
IMPORTANT: Specifications are for st atic • Pump damaged
hydraulic test s. DO NOT att empt to pe rform the • O-rings leaking
following tests while the boat is moving.
• Manual release valve damaged
• Relief valve springs weak
• Check valves fouled or damaged
B. High current draw – Check for:
• Pump binding
• Motor binding
• Cylinder binding
• Valves sticking
344
TRIM AND TILT
C. Normal current draw, slow operating The motor shaft must rotate clockwise, as viewe d
speed – Check for: from the pump end, when positive (+) is applied to
• Manual release valve damaged the blu e le ad, a nd ne gative (– ) is connected to
• Impact valves damaged green lead.
• Check valve or shuttle valve malfunctioning
The motor shaft must rotate counterclockwise, as
viewed from the pump end, when po sitive (+) is
Trim and Tilt Motor No Load Test applied to the green lead, and negative (–) is
IMPORTANT: Securely fasten m otor i n a su it- applied to the blue lead.
able fixture before proceeding with this test.
Blue lead (+) Green lead (+)
Use a battery rated at 360 CCA (50 Ah) or higher Green lead (-) Blue lead (-)
that is in good condition and fully charged to per-

form this test.
Connect a 0 to 50 A a mmeter in series with the
battery p ositive (+) terminal, ammete r red le ad
toward battery.
Attach or hold a vibration or mechanical tachome-

ter to the motor while performing this test. DR4238r
Monitor motor RPM and current draw. If test results vary, replace the motor.
30957
14
345
TRIM AND TILT
Trim Gauge Test Trim Sender Test

STEP 1 IMPORTANT: To avoid immedia te me ter dam-
Turn key switch ON. Using a voltmeter , check for age, never apply a multimeter to an electrical cir-
voltage between the trim gauge “I” and “G” termi- cuit where voltage is present.
nals.
Disconnect the 3-pin connector betwee n the
• If no voltage, check condition of instrument har-
instrument harness and engine trim harness.
ness, key switch, and engine 10 A fuse.
• If voltage, go to STEP 2. Connect an ohmmeter between the white/tan wire,
terminal “C,” of the en gine h arness and a cle an
engine ground.
With the outboard fully DOW N, meter must show

a reading above 80 Ω.
With the outb oard fully UP , meter must show a

reading below 10 Ω.
• If result s agree, refer to Trim Gauge Test on
p. 346.
• If results are different, replace trim sender.
DRC6245
STEP 2
Remove th e white/t an lead fro m the trim gau ge
“S” terminal. With key switch ON, gau ge shou ld
indicate full-trim DOWN position. Now connect a
jumper wire between terminals “S” and “G.” Gauge
should indicate full-trim UP position.
• If results are different, replace the trim gauge.
• If results agree, refer to Trim Sender Test.
DRC6247
DRC6246A
346
TRIM AND TILT
TRIM AND TILT REPLACEMENT
TRIM AND TILT Separate the trim/tilt unit wires in the braided tube
to p ermit removal t hrough the hole in t he ste rn
REPLACEMENT bracket.
Removal
Raise the outboard and engage the tilt support.
Remove the rubber grommet from the blue/green

trim/tilt cable connector.
25078
Remove the ground wire from the trim/tilt unit.
000686
1
Remove the terminals from the co nnector by
using a suitable tool to depress the tab. While the
tab is depressed, pull on the wire from the rear of
the connector to release it from the connector.
1. Ground wire 25057
Remove t he external sn ap rings from t he upp er

pin.
000687
25064
14
347
TRIM AND TILT
TRIM AND TILT REPLACEMENT
Use a punch to remove the upper pin. Installation

Place trim/tilt unit into position. Apply Triple-Guard
grease to the lower pin and install the pin.
Install external snap rings on lower pin with sharp

edge of ring facing out.
25065
Retract the tilt cylinder rod.
Remove th e extern al sn ap rings from th e lower

pin.
25077
Loosen the manual release valve if necessary and

extend tilt cylinder rod to match with holes in
swivel bracket.
Apply Triple-Guard grease to upper pin and install
the pin.
Install e xternal sn ap rin gs on to uppe r pin with

sharp edge facing out.
25077
Use a punch to remove the lower pin and remove

the trim/tilt unit from the stern brackets.
25064
25076
348
TRIM AND TILT
TRIM AND TILT SERVICE
Place trim/tilt wire s in b raided tu be a nd install

through hole in the stern bracket.
Disassembly
A WARNING
Before removing the manual release valve,
operate the unit to the full UP position,
then run the unit down mom entarily and
loosen the reservoir cap one full turn.
To avoid personal injury, always wear eye
protection wh en servic ing the hydraulic
unit. Sinc e there might be sig nificant
25079
residual pressure be hind some compo-
nents, cover each component with a shop
Attach the ground wire to the trim/tilt unit. cloth as you remove it.
Thoroughly clean the unit before disassembling it.

Scrub all o utside surfaces with a st iff brush an d
hot, soapy water to prevent surface dirt from con-
taminating internal parts.
A CAUTION
Do not apply he at to the cylinde r body or
1 cylinders. Exc essive hea t can cause high
pressure leaks or failure of parts.
25057
1. Ground wire
Always use a “lint free ” shop cloth when han dling
power trim/tilt components.
Release the tilt suppor t and lower the outbo ard.
Tighten the manual release valve to a torque of 45 If p ainting the unit is required, p aint it af ter it is
to 55 in. lbs. (5.1 to 6.2 N·m). completely assembled. Painting of individual com-
ponents may ca use flakes of paint to en ter th e
Install conne ctor on trim/ tilt cable and reconne ct
hydraulic p assages dur ing assembly . Tape th e
trim connectors to engine wire harness.
trim/tilt piston rods before painting.
14
349
TRIM AND TILT
Screw the man ual rele ase valve in. Remo ve the Remove the three Pozidriv sc rews securing the
retaining ring using re taining ring pliers. Remove reservoir to cylinder body. Remove reservoir.
the manual release valve.
41753
Remove the reservoir O-ring from the cylinder

41739
body. Check the machined surfaces fo r nicks and
scratches.
Inspect O-ring and two pl astic split rings on the
manual rele ase valve for nicks and cut s. I nspect
tip of valve for damage. The two plastic split rings
are not available separately. If rings are damaged,
replace the manual release valve.
2 1
1. O-ring 41759
22863
1. O-ring
2. Plastic split rings
Use a 6 mm hex wren ch to remove the plug from
the cylinder body. Inspect the O-ring and the filter.
Remove reservoir ca p an d dra in th e fluid into a Replace, if necessary.
container. Inspect the O-ring in the cap.
41787
1. Reservoir cap 41736

41751
350
TRIM AND TILT
Remove the four screws securing motor to pump solvent and inspect it for tears, clogging, or other
manifold assembly. damage.
41760 1. Coupler 41763

2. Filter screen
Remove the wire shield from the pump manifold.

Remove the motor an d in spect t he motor O-ring Remove the three Allen head screws securing the
and the O-ring on the cable connector. pump manifold assembly to cylinder body.
41798
22878
IMPORTANT: Individual parts in the pump mani-
fold assembly are not available separately. Do not
Remove and inspect the coupler. Remove the fil- remove pump or any control valves from the body.
ter screen fro m th e pump manifo ld. Che ck the
machined surfaces on the manifo ld for nicks and
scratches. The pump manifold is not se rviceable.
Do no t remove the pump or any contro l va lves
from the manifo ld. Clea n the screen with a mild
14
351
TRIM AND TILT
Remove the ma nifold. Rem ove f ive O-rings fro m Slowly pull the piston out with a rag wrapped
cylinder body. Check machined surfaces for nicks around the ro d and th e top of the cylinder . Drain
and scratches. the remaining fluid from the cylinder.
41799 41765
Tilt Piston Removal Inspect the bo re of the t ilt cylinder f or excessive

scoring. If the b ore of the tilt cylinde r is score d or
Use Tilt Cylinder End Cap Remo ver/Installer,
damaged, the hydraulic assemb ly must be
P/N 326485, or Universa l S panner W rench,
replaced.
P/N 912084, and a breaker bar to unscrew the tilt
rod end cap.
41767
41788
Clamp t he rod eye tightly in a soft jaw vise.
Remove the nut from the piston end of the rod.
Drain the fluid from above the piston.
41789
1. End cap 41781
352
TRIM AND TILT
Remove the washer . Slide t he tilt piston of f the Two of the piston relief holes are small, the oth er
rod. Be careful not to lo se the springs, plunger s, two holes are larger. Two of the springs have five
or small check valves in the piston assembly. coils and the other two have nine coils. On assem-
bly, the two five-coil springs go in the la rge relief
holes, and the two nine-coil springs go in the small
relief holes.
2 1
41784
Remove and discard the small in ner O-ring and

large outer O-ring.
1. Small piston relief holes 41879
2. Large piston relief holes
1 Tilt Piston Assembly

Piston ch eck balls and plu ngers are identical.
2 Lubricate and install a new outer O-ring on the tilt
piston. Place one ball, on e plunge r, an d on e
spring in each hole in the piston as indicated.
The two five-coil springs go in the la rge relief

41819
1. Small inner O-ring
2. Large outer O-ring
holes and the two nine-coil springs go in the small
relief holes. Set the piston aside.
Tilt Piston Identification
A WARNING
Different tilt pistons are used on hydraulic 2
units for various outboard m odels. All
plungers a nd ch eck balls are id entical.
The tilt p iston assemblies contain valving
specific to ce rtain m odels. To provide 4
impact p rotection, it is important the c or-
rect piston assembly be installed. 3 1
1. Five-coil spring 41817

2. Nine-coil spring
3. Piston check ball
4. Plunger
14
353
TRIM AND TILT
Use a screwdriver t o carefully pry the scraper out Use a wire brush to clean all thread-locking mate-
of the end cap. Discard the scraper. Remove and rial from the threads on the tilt rod.
discard the large outer O-ring.
41821
41791
Remove and discard inner O-ring of the end cap. Lubricate the inside surface of the end cap. Lubri-
cate an d in stall T ilt Cylinder Seal Protector,
P/N 326005. Use a deep-well socket and a plastic
mallet to drive the end cap ont o the rod, th en
remove the seal protector. Slide the end cap down
the tilt rod.
41792
Tilt Rod Assembly

Clean the end cap thoro ughly, then lubricate and
install a new O-ring in the en d cap. Lubricate and 1
install a new scraper. The scraper is installed with
the lip fa cing out. Lu bricate and inst all a new
O-ring on the outside of the end cap. 1. Tilt Cylinder Seal Protector P/N 326005 41824
Remove any lubricant from the threads on the tilt

1 2 rod, prime with Locquic Primer, and let d ry. Slide
the piston assembly onto the tilt rod. Place a new
rod O-ring over the threads.
3
1
1. Inner O-ring 41795
2. Lip
3. Outer O-ring
1. O-ring 41816
354
TRIM AND TILT
Clean any thread -locking ma terial from the Trim Rod Removal
threads on the inside of the nu t. Spray threads of
Unscrew trim cylin der end caps using T rim Cylin-
with Locquic Primer and let dry . App ly a small
der End Cap Remove r/Installer, P/N 43 6710, or
amount of Nut Lock to the threads. Slide the
Universal S panner W rench, P/N 912084, and a
washer o ver the th reads and inst all the n ut.
breaker bar. Small pins must be used in the span-
Tighten to a torqu e of 58 t o 87 f t. lbs. (79 to 1 18
ner wrench.
N·m).
41783
41829
To en sure that the tilt piston ha s b een p roperly
assembled and the impact relief balls are properly
Slide t he cap s to th e e nd o f the rods. Drain th e
seated, apply Power Trim/Tilt & Steering Fluid on
fluid from the top of the pistons.
top of the tilt piston. Fluid should not leak p ast the
impact relief b alls while seated. If fluid does leak,
disassemble the piston assembly and inspect the
relief ball seats. Set the tilt rod assembly aside.
41837
41828 Slowly pu ll each piston out wit h a ra g wrappe d

around the rod and the top of the cylinder.
41838
14
355
TRIM AND TILT
Drain th e re maining fluid from th e cylinder s. Remove the rod from the vise. Use a small screw-
Inspect both bores of the trim cylin ders for exces- driver to carefully pry the scraper out of t he e nd
sive scoring. If one or both trim bore s are sco red cap. Discard the scraper.
or damaged, the hydra ulic assembly must be
replaced.
41843
Use a suitable tool to remove the inner quad-ring

and the ou ter O-ring. Discard the quad-ring a nd
O-ring.
41840
Remove and discard both back-up rings and the

O-ring from each trim rod piston.
41844
Trim Rod Assembly

41841
Lubricate and install a new quad-ring and scraper
in the end cap. Install a new scraper with the bevel
Using Hyd raulic Cylind er Rod Hold er, facing out. Lubricate and install a new O-ring on
P/N 983213, clamp the rod tigh tly in a vise. the outside of the end cap.
Remove the thrust p ad from the trim rod, then
remove the end cap.
1. Bevel 41845
2. O-ring
41842
356
TRIM AND TILT
Lubricate a nd inst all a new O-ring and two new Manifold and Reservoir
back-up rin gs on the trim rod piston. Place o ne
back-up ring on each sid e of the O-ring. Position
Installation
the open end of the back-up rings 180° apart. Lubricate five new manifo ld b ody O-rings. Place
them in the cylinder body.
2 1
1. O-ring 41847
2. Back-up rings 41849
Using Hyd raulic Cylind er Rod Hold er, Attach th e valve pump assembly to the cylind er
P/N 983213, clamp the rod tightly in a vise a nd body with three Pozidriv screws. T ighten scre ws
lubricate the cap and rod . Slide the end cap onto to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
the rod and install thrust pad. Tighten thrust pad to
a torque of 84 to 108 in. lbs. (9.5 to 12 N·m).
41850
1. Thrust pad 41848 Oil and in stall the manual release valve. Threa d
the valve just p ast the snap ring groo ve. Do n ot
install the snap ring at this time. The valve will be
14
357
TRIM AND TILT
removed later for the Pressure Leak down Test Attach the reservoir to the cylinder body with three
on p. 341. Pozidriv screws. Tighten the screws to a torque of
35 to 52 in. lbs. (4.0 to 5.9 N·m).
41851
41866
Install the re servoir f ilter screen in the cylin der
body. Make sure that the screen is seate d. Use a
6 mm Allen wrench to install the plug. Tighten the Trim Rod Installation
plug securely. Lubricate th e trim rod pistons. Place the r od
assemblies in to the bo dy. Push the m in until the
end cap s just clea r the top s o f the cylinders. Fill
the cylinders with Power Trim/Tilt & Steering Fluid.
Failure to fill the cylinders could cause difficulty in
purging air from the unit.
41863
Lubricate and place a new rese rvoir O-ring in the

cylinder body.
41867
Screw the trim rod end caps into the cylinder body.
1 Use Trim Cylin der End Cap Remover/In staller,
P/N 436710, o r Universal S panner W rench,
1. O-ring 41865
358
TRIM AND TILT
P/N 912084. Tighten caps to a torque of 60 to 70 P/N 912084. Tighten cap to a torque of 58 to 87 ft.
ft. lbs. (81 to 95 N·m). lbs. (79 to 118 N·m).
41868 41870
Tilt Rod Installation Motor Installation

Lubricate the tilt rod piston. Slide the end cap all Position the pump manifold so the pump mounting
the way up on the rod assembly. Place the piston surface is level. Install the coupler into the pump.
end of the rod assembly into the cylin der body.
Push it in until the end cap just clears the cylinder
top. Leave enough room to pour fluid into the cyl-
inder. Fill the cylinder with Power Trim/Tilt & Steer-
ing Fluid. Failure to fill the cylinde r co uld cause
difficulty purging air from the unit.
1
1. Coupler 41852
Fill the pump cavity with Power Trim/Tilt & Steer-

ing Fluid up to the top of the two bosses. Rotate
the coupler clo ckwise and then co unterclockwise
until no more air bubbles come out of the pump.
41869
Screw tilt cylinder end cap into cylinder body. Use

Tilt Cylinde r End Cap Remo ver/Installer,
P/N 326485, o r Universa l S panner W rench, 1
1. Bosses 41854 14
359
TRIM AND TILT
Install the filter screen. Fill the reservoir to the bottom of the fill hole with
Power Trim/Tilt & Steering Fluid. Inst all a nd
tighten the reservoir cap. Turn the manual release
valve in until it sea ts. Cycle the unit up and down
several times to purge air.
1. Filter screen 41856
Lubricate and place a new O-ring on the mo tor.

Make sure the cable is on the transom side of the
41859
unit; align th e coupler slot with the motor shaf t.
Place the motor on the pump manifold assembly.
Operate th e unit to the full UP position, then run
down momentarily to release pressure. Check the
fluid leve l ag ain and add fluid , if necessary.
Remember that all rods must be completely up to
1 check the fluid leve l. Test the unit b y perfo rming
the Pressure Leakdown Test on p. 341.
1. O-ring 41857
2. Cable
Install the four motor screws. Tighten the screws

to a torque of 35 to 52 in. lbs. (4.0 to 5.9 N·m).
41885
41858
360
TRIM AND TILT
Check the tilt ro d bushings. Replace them if the y

are worn excessively.
41888
Check the bushings on the bottom of the manifold

body. Replace them if they are worn excessively.
41878
Check system operation in both trim and tilt range.
14
361
TRIM AND TILT
NOTES
NOTES
Bulletins
Instruction Sheets
Other
362
SAFETY
SAFETY
TABLE OF CONTENTS
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM . . . . . . . . . . . . . . . . . . . . . S–3
OUTBOARD SHIFT SYSTEMS AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–4
OUTBOARD SPEED CONTROL SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–5
OUTBOARD STEERING CONTROL SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–6
OUTBOARD FUEL, ELECTRICAL SYSTEM, AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–8
OUTBOARD MOUNTING SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–11
OUTBOARD HYDRAULIC TILT/TRIM SHOCK ABSORPTION SYSTEM AND SAFETY . . . . . . . . . . . . . . . . S–13
OUTBOARD EMERGENCY STOP SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–14
SUMMING UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–16
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM . . . . . . . . . . . . . . . . . . . . . S–17
HANDLING OUTBOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–17
HANDLING LEAD/ACID BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–21
GASOLINE – HANDLE WITH CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–22
HAZARDOUS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–23
SAFETY AWARENESS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–24
S–1
S–2
SAFETY
MARINE PRODUCTS AND THE SAFETY OF PEOPLE

WHO USE THEM
A WARNING
This Safety section contains information relevant to the safety of boaters and people that ser-
vice boats. Please read this section carefully and share it with a ll shop technicians. Always
follow common shop safety practices. If you have not had training rel ated to common shop
safety practices, you should do so not only to protect yourself, but also to protect the people
around you.
It is impo ssible for this m anual to cover e very pote ntially hazardous situa tion you may
encounter. However, your understanding and adherence to the re commendations contained
in this manual and use of good judgment when servicing outboards will help promote safety.
Always be alert and careful: a good foundation for safety.
Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manu-
facturers are careful to make sure:
• Product user is informed; and
• Products are safe and reliable.
It is up to you, the people who...
• Rig boats;
• Fix machinery; and
• Maintain equipment
...to keep the products safe and reliable.
This section talks about safe boating a nd how you can help make it safe. Some of these safety issues
you will know, others you may not.
First!
A word about parts... Plain parts; special parts; all parts!
DO NOT SUBSTITUTE PARTS

“They look the same, but are they the same?”
• Same size?
• Same strength?
• Same material?
• Same type?
Don’t substitute unless you know they are the same in all characteristics.
Second!
• Special locking bolt s and nu ts are of ten u sed to hold ste ering, shif t, and thro ttle re mote cont rol
cables to the outboard.
• When you take any outboard off a boat, keep track of special nuts and bolts. Do not mix with o ther
parts. Store them on the outboard, then they are there when you need them.
• When the outboard is returned to the boat, use only the special nuts and bolts to hold remote steer-
ing, shift, and throttle cables to the outboard.
S–3
SAFETY
Outboard Shift Systems and Safety

The outboard Shift
System starts here
at the remote
control lever...
...and ends here

at the propeller.
What is most important? When control lever is in

FORWARD, NEUTRAL
or REVERSE...
...shift linkage must

match control lever
position.
What could happen?
IF... IF...
NEUTRAL FORWARD
...propeller still FORWARD

powered (turning) or
unknown to operator, REVERSE
or outboard will START ...boat will move
REVERSE
in gear, and boat will opposite to
move suddenly. direction wanted
by operator.
How can loss of shift control be minimized?

Read, understand, and follow manufacturer’s instructions
• Follow warnings marked “ ” closely.
When
• Assemble parts carefully.
rigging
• Make adjustments carefully.
or after
• Test your work. Do not guess. Make sure prop eller does just what the operator wants
servicing
and nothing else.
• Do not shift gears on a stopped outboard. Adjustments can be lost and parts weakened.
S–4
SAFETY
Outboard Speed Control System and Safety

The outboard speed control system
starts here at the remote control
lever... (single lever remote control)
...and ends here on

the powerhead.
What is most important?
When control lever is moved from

FORWARD (or REVERSE) to
NEUTRAL...
Powerhead speed must
slow down to allow operator
to shift into NEUTRAL.
Operator must be able to

STOP propeller.
What could happen?
If Operat or ca nnot slow do wn the ou tboard o r shif t into NEUTRAL gea r (stop prope ller), Ope rator
could panic and lose control of boat.
How can loss of speed control be minimized?

Read, understand, and follow manufacturer’s instructions
When
rigging
or after
• Test your work. Do not guess. Make sure speed control system does just what the oper-
servicing
ator wants and nothing else.
• Make sure full throttle can be obtained so Operator will not overload parts.
S–5
SAFETY
Outboard Steering Control System and Safety

The outboard steering system starts
here at the steering wheel...
...and ends here at the

trim tab on the outboard.
The steering system:

• Must not come apart;
• Must not jam; and
• Must not be sloppy or loose.
What could happen?
• If steering system comes ap art, boat might turn suddenly and circle. Persons thrown into the water
could be hit.
• If steering jams, operator may not be able to

avoid obstacles. Operator could panic.
• If steering is loose, boat may weave while operator

tries to steer a straight course. With some rigs (at
high spe ed), lo ose steering co uld lead to loss of
boat control.
S–6
SAFETY
How can loss of steering control be minimized?

• Use a steer ing syst em recommende d by th e outbo ard ma nufacturer which me ets
Marine Industry Safety Standards (ABYC).
• Read, understand, and follow manufacturer’s instructions
When
rigging
or after
servicing
• Keep parts moving freely. Lubricate parts as shown in manual.
• Use the bolts, nuts and washers supplied with steering attachment kits—they are a spe-
cial locking type that will not loosen, rust, or weaken.
Transom Mounted Steering Systems – Check to Uncover Possible Trouble!
Tilt outboard into boat, then turn it.
During this procedure, steering parts:

• Must not bind; and
• Must not tou ch ot her boat , outboa rd,
or accessory parts in transom area.
Why? A hard blow to the outboa rd’s
gearcase can resu lt in damage to st eer-
transom ing parts.
mounted
steerer stop stop
to
Be a ware that raising or lowering ou tboard on

transom ca n change a set-up which was OK
earlier. If moved up or down even one-half inch,
run test a gain to make sure steering parts are
free and clear.
Check for damaged parts. Blows to the outboard like this
or this can put heavy loads on steering parts. Look for:

• Cracked parts, including steering parts, swive l b rack-
ets, and transom brackets;
• Bent parts; and
• Loose nuts and bolts.
Replace damaged parts. If weakened, parts could fail later on the water when least expected.
S–7
SAFETY
Outboard Fuel, Electrical System, and Safety
The fuel system The electrical system begins

starts here at the here at the battery...
fuel tank...
...and ends here at

the fuel injector.
...and ends here on the powerhead.
• Fuel leakage must be eliminated.

• Stray electric sparks must be avoided.
What could happen?
• 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.
How Can Fire and Explosion Be Minimized?

• Do not substitute fue l o r electrical systems p arts with other parts which may look th e same . Some
electrical parts, like starter motors, are of special design to prevent stray sparks outside their cases.
• Replace wires, sleeves, and boots which are cracked or torn or look in poor condition.
When mixing and refueling, always mix Always fill the tank
gas and oil outside... outside the boat
GA
S
GA
S
Fumes are hard to

control. They collect and
hide in the bottom of the
boat.
Remember:
Do not use electrical devices

such as cellular phones in the To avoid those
vicinity of a fuel leak or while static electric
fueling. sparks, ground
(touch) the spout
If you use a funnel, it has to be against the tank.
metal to ground the spout to
the tank.
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
Metal Clamps – Tie Straps

• Position as shown in manual
Screws, Nuts, Washers

• Tighten firmly–these keep
clamps in position and ends
of wires from sparking
• Where lock washers are
called for, use them
Spark Plug Boots

• Not torn or cracked
• Fully pushed onto spark
plug
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
Check for leaks

GASOLINE
under engine cover
GASOLINE
Whenever possible, remove

hose from outboard and from
tank.
If tank cap has an air
vent valve, make sure
it is closed. Store hose around ears
of tank. This way,
gasoline is trapped in
tank and not in the hose,
where it might leak onto
If gasoline tank is stored the floor if the hose
indoors, do not put it in a room deteriorates.
having an appliance with a
pilot light or where electrical
appliances or switches (which
may spark) will be used.
When Running:
Carburetor air intake

silencer will catch and
hold fuel which may flood
into engine if carburetor
float sticks.
• 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 Mounting System and Safety

The mounting system includes:
• outboard parts
• bolts, nuts, and washers

• boat’s transom
• Outboard must stay in position on boat’s transom.
What could happen?
Outboard may Outboard may
S...L...I...D...E on transom T...I...L...T on transom
Boat may turn and be hard Boat may turn and be

to steer. hard to steer.
• If outboard hits something solid and does not stay on

the tra nsom, b oat o ccupants may be injured from the
outboard or its parts entering the boat.
Boat’s transom could break away. Outboard may be lost overboard.

Boat may SINK.
How Can Loss of Mounting Be Minimized?

• Read, understand, and follow manufacturer’s instructions.
S–11
SAFETY
If weakened, parts could fail later on the water, when not expected
If boat plate
shows...
Use only
or smaller
When rigging or fixing

any boat, if transom
looks weak, tell the
owner.
If transom is Mount on flat surface only.
curved, outboard Use shims to make surface flat.
may come loose.
Use bolts, nuts, and washers

supplied with outboard. They are
usually special, and will not rust or
weaken.
If owner tells you “I hit something really hard...”
Check for a high speed blow to the lower unit. OR...
“I was backing up and I think the

outboard may have hit a tree or
something.”
Check for a slow, heavy squash to
the outboard.
• Look for damaged parts and
loosened nuts and bolts in both the
steering and mounting systems.
Replace damaged parts.
S–12
SAFETY
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety

• Shock absorption system must always be ready to absorb

some blows to the lower parts of the outboard.
• Outboard must not trim in too far suddenly.
What can happen?

Without shock protection, a blow like this could cause serious damage to the outboard and injury to boat
occupants from the outboard or its parts entering the boat. Transom could break away and outboard may
be lost overboard.
Boat may SINK.
At high speeds, sudden trimming

in too far may dive boat under
water or spin it around.
How can possible conditions be minimized?
• Read, understand, and Make sure manual

follow manufacturer’s release valve is
instructions. closed tight. Torque
• Follow warnings marked “ ” to 45 to 55 in. lbs.
closely. (5.1 to 6.2 N·m).
• Test your work whenever
possible. If left open, outboard
• If oil leaks are seen in service has no shock
areas, determine source. protection.
Keep reservoir filled.
• If outboard is hydraulic tilt/ Trimming “in” too far can
trim model, always return rod happen when angle adjusting
to hole position determined rod is not in the right hole or
by boat operator and make is not in any hole (lost).
sure angle adjusting rod
retain is in locked position.
S–13
SAFETY
Outboard Emergency Stop System and Safety
The emergency system

begins here at the clip
and lanyard...
...and ends here in the ignition

system on the powerhead.
• The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled
from the emergency stop / key switch.
What could happen?
If switch fails...
...engine will keep

running when clip
is pulled from the
switch
If lanyard is caught...
...engine will keep running.
S–14
SAFETY
What could happen?
If lanyard is cut or frayed...
...lanyard or clip may break when pulled...
If engine does NOT stop when lanyard

is pulled, an operator thrown from the
boat could be hit as boat circles area.
Or, boat may not turn but leave area
as a runaway. Operator may drown
and boat WILL run into something.
How can failure of the emergency stop system be minimized?

When • Assemble parts carefully.
rigging • Inspect lanyard for cuts or fraying; clip for wear. Replace with original parts. Do not
or after substitute.
servicing • Locate control box and other items in area to keep lanyard from being caught.
• ALWAYS TEST EMERGENCY STOP SYSTEM. PULL LANYARD. ENGINE MUST
STOP. IF IT DOES NOT, REPAIR BEFORE NEXT USE.
S–15
SAFETY
Summing up
Now you know some things that can take the joy out of boating.
No doubt about it—proper safety takes time!

• Reading and understanding instructions
• Re-reading warnings marked “ ”
• Putting parts together correctly
• Making correct adjustments
• Testing your work
And making sure

• Worn or damaged parts are replaced
• Replaced parts are like originals in every way
• Customer is told of things which need attention
But, do you really want the alternative?
S–16
SAFETY
MARINE PRODUCTS AND THE SAFETY OF PEOPLE

WHO FIX THEM
The first part of this Safety section talked about safe boating and how you, the technician, can help keep
it safe for the boater. But what about you? Technicians can be hurt while:
• Rigging boats
• Troubleshooting problems
• Fixing components
• Testing their work
Some of these safety issues you will know, others you may not.
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...
...use only the special

hardened screws and
washers from the set.
Regular screws are not
strong enough. Screws
may break and outboard
Outboard can 300 lbs. may drop suddenly.
drop suddenly if (136.1 kg)
hoist or engine
stand are in poor
shape, or too
small for the job.
V6
455 lbs.
(206.4 kg)
• Make sure shop aids have extra capacity, and keep them in good repair.
S–17
SAFETY
Running outboard with engine cover removed

Engine cover is a guard. When you remove cover/guard to work on the outboard,
remember: loose clothing (open shirt sleeves, neckties), hair, jewelry (rings,
watches, bracelets), hands and arms can be caught by the spinning flywheel.
Handling high voltage

parts like spark plugs
and coils can shock
you and may cause you
to recoil into the
rotating flywheel.
• 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?
NO SPARK NO START NO SURPRISES
S–18
SAFETY
Running outboard too fast (Overspeeding)

• “Too fast” means running faster than outboard normally runs on boat.
Running too fast can happen when:

1) Using a flushing device...
Turn on water before starting outboard.
Keep eng ine speed below 200 0 RPM.
With no load, outboard will run too fa st
very easily. Wear eye protectors.
2) Running with the

wrong test wheel...
Use the right
This may happen if test wheel.
outboard runs too fast.
Running outboards: Exhaust fumes
A DANGER
DO NOT run the e ngine indoors or witho ut adequate ventilation or permit e xhaust fumes to
accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled,
can cause serious brain damage or death.
• Whenever running the engine, assure there is proper ventilation to avoid the accumulation of carbo n
monoxide (CO), which is odo rless, colorless, and tasteless, and ca n lead to unconsciousness, brain
damage, or de ath if inh aled in suf ficient conc entrations. CO accumula tion can occur while do cked,
anchored, or underway, and in many confined areas such as the boat cab in, cockpit, swim platform,
and heads. It can b e worsened or caused by weat her, mooring and operating conditions, and other
boats. Avoid exh aust fumes fro m th e engine o r other boats, provide p roper ventilation, shut off th e
engine when not needed, and be aware of the risk of backdrafting and conditions that create CO accu-
mulation. In hig h concentrations, CO can be fat al within minutes. Lower con centrations are just as
lethal over long periods of time.
S–19
SAFETY
Running outboards: Propellers
A DANGER
Contact with a rotating propeller is lik ely t o result in s erious in jury or de ath. Ass ure the
engine and prop area is clear of people and objects before starting engine or operating boat.
Do not allow anyon e near a propeller, even when th e engine is off. Blades can be s harp and
the propeller can continue to turn even af ter the engine is off. Always shut off the engine
when near people in the water.
Eye protection
Eyes need protection when:
• Grinding • Spraying cleaners

and paints
• 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
Handling Lead/Acid Batteries
If spilled or
Strong acid solution splashed on any
(sulfuric acid) part of body...
If solution gets into eyes, wash

and contact a doctor immediately.
Wash with
lots of water.
Charging lead acid batteries

1) Attach and remove these cables with
charger UNPLUGGED from 110 V wall
socket. (This prevents shocks if charger
is defective.)
2) Observe correct polarity when
connecting these larger leads.
3) Always charge in a well ventilated
area. Charging causes acid solution to
give off hydrogen gas through the vents
in the caps. Make sure vents are open.
If clogged, pressure inside may build.
Battery may EXPLODE.
Battery gas is explosive!

While charging or discharging, Never remove charger cables
remember: from battery posts. It is a sure
• No smoking way to make a lot of sparks in an
• No flames area surrounded by battery gas.
• No sparks
After charging:
DO NOT check battery charge by • Shut off charger
placing metal objects across • Pull char ger plug out of 1 10 V
posts. You will make sparks and outlet
serious burns are possible. • Take charger cables off battery
posts
S–21
SAFETY
Gasoline – Handle With Care!

Gasoline vapor and air mixtures
explode easily and violently when 1 Part Gasoline
mixed as shown...
20
Parts By
Air Volume
When you smell ANY odor of gasoline,

explosion is possible. Gas
Fumes
If the air around you is

calm, the pilot light in
Gasoline fumes are heavy and will sink the heater could ignite
to the lowest point in the boat or room the heavy fumes before
and will STAY there, WAITING... your nose ever smells
the fumes.
What can you do?
Store gasoline in sturdy, approved,

sealed gas can and keep outside.
• 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
How many of these are in your repair area?
S–22
SAFETY
Hazardous Products
Know how items in

the shop can hurt
people...
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”
It’s all on the back of the can or bottle label.
And remember: Little children are very curious and will try to taste
everything so keep containers away from children!
S–23
SAFETY
Safety Awareness Test

The Technician’s Safety Awareness Test....
1) Did you read this Safety section from page S–1 to page S–24?
2) Are you ready to t ake resp onsibility for the safe mainte nance practices and proce-
dures of your repair shop, co-workers, and technicians?
3) Do you understand all the safety precautions and instructions contained in this entire
service manual?
4) Will you follow all safety warnings, precau tions, instructions and recommendations
outlined in this service manual?
5) Do you understand that the service manual as a whole and this Safety section, in par-
ticular, contain essential information to help prevent personal injury and damage to
equipment and your customers?
6) Have you received training related to commo n shop safety practices to protect your-
self and others around you?
7) When replacement p arts are required, will you use Evinrude ®/Johnson ® Genuine
Parts or parts with equivalent characteristics, including type, strength and material?
8) Are you ready to follow the rec ommendations in this service m anual before you s er-
vice any boat or outboard?
9) Do you underst and that safety -related a ccidents can be caused by carelessness,
fatigue, overload, preoccupation, unfamiliarity of operator with the product, drugs and
alcohol, just to name a few?
S–24
INDEX
INDEX
A Procedure 67
Abbreviations 6
Accessories C
I-Command Water Pressure Transducer Cable, Hose, and Wire Routing 18
Kit, P/N 5008300 24 Capacitor Test 84
XD100 Outboard Oil Decal, P/N 352369 Connecting Rods
169 Installation on Crankshaft 235, 233
Adapter Housing 186 Orientation 233, 236
Service 266 Removal from Crankshaft 223
Adjustments TIghtening 236
Control Cable 20 Control Cable
Shift Rod 295 Adjustments 20
Tilt Limit Switch 28, 112, 68, 113, 29, 30 Installation 19
Air Silencer Cooling System
Description 41 Components 186, 187
Removal 219 EMM and Vapor Separator Cooling 189,
Air Temperature Sensor 186
Connections 91 Flushing 34
Description 58 Hose Routing and Water Flow 184, 185
Resistance Test 95 Operating Temperatures 33, 188
Alternator Circuit Test 98 Pressure Relief Valve 187, 193
AMP Connector Servicing 123 Running on a hose 35
Anodes Thermostats 187, 192
Anti-Corrosion 43 Vapor Separator 136
Continuity Check 43 Water Intake Screens 33, 312, 329
Propeller Shaft Bearing Housing 308, 326 Corrosion
Stern Bracket 276, 279 Anodes 276, 279, 308, 326
Cylinder walls 227
B Long Term Storage 44
Barometric Pressure Sensor 57 Steering Cable 36
Batteries Corrosion Protection 43
Charging System Tests 97, 25 Counter Rotation Gearcase Service 319
Maintenance 25 Cover Service 50
Requirements 11, 13 Crankcase
Storage 45 Assembly 238
Bearing Disassembly 222
Connecting Rod 235, 230, 231 Crankshaft
Pinion Gear 302, 303 Assembly 230
Break-In Bearings 230
EMM Programming 169, 243 Disassembly 224
Gearcase 291, 318, 330 Inspection 228, 235
Oiling 169 Crankshaft Position Sensor
I–1
INDEX
Description 60 AMP Connectors 123

Operation Test 81 Deutsch Connectors 122
Resistance Test 94 Packard Connectors 125
Cylinder Bore Electrical Harness
Honing 227 Connections 21, 22, 23
Inspection 229 Pin Locations 91
Cylinder Head Emergency Stop Switch
Inspection 228, 234 Operation Check 32
Removal 223 Test 104
Emissions Information 7
D EMM
Deutsch Connector Servicing 122 12 V Circuit Sensor 56
Diagnostic Procedures Connections 54, 55
Dynamic Tests 77 Diagnostics 64, 74, 78
Fuel Delivery Tests 85 Fuel Injector Servicing 68, 54, 61
Ignition Tests 80 LED Indicators 78
LED Indicators 78 Pin Locations 91
Strategy 74 Reports 69
Diagnostic Software Sensors 56, 58, 65, 70, 69
Break-In Programming 67, 169 Timing Verification 113, 68, 70
Communication with Outboard 64, 81, 77 Engine Monitor
Diagnostic Procedures Overview 74 Description 62
Fuel Injector Programming 68, 147, 85 Low Oil Warning 177
I-Command settings 23 No Oil Warning 166
Oil Injector Test 173, 174, 67, 170 Operation Check 32
Reports 69 Engine Temperature Check 186
Sensor Monitoring 94, 82 Engine Temperature Sensor
Timing Verification 68, 113, 68, 113 Description 58
Driveshaft Resistance Test 95
Installation 313 Exhaust Housing
Removal 298, 320 Assembly 271, 273
Service 300, 310, 299 Cleaning and Inspection 270
Driveshaft Bearing Housing Disassembly 268, 269
Seal Removal 307 Installation 267
Dual-Outboard Removal 266
Alignment 31 Exhaust Pressure Fitting 42
I-Command settings 23 Exterior Finish Protection 43
E F
Electrical Circuits Flushing, Cooling System 34
EMM Pin Locations 91 Flywheel
Fuse 93 Installation 110
Ground Circuits 93 Removal 109
Key Switch 101 Servicing 109
Start Circuit 99, 105, 106 Forward Gear, Counter Rotation
Electrical Connectors 122 Assembly 325
I–2
INDEX
Fuel Filter Water Pressure Gauge 24

Installation 144 I-Command Network
Removal 144 Outboard connections 22
Fuel Injectors ICON Component Servicing
Crush Ring Replacement 148 Electronic Servo Module (ESM) 199
EMM Programming 68, 147, 149 Shift Actuator 202
Installation 149 Throttle Actuator 204
Removal 147 ICON Network
Tests 140, 141 Outboard connections 23
Fuel System ICON Remote Control System
Additives 134 Components 197
Components 135 Electronic Servo Module (ESM) 197
Filter 135, 144, 136, 41, 144, 135, 142, 145, Shift Actuator 197
146, 134 Throttle Actuator 198
Hose Routing 131 ICON System Faults 210
Injector Servicing 147, 151 ICON System Failsafe Mode 198, 212
Minimum Octane 134 Non-recoverable Faults 211
Pressure Tests 139, 138 Recoverable Faults 210
Relieving Pressure 143, 133 ICON System Settings
Troubleshooting 139 Calibrate Actuator Stroke 207
Vapor Separator 135, 146 Set Engine Identity (Instance) 207
Fuse 93 Shift Actuator Stroke 208
Throttle Actuator Stroke 207
G Idle Controller 61
Gauges Ignition
Tachometer 33, 346 Electrical Circuits 90
Gearcase Ignition Coil Servicing 111, 84
Assembly 312, 329 Primary Circuit Resistance Test 84
Counter Rotation Service 319 Required Systems 80, 83
Disassembly 296 Static IgnitionTest 82
Housing Identification 285 Timing 68
Inspection 296, 290 Intake Manifold
Leak Test Procedure 288, 37, 288 Assembly 152
Removal 289 Disassembly 151
Grommet 18, 19 Inspection 151, 152
Removal 151
H
Honing 227 K
Hoses Key Switch
Inspection 41 Circuit Tests 103
Oil Distribution 178, 167 Operation Check 32
Routing, Cooling System 184, 185, 131 Start Circuit 101
Knock Sensor 61, 95
I
I-Command L
System settings 23 LED Indicators 78
I–3
INDEX
Lower Cover Removal 180

Installation 51 Oil Tank 164
Removal 51 Oiling Rate 67, 168
Lubrication Oiling System
Engine Oil 164 Components 164
Gearcase 37, 288 Electrical Circuits 157, 164
Propeller Shaft 37 New Engine Set-Up 164
Swivel Bracket 36 Oil Distribution Hose Replacement 178, 41,
Throttle and Shift Linkage 36, 39 59, 162, 167, 158, 159, 161, 67
Priming 170
M Servicing 178
Maintenance and Inspection Schedule 16 Tests 173
Manual Release Valve, Trim and Tilt
Operation 338, 339 P
Midsection Packard Connector Servicing 125
Stern Bracket Servicing 275 Pinion Gear
Tilt Tube Servicing 264 Bearing Installation 303, 302
Models Installation 313
Included Models 9 Removal 298
Model Designation 8 Piston Rings
Serial Number Location 8 End Gap 234
Motor Mounts Inspection 229, 234
Lower Mount Servicing 266, 267, 273 Removal 224
Upper Mount Servicing 268, 270, 272, 274 Pistons
Assembly 233
N Inspection 229, 234
Neutral Start Switch Removal 223
Tests 103 Powerhead
Neutral Switch 60 Assembly 230
New Engines Cleaning 227, 218
Outboard Rigging Procedure 17 Disassembly 221
Inspection 228, 241
O Removal 219
Oetiker Clamp Servicing 26 Views 244
Oil Injector Predelivery Checks 32
Description 165 Pre-Season Service 46
Electrical Circuit (40 V) 165, 173 Pressure Relief Valve, Cooling System 193
Functional Test 177 Priming
Installation 179, 181 Fuel System 138
Removal 179, 180 Oiling System 170
Oil Pressure Sensor Propeller
Description 165 Inspection 286, 287
Oil Pump, Rear 166 Selection 286
Description 166 Propeller Shaft
Electrical Circuit 166, 175 Installation 312, 329
Installation 180 Lubrication 37
I–4
INDEX
Removal 300 Assembly 305, 322

Propeller Shaft Bearing Housing Installation 312, 329
Bearing Installation 309, 308 Removal 300
Installation 315 Shift Housing, Counter Rotation
Rear Seal Installation 310, 308 Disassembly 321
Propeller Shaft Bearing Housing, Counter Removal 320
Rotation Shift Interrupt Switch 60
Assembly 325 Shift Linkage
Installation 329 Installation 239
Propeller Shaft, Counter Rotation Lubrication 36
Removal 320 Removal 221
Shift Rod
R Adjustment 295
Relays Housing Installation 312
Trim and Tilt 105 Shimming, Driveshaft 310, 327
Remote Controls Spark Plugs
Cable Adjustment 20, 19 Gap 40
Rigging Indexing 40
Outboard 17 Maintenance Schedule 16
RPM Limit 59, 61 Recommendation 40
Service 40
S Specifications 10
S.A.F.E. Starter
Description 63 Circuit Description 99, 102
Oil Pressure 59 Installation 121
Temperature 56, 58 Servicing 115, 101
Voltage 56 Voltage Drop Test 102
Sensors 94 Start-In-Gear Protection 32, 103
Air Temperature Sensor 58, 95 Stator
Barometric Pressure Sensor 57 Resistance Test 96
Crankshaft Position Sensor 60, 81, 94 Servicing 109
EMM 56, 58, 95, 192, 42, 57 Voltage Output Test 96
Knock sensor 61, 95 Steering System
Oil Pressure 59, 165 Lubrication 36
Tests 94, 59, 94, 113 Steering Arm and Shaft 275, 278, 30
Service Charts Stern Bracket
Electrical and Ignition 88 Assembly 277
Fuel System 128 Disassembly 275
Gearcase 282 Stop Circuit 104
ICON Remote Control System 196 Storage 44
Midsection 260 Submerged Engines 46
Oiling System 156 Switches
Powerhead 216 Key Switch 103
Trim and Tilt 332 Swivel Bracket
Shift Actuator Removal 202 Installation 279
Shift Housing Lubrication 36
I–5
INDEX
Removal 276 Lubrication 36

SystemCheck Removal 264
Circuits 105, 106 Timing Adjustments
Oil System Warnings 166, 21 Timing Pointer 112, 113
Tests 106, 107, 108 Tools
Winterization Procedure 44 Alignment Pins, P/N 354140 317, 330
Backing Plate, P/N 325867299, 151, 309, 69
T Collar, P/N 341440 311, 327, 122, 230, 123,
Tachometer 122
Pulse Setting 33 Diagnostic Interface Cable, P/N 43795564,
Test 108 298, 314, 299, 310, 311, 314, 327, 328,
Taper Pin Tool 218 310, 327
Temperature Electrical Test Probe Kit, P/N 342677 98
Operating 33, 189, 164 Flywheel Holder, P/N 771311 109, 141, 139
Sensors 58 Gauge and Collar Assembly, P/N 983975
Temperature Sender 342, 301, 290, 38, 315, 317, 330, 288,
Service 192 232
Temperature Sensor Hydraulic Cylinder Rod Holder, P/N
Description 56 983213 356, 357
Thermostat Injector Test Fitting Kit, P/N 5005844 140,
Assembly 192 315, 317, 330
Description 187, 192 Large Puller Jaws, P/N 432129 225, 307,
Inspection 192 308, 220, 241, 299
Temperature 11, 13 Oetiker Pincers, P/N 787145 27
Throttle Actuator Removal 204 Pinion Bearing Remover and Installer, P/N
Throttle Linkage 5005927 302, 303, 298, 314, 112, 176,
Installation 240 123, 317, 330, 315, 297, 319, 307, 308
Lubrication 36 Rod Cap Alignment Fixture, P/N 396749
Removal 221 236
Throttle Position Sensor Seal Installation Tool, P/N 325453232, 307,
Calibration 113 310, 123, 311, 327, 148, 231, 299, 225,
Description 59 265, 308, 324, 326, 96, 177
Resistance Test 94 Taper Pin Tool 218, 190, 124, 10, 12, 190,
Tilt Limit Switch 352, 359, 354, 264, 223, 237, 355, 358,
Adjustment 28 342, 341
Cam Installation 264, 265 Universal Puller Set, P/N 378103 109, 295,
Tilt Piston 352, 355, 358, 359
Assembly 353 Wrench Retainer, P/N 341438 298, 314,
Identification 353 233, 224, 233
Removal 352 Torque Charts
Tilt Rod see Service Charts
Assembly 354 TPS Calibration 68, 113
Installation 359 Trailering Bracket
Tilt Support 333 Lubrication 36
Tilt Tube Operation 333
Installation 265 Trim and Tilt
I–6
INDEX
Circuits 105 W
Disassembly 349 Water Intake Screens 33
Electrical Circuit Tests 105 Inspection 33, 312, 329
Inspection 340, 348 Removal 301, 320
Lubrication 39 Water Pressure Gauge 24
Manifold and Reservoir Installation 357, 338 Water Pump
Pressure Leakdown Test 341 Assembly 292
Removal 347, 340 Description 186, 292
Troubleshooting 340 Inspection 292
Trim and Tilt Motor Water Supply Tube 186
Current Draw Tests 344 Winterizing 44
Installation 359 Wiring Harness Connections 22
No Load Test 345 Wrist Pin
Trim Gauge Test 346 Installation 233
Trim Rods Removal 224
Assembly 356
Installation 358
Removal 355
Trim Sender
Adjustment 29
Test 346
Trim Tab
Adjustment 30
Installation 291
Removal 289
Troubleshooting
Charging System Tests 97, 77
Diagnostic Procedures 74
Fuel Control Adjustment 77, 139
Ignition 80, 83, 77
Oiling System 173, 5, 3, 4, 5, 6, 1, 4
Strategy 76
Timing Light Test 77, 340, 346, 1
U
Upper Mount
Installation 272, 274
Removal 268, 270
V
Vapor Separator
Description 135
Installation 146
Removal 146
Voltage Drop Test 102
I–7
INDEX
I–8
TROUBLE CHECK CHART
OUTBOARD WILL NOT START
TROUBLE CHECK CHART

OBSERVATION POSSIBLE CAUSE PROCEDURE
Battery switch not ON Check battery switch operation
Discharged battery Check battery, recharge or replace
Clean and tighten connections. Check for voltage
Battery cables and connections
drop in starter circuit.
Faulty connection or ground,
Check all grounds, connections and wiring
Outboard does not damaged electrical harness
turn over Fuse (10 A) Check wiring, then replace faulty fuse
Wiring harness Check for 12 V at terminal “B” of key switch
Key switch Check key switch operation
Starter solenoid Check wiring and test solenoid
Starter or bendix/drive gears Check starter, inspect bendix/drive gears
Seized powerhead or gearcase Check and repair as needed
Discharged battery Check battery, recharge or replace
Clean and tighten connections. Check voltage
drop in starter circuit.
Outboard turns slowly Powerhead hydro-locked Check cylinders for water
Partially seized powerhead or
Check and repair as needed
gearcase
T–1
TROUBLE CHECK CHART

Check wiring and emergency stop switch. Check
Stop circuit grounded the safety lanyard is installed and stop circuit is
not grounded.
No Fuel Check for fuel in fuel tank
Check fuel filter, sample fuel from fuel return
Water in fuel
manifold.
Contaminated or poor fuel
Check or replace fuel supply
quality
Check primer, anti-siphon valve, and fuel pick-up.
Fuel supply restricted
Use primer to fill vapor separator with fuel.
Check for air in fuel supply manifold, refer to
Air in fuel system FUEL SYSTEM (vapor separator venting and fuel
supply)
Low or no fuel pressure to Check fuel manifold pressure, refer to FUEL
injectors SYSTEM
Incorrect, fouled, or worn spark
Replace spark plugs
plugs
Fuel injectors not working Check voltage at injectors
Check for leaking injectors, leaking fuel or oil lift
Excessive fuel or oil, engine
Outboard turns over pump, or leaking vapor separator vent, refer to
flooded
SYSTEM ANALYSIS
Low or no 55 V alternator Check voltage on 55 V circuit, refer to SYSTEM
output ANALYSIS and ELECTRICAL AND IGNITION
Check capacitor and 55 V circuits, refer to
Capacitor or 55 V circuit wiring SYSTEM ANALYSIS and ELECTRICAL AND
IGNITION
Check ignition, refer to SYSTEM ANALYSIS and
Ignition
CPS input to EMM, no sync Check RPM reading while cranking
No ignition system primary
Check cranking RPM (300 minimum), refer to
voltage output from EMM to
SYSTEM ANALYSIS
ignition coils
Low or no compression Check compression
Water in engine Check condition of spark plugs and cylinders
Internal powerhead damage Check and repair as needed
Leaking cylinder/crankcase,
intake manifold, or reed valves
EMM program, timing, or Check EMM program and timing; check injector
operation information (by location and serial number)
T–2
TROUBLE CHECK CHART
OUTBOARD HARD TO START
OUTBOARD HARD TO START

Weak battery Check battery, recharge or replace
Clean and tighten connections, check voltage
drop on high amperage circuit
Check water separator/fuel filter, sample fuel from
Water in fuel system
fuel return manifold test port
quality
supply)
Replace spark plugs
plugs
Low fuel pressure Check pressure, refer to FUEL SYSTEM
Check primer bulb, anti-siphon valve, and fuel
pick-up, check for fuel system air leaks
Low or no alternator output Check voltage on 55 V circuit, refer to SYSTEM
Outboard eventually
(55 V) ANALYSIS and ELECTRICAL AND IGNITION
starts, may or may not
run properly once Check capacitor and 55 V circuit (white/red), refer
started Capacitor or 55 V circuit wiring to SYSTEM ANALYSIS and ELECTRICAL AND
IGNITION
Restricted or leaking fuel
Check injectors, refer to FUEL SYSTEM
injector(s)
Weak or erratic ignition Check ignition, refer to SYSTEM ANALYSIS and
operation ELECTRICAL AND IGNITION
Crankshaft Position Sensor
Check CPS air gap and EMM LED indicators
(CPS)
Check for leaking injectors, leaking fuel or oil lift
Excessive fuel or oil, engine
pump, or leaking vapor separator vent. Refer to
flooding
SYSTEM ANALYSIS.
Check EMM program and timing; check injector
EMM program, timing, or
coefficients; and monitor injector circuits and
operation
ignition primary outputs
Low compression Check compression
Leaking cylinder/crankcase,
intake manifold, or reed valves
T–3
TROUBLE CHECK CHART
OUTBOARD WILL NOT SHUT OFF
OUTBOARD WILL NOT SHUT OFF

Check key switch and ground to key switch, refer
Key switch or wire harness
to SYSTEM ANALYSIS and ELECTRICAL AND
ground
IGNITION
Outboard starts and
Check EMM LED indicators. Check wire harness
runs, normal Stop circuit wiring
(black/yellow) and key/stop switch(s).
performance while
running Check EMM LED indicators and eliminate stop
circuit as possible cause. Stop wire (black/yellow)
EMM failure
has 4.0 VDC from EMM with key on or outboard
running.
OUTBOARD STARTS AND STALLS

Faulty wiring, connections, or
Check all grounds, connections, and wiring
grounds
Replace spark plugs
plugs
Low or no alternator output Check voltage on 55 V circuits, refer to SYSTEM
(55 V) ANALYSIS and ELECTRICAL AND IGNITION
Check capacitor and 55 V circuit, refer to
Capacitor or 55 V circuit wiring SYSTEM ANALYSIS and ELECTRICAL AND
IGNITION
quality
Low fuel pressure Check pressure, refer to FUEL SYSTEM
Outboard may not run Check for air in fuel supply manifold, refer to
for more than a few Air in fuel system FUEL SYSTEM (vapor separator venting and fuel
seconds supply)
Injector electrical circuit or Check voltage at injectors, refer to SYSTEM
control function ANALYSIS
injector(s)
coefficients; and monitor injector control wires and
operation
Check ignition, refer to SYSTEM ANALYSIS and
Weak or erratic ignition output
T–4
TROUBLE CHECK CHART
OUTBOARD STARTS, LOW MAXIMUM RPM
OUTBOARD STARTS, LOW MAXIMUM RPM

Access EMM service codes and check System-
SystemCheck light Outboard is in S.A.F.E.
Check warning
Refer to specifications, check recommended WOT
Incorrect propeller
Setup or rigging RPM; water test and install correct pitch propeller
change Incorrect outboard mounting
Refer to installation guidelines
height
Throttle plate opening Check throttle plate and WOT opening
Replace spark plugs
plugs
Contaminated or poor quality
fuel
Check voltage on 55 V circuits, refer to SYSTEM
Low alternator output (55 V)
ANALYSIS and ELECTRICAL AND IGNITION
Performance of
outboard at lower
speeds appears
normal Fuel injector electrical circuit or Check voltage at injectors, refer to SYSTEM
control function ANALYSIS
injectors
Check circulation pump operation, refer to FUEL
Low fuel pressure
SYSTEM
EMM programming, timing, or
operation
Restricted engine exhaust Check and repair as needed
EXCESSIVE SMOKING
Contaminated or poor fuel Check or replace fuel supply
Excessive fuel or oil Check fuel system for fuel supply air leaks or
May coincide with consumption leaking fuel injectors
increased oil Outboard in break-in mode Use diagnostic program to confirm
consumption Outboard mounted too low Check installation height of outboard
(normal if occurs after Check vapor separator assembly for proper
winterization) Vapor separator vent
venting/float valve operation
Faulty/leaking fuel injector(s) Check injectors, refer to FUEL SYSTEM
Damaged fuel lift pump Check for internal leaks
T–5
TROUBLE CHECK CHART
OUTBOARD SURGES, RUNS ROUGH
OUTBOARD SURGES, RUNS ROUGH

1200 RPM and above S.A.F.E. Access EMM fault codes
Replace spark plugs
plugs
Check water separator/fuel filter, sample fuel from
Water in fuel system
fuel return manifold test port
Check and replace fuel supply
quality
Low or erratic fuel pressure Check pressure, refer to FUEL SYSTEM
supply)
May be erratic or injector(s)
inconsistent Faulty wiring, connections, Check all grounds, connections, and wiring.
grounds, or CPS air gap Check CPS air gap.
Check voltage on 55 V circuit, refer to SYSTEM
Low alternator output (55 V)
ANALYSIS and ELECTRICAL AND IGNITION
operation
Check capacitor and 55 V circuit (white/red), refer
Capacitor or 55 V circuit wiring to SYSTEM ANALYSIS and ELECTRICAL AND
IGNITION
Restricted engine exhaust Check and repair as needed
Propping Change propeller type or size as needed
Audible noise
Damaged gearcase Inspect gearcase and lubricate
T–6
MWS Instrument Wiring Harness
A A
B B
C C
5 5
1 1
2 2
3 3
6 6
4 4
6 6
4 5
5 4
7 2
1
2 3
3 1
8
1
2
DRC6165R
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
VOLTMETER TRIM/TILT WATER PRES. FUEL

FUEL
TANK
SENDER
WARNING
HORN
DRC6278R
Evinrude E-TEC
EMM LED Diagnostic Indicators
In-line Models V Models
1 Charging / 55V Circuit 1

1
2
2
1
2
3
CPS OK - Injection/Ignition/Fault 2 3
4
4
3 Sensors / 5V Circuits
3
Stop Circuit - No Oil/Overheat
4 4
For more information, refer to SYSTEM ANALYSIS in the Service Manual.
KEY ON : LED’s illuminate to indicate circuit function
1 Start assist circuit (SAC) OK (V models only) 1

2 Sensors / 5V Circuits OK 2
3 FLASHING LED – URGENT conditon – Code 57 3
4 Engine will not start – Correct problem and clear codes 4
Stop circuit OK
FLASHING LED – URGENT overheat or no oil condition
Engine will not start – Correct problem and clear codes
Note: No LED’s ON indicates EMM not receiving battery voltage
or Recoil Start model.
STARTING : LED’s illuminate to indicate circuit function
1 Indicates 30V (or higher) on 55V circuit

2 Indicates CPS working and EMM SYNC
3 Sensor circuits working
4 Stop circuit OK
RUNNING : LED’s illuminate to indicate circuit fault
1
2 Exception: ALL LED’s ON / FLASHING indicates
3 Winterization Mode
4
FUSE
1 3
ABC
3.3 L V6 / 200-250HP E-TEC 7 9 10
5
4
B A
1 2
B A
4
2
5
3
C A B
123
6
12345
8
12345
16
A B
+
2 1
1 2
11 12 13
1 2 3 4
20 21 22 23
17
14 15
J2
5 6 7 8 9 10
24 25 26 27 28 29
15
16 17
12 18
13
18 19
321
11
26 27 28 29 30 31 32 33 34
1 2 3 4 5 6 7 8 9
18 19 20 21 22 23 24 25
10 11 12 13 14 15 16 17
12 3 4
14
4
1. Oil Injector
3
J1-A
5
2
2. Electric Starter
6
1
3. Air Temperature Sensor 19
4. Throttle Position Sensor
20 21 22 23 24 25 26
1 2 3 4 5 6 7
14 15 16 17 18 19
8 9 10 11 12 13
5. Crankshaft Position Sensor
1
J1-B
6
6. Stator
2
5
3
7. Diagnostic Connector
4
20
8. Main Harness Ground
9. Capacitor
10. Fuse (10 Amp)
CBA
11. Water-in-Fuel Sensor 21
12. High Pressure Fuel Pump
13. Water Pressure Sensor (CANbus)
22
14. CANbus Connector
15. EMM
3 2 1
16. Starter Solenoid
17. Accessory Charge Connector
23
18. Trim/Tilt Relay Module
19. Key Switch
2 1
1 2
20. SystemCheck Connector

25
21. Trim/Tilt Connector
12
2
2 26 1
25
22. Trim/Tilt Switch 27 27 26 1
23. Shift Switch
1 2
321
321
24. Temperature Sensor (2)

1 2
12
25. Knock Sensor A B
4
4 3
A B
26. Fuel Injector (6) 3

27. Ignition Coil (6) 24 24
321
321
28. Low Oil Switch

B A
12
2 1
12
6 5 C B A
29. Trim Sending Unit

1 2
6
30. Tilt Limit Switch 5
31. Trim/Tilt Motor
321
28 29 30 31
321
008332
FUSE
1 3
ABC
3.4 L V6 / 250-300HP E-TEC 7 9 10
5
4
B A
1 2
B A
4
2
5
3
C A B
123
6
12345
8
12345
17
A B
+
2 1
1 2
11 12 13
1 2 3 4
20 21 22 23
18
14 15
J2
5 6 7 8 9 10
24 25 26 27 28 29
16
16 17
12 19
13
18 19
321
11
26 27 28 29 30 31 32 33 34
1 2 3 4 5 6 7 8 9
18 19 20 21 22 23 24 25
10 11 12 13 14 15 16 17
12 3 4
14
1. Oil Injector
4
3
J1-A
5
2. Electric Starter
2
6
1
3. Air Temperature Sensor 15 20
A B
4. Throttle Position Sensor
20 21 22 23 24 25 26
1 2 3 4 5 6 7
14 15 16 17 18 19
8 9 10 11 12 13
5. Crankshaft Position Sensor
1
J1-B
6
6. Stator
2
5
3
7. Diagnostic Connector
4
21
8. Main Harness Ground
9. Capacitor
10. Fuse (10 Amp)
CBA
11. Water-in-Fuel Sensor 22
12. High Pressure Fuel Pump
13. Water Pressure Sensor (CANbus)
14. CANbus Connector 23
15. Rear Oil Pump
3 2 1
16. EMM
17. Starter Solenoid
18. Accessory Charge Connector 24
19. Trim/Tilt Relay Module
2 1
20. Key Switch
1 2
21. SystemCheck Connector 26
12
2
2 27 1
26
22. Trim/Tilt Connector 28 28 27 1
23. Trim/Tilt Switch
1 2
24. Shift Switch
321
321
1 2
12
25. Temperature Sensor (2) A B 4 3
4 A B
26. Knock Sensor 3

27. Fuel Injector (6)
25 25
321
28. Ignition Coil (6)

321
B A
12
2 1
12
29. Low Oil Switch 6 5 C B A 1 2
30. Trim Sending Unit 6 5

31. Tilt Limit Switch
321
29 30 31 32
321
32. Trim/Tilt Motor 008331

EVINRUDE 115 – 300 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
Code number indicates affected cylinder. 20 knock events in 100 combustion cycles with maximum correction applied.
1-6 Excessive knock detected 3 - CHECK ENGINE Immediate Make sure sensor is securely fastened to the cylinder head.
Check timing adjustments. Test fuel and cooling systems. Check fuel quality.
7-8 Knock Sensor circuit OPEN – Port/Stbd LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 5 seconds Sensor output < 0.15 V and RPM > 3000. Check sensor connection.
TPS Voltage > 0.65 V with key ON (or cranking). Becomes stored fault when outboard starts.
Throttle Position Sensor
11 - - 2 seconds When both hard and stored faults are present, check for improperly adjusted throttle cable.
(TPS) out of idle range
If voltage is > .78 V, engine speed is limited to idle.
Throttle Position Sensor TPS Voltage: < 0.14 V, or > 4.92 V. Engine limited to idle speed.
12 LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 2 seconds
(TPS) circuit fault Check sensor resistance—3000 Ω (between pins A and B) & 4000 Ω (between pins A and C)
13 TPS below range LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 10 seconds TPS Voltage < 0.2 V. Check linkage and IDLE stop.
14 TPS above range LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 10 seconds TPS Voltage > 4.85 V. Check linkage and WOT stop.
15 ROM (EMM program) 3 - - 15 seconds ROM “CHECKSUM” failure. Check software program number in EMM. Reload or replace with proper program.
Crankshaft Position Sensor (CPS) LED 2: OFF (Cranking) 5 losses, rpm<2000 EMM counts losses of synchronization with crankshaft sensor. Check CPS mounting and resistance. Air gap range: 00.036 to
16 -
Intermittent loss of SYNC LED 3: ON (Running) 1 loss, rpm >2000 0.110 in. (1 to 2.8 mm), nominal 0.073 in. (1.85 mm) Resistance: 560 Ω ± 10% @ 77°F (25°C)
1 min: V4–3.3L V6 55 V alternator output < 45 V at 500 to 1000 RPM, or < 52 V above 1000 RPM.
17 55 V circuit BELOW range 3 3 LED 1: ON (Running) CHECK ENGINE
10 sec: 3.4L V6 Engine limited to 1200 RPM. Perform stator/charging tests.
System Voltage > 57 V. Engine limited to 1200 RPM. Perform stator/charging tests.
18 55 V circuit ABOVE range 3 3 LED 1: ON (Running) CHECK ENGINE 1 minute
Check for loose connections in 55 V circuit. Check capacitor.
19 Start-in-gear LED 3: OFF (Cranking) CHECK ENGINE - Attempted engine start while in gear (EMM in tiller mode). Engine will not start.
21 Winterization activated All LEDs FLASHING All LEDs FLASHING - Engine is speed limited, and stops after 360 oil pulses. Refer to Maintenance or Operator’s Guide.
23 EMM Temperature Sensor circuit fault 3 LED 3: OFF (Cranking) / ON (Running) - 10 seconds EMM Temperature < -67° F (-55° C), or > 311° F (155° C).
24 EMM Temperature BELOW range 3 LED 3: OFF (Cranking) / ON (Running) - 10 seconds EMM Temperature < -22 ° F (-30° C).
25 EMM Temperature ABOVE range 3 3 LED 4: ON (Running) WATER TEMP/HOT 10 seconds EMM Temperature > 176°F (80°C). Engine limited to 1200 RPM. See Code 29.
26 12 V circuit BELOW range 3 LED 1: ON (Running) LOW BATTERY 5 minutes Battery voltage <12 V below 2000 RPM or < 12.5 V above 2000 RPM. Perform stator/charging tests.
27 12 V circuit ABOVE range 3 LED 1: ON (Running) LOW BATTERY 5 minutes Battery voltage > 15.5 V. Check battery connections and wiring.
Check shift switch linkage and switch activation. Check continuity of switch: normally open / continuity depressed.
28 Shift switch malfunction LED 3: ON (Running) - 10 seconds
90°V6 models only.
WATER TEMP/HOT EMM Temperature > 212° F (100° C). Engine SHUTDOWN. Will NOT restart until EMM temperature
29 EMM Temperature OVER range 3 3 LED 4: FLASHING 5 seconds
(FLASHING) returns to operating range. Check outboard and EMM cooling systems.
WATER TEMP/HOT Engine Temperature > 248° F (120° C). Engine SHUTDOWN. Check cooling system.
31 Engine temperature OVER range 3 LED 4: FLASHING 3 seconds
(FLASHING) Check temperature sensor resistance—9000 to 11000 Ω @ 77°F (25°C).
33 Critical NO OIL detected 3 3 LED 4: FLASHING NO OIL (FLASHING) 5 hours Outboard has run five hours with code 34 or 38. Engine SHUTDOWN. Will restart and run for 1 minute intervals.
34 Oil injection pump circuit OPEN 3 LED 4: ON (Running) NO OIL 4 seconds Engine limited to 1200 RPM. Check oil injection pump circuit resistance—2-3 Ω.
36 Rear Oil injection pump circuit OPEN (3.4 L) 3 LED 4: ON (Running) NO OIL 4 seconds Engine limited to 1200 RPM. Check oil injection pump circuit resistance—5-6 Ω.
37 Water in fuel LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 10 seconds Check fuel supply, 5 V circuit, and ground (NEG). Resistance between probes should be infinite (no continuity).
60° V4 100 oiler cycles
60° V6 150 oiler cycles Loss of oil manifold pressure. Engine limited to 1200 RPM. Check oil supply.
38 Oil pressure feedback NOT detected 3 LED 4: ON (Running) NO OIL
90° V6 (3.3L) 150 oiler cycles Test injection pump. Monitor oil flow to distribution hoses.
90° V6 (3.4L) 75 oiler cycles
Engine Temperature ABOVE range (port)– 60° V4 & V6 Models: Engine Temperature > 230° F (110° C) below 3000 RPM
40 3 LED 4: ON (Running) WATER TEMP/HOT 3 seconds
low speed 90° V6 Models: Engine Temperature > 230° F (110° C) below 2000 RPM
Engine Temperature Sensor circuit fault Engine Temperature < -13° F (-25° C), or > 329° F (165° C).
41 LED 3: OFF (Cranking) / ON (Running) - 10 seconds
(port) Check 5 V circuit and ground (NEG), and sensor resistance—9000 to 11000 Ω @ 77°F (25°C).
42 Engine Temperature BELOW range (port) LED 3: OFF (Cranking) / ON (Running) - 10 seconds Engine Temperature < -4° F (-20° C). Check engine temperature and sensor resistance.
60° V4 & V6 Models: Engine Temperature > 194°F (90°C) above 3000 RPM activates S.A.F.E.
90° V6 Models: Engine Temperature > 185° F (85° C) above 2000 RPM for 60 seconds activates warning light and horn;
43 Engine Temperature ABOVE range (port) 3 LED 4: ON (Running) WATER TEMP/HOT 3 seconds
90° V6 Models: Engine Temperature > 194°F (90°C) above 2000 RPM for 3 seconds activates S.A.F.E.
Engine limited to 1200 RPM. Check cooling system.
Barometric Pressure (BP) Sensor circuit Pressure < 3.8 in. Hg (13 kPa), or > 35.1 in. Hg (119.0 kPa). Make sure EMM BP sensor tube is NOT plugged.
44 3 - - 10 seconds
fault Check atmospheric condition for comparison. Clear code and retest.
45 BP Sensor BELOW range 3 - - 10 seconds Pressure < 20.7 in. Hg (70 kPa).
46 BP Sensor ABOVE range 3 - - 10 seconds Pressure > 31 in. Hg (105 kPa).
Air temperature < -67° F (-55° C), or > 212° F (100° C).
47 Air Temperature (AT) circuit fault LED 3: OFF (Cranking) / ON (Running) - 10 seconds
Check 5 V circuit and ground (NEG), and sensor resistance—9000 to 11000 Ω @ 77°F (25°C).
48 Air Temperature BELOW range LED 3: OFF (Cranking) / ON (Running) - 10 seconds Air temperature below -22°F (-30°C)
49 Air Temperature ABOVE range LED 3: OFF (Cranking) / ON (Running) - 10 seconds Air temperature above 158°F (70°C)
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
Last digit indicates affected cylinder.

51-6 Fuel injector circuit OPEN LED 2: ON (Running) - 10 seconds
Check injector/circuit resistance—2 to 3 Ω @ 72°F (22°C).
CHECK ENGINE TPS < 5% and RPM > 3000. Engine SHUTDOWN. Will NOT restart until code has been cleared. The problem could be caused
57 High RPM with low TPS setting 3 3 LED 3: FLASHING 10 seconds
(FLASHING) by uncontrolled fuel entering the engine. DO NOT attempt to start the outboard until the problem has been found and repaired.
Engine temperature < 122°F (50°C) with engine speed < 1000 RPM.
58 Operating temperature not reached (port) LED 3: OFF (Cranking) / ON (Running) - 10 minutes
Check thermostat and pressure relief valve.
Engine temperature < 122°F (50°C) with engine speed < 1000 RPM.
59 Operating temperature not reached (stbd) LED 3: OFF (Cranking) / ON (Running) - 10 minutes
Check thermostat and pressure relief valve.
61-6 Fuel injector circuit SHORTED LED 2: ON (Running) - 10 seconds
Check injector/circuit resistance—2 to 3 Ω @ 72°F (22°C).
Engine Temperature Sensor circuit fault Engine Temperature < -13° F (-25° C), or > 329° F (165° C).
67 LED 3: OFF (Cranking) / ON (Running) - 10 seconds
(stbd) Check 5 V circuit and ground (NEG), and sensor resistance—9000 to 11000 Ω @ 77°F (25°C).
68 Engine Temperature BELOW range (stbd) LED 3: OFF (Cranking) / ON (Running) - 10 seconds Engine Temperature < -4° F (-20° C). Check engine temperature and sensor resistance.
60° V4 & V6 Models: Engine Temperature > 194°F (90°C) above 3000 RPM activates S.A.F.E.
90° V6 Models: Engine Temperature > 185° F (85° C) above 2000 RPM for 60 seconds activates warning light and horn;
69 Engine Temperature ABOVE range (stbd) 3 LED 4: ON (Running) WATER TEMP/HOT 3 seconds
90° V6 Models: Engine Temperature > 194°F (90°C) above 2000 RPM for 3 seconds activates S.A.F.E.
Engine limited to 1200 RPM. Check cooling system.
Engine Temperature ABOVE range (stbd)– 60° V4 & V6 Models: Engine Temperature > 230° F (110° C) below 3000 RPM
70 3 LED 4: ON (Running) WATER TEMP/HOT 3 seconds
low speed 90° V6 Models: Engine Temperature > 212° F (100° C) below 2000 RPM
71 Oil pressure sensor circuit fault detected LED 3: OFF (Cranking) / ON (Running) - 10 seconds < 0.15 V , > 4.85 V
72 Oil pressure BELOW expected range LED 3: OFF (Cranking) / ON (Running) - 10 seconds < 0.4 V
73 Oil pressure ABOVE expected range LED 3: OFF (Cranking) / ON (Running) - 10 seconds > 4.6 V
74 Water pressure sensor circuit fault detected LED 3: OFF (Cranking) / ON (Running) - 10 seconds < 0.15 V , > 4.85 V. EMM water pressure option (I-Command) active
75 Water pressure BELOW expected range LED 3: OFF (Cranking) / ON (Running) - 10 seconds < 0.4 V. EMM water pressure option (I-Command) active
76 Water pressure ABOVE expected range LED 3: OFF (Cranking) / ON (Running) - 10 seconds > 4.6 V. EMM water pressure option (I-Command) active
77 S.A.C. overcurrent fault 3 LED 1: OFF (Key On) / ON (Running) - 10 instances SAC current > 2 amps and/or < 20 V. Check for shorted 55 V wiring (injector circuits). Check for pinched or chafed wiring.
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.
79 Starter solenoid circuit OPEN LED 3: OFF (Key On) CHECK ENGINE 10 seconds Check starter solenoid circuit for continuity (key switch OFF) and for 12 V with key switch ON.
81-6 Ignition timing circuit OPEN LED 2: ON (Running) - 16 instances
EMM counts failed ignition events (crankshaft revolutions). Check circuit resistance.
87 Exhaust pressure circuit fault 3 LED 3: OFF (Cranking) / ON (Running) - 10 seconds < -85 in. water or > 85 in. water. Check for plugged or pinched hose or exhaust fitting.
88 Exhaust pressure BELOW expected range 3 LED 3: OFF (Cranking) / ON (Running) - 10 seconds <-40 in. water
89 Exhaust pressure ABOVE expected range 3 LED 3: OFF (Cranking) / ON (Running) - 10 seconds > 80 in. water
91 Fuel pump circuit OPEN LED 2: ON (Running) - 10 seconds Check pump/circuit resistance—2 to 3 Ω @ 77°F (25°C).
92 Exhaust valve solenoid OPEN (V4) LED 2: ON (Running) - 10 seconds Refer to exhaust valve relay tests.
94 Fuel pump circuit SHORTED LED 2: ON (Running) - 2 seconds Check pump/circuit resistance—2 to 3 Ω @ 77°F (25°C).
97 Intermittent switched B+ detected LED 3: ON (Running) - 10 seconds Switched battery voltage < 7 V. Check connections and wiring
101- 9 events at low RPM, Last digit indicates affected cylinder.
Ignition timing circuit SHORTED LED 2: ON (Running) -
6 3 events at high RPM EMM counts failed ignition events. Check wiring. Test with known good ignition coil.
107 ICON control communication error 3 - CHECK ENGINE Immediate Cycle master power switch off and back on. Check ICON 10 Amp fuse, buss cables, and ESM to EMM connections.
108 ICON system fail-safe mode 3 - CHECK ENGINE 2 seconds ICON control head commands EMM to activate S.A.F.E. Check other ICON codes.
109 ICON control head failure 3 - CHECK ENGINE 2 seconds Cycle master power switch off and back on. See Evinrude ICON Installation Guide.
110 ICON trim switch communication error - - 2 seconds Cycle master power switch off and back on. Check harness between panel and control.
111 ICON ESM communication error 3 - CHECK ENGINE 2 seconds Cycle master power switch off and back on. Check ICON buss cable connections. See Evinrude ICON Installation Guide.
Check actuator harness and connections. Check for RFI from excessive spark plug gap. See Evinrude ICON Installation
149 ICON throttle actuator sensor fault 3 - CHECK ENGINE 2 seconds
Guide.
150 ICON throttle actuator motion fault 3 - CHECK ENGINE 2 seconds Cycle master power switch off and back on. Check for throttle linkage for obstructions. Check harnesses.
Check actuator harness and connections. Check for RFI from excessive spark plug gap. See Evinrude ICON Installation
151 ICON shift actuator sensor fault 3 - CHECK ENGINE 2 seconds
Guide.
152 ICON shift actuator motion fault - CHECK ENGINE 2 seconds Cycle master power switch off and back on. Check actuator calibration. Check harnesses.
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.
Rev 10/10 page 2

evinrude_etec_200

Uploaded by

Document Informationclick to expand document information

Copyright:

Available Formats

evinrude_etec_200

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

evinrude_etec_200

Uploaded by

Copyright:

Available Formats

BRP US Inc.

† AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II

Johnson ® Nut Lock™

Evinrude ® E-TEC ® Screw Lock™

Evinrude ® / Johnson ® XD50™ Outboard Oil HPF XR™ Gearcase Lubricant

Evinrude ® / Johnson ® XD100™ Outboard Oil HPF PRO™ Gearcase Lubricant

Printed in the United States.

When repla cement p arts are required, use

Always wear EYE PROTECTION AND APPRO-

IMPORTANT: Identifies information that controls

ABBREVIATIONS USED IN THIS MANUAL

EMISSION-RELATED Owner’s Responsibility

The owner/operator is not to, and should not allow

Manufacturer’s Responsibility EPA Emission Regulations

1. Model and serial number 000449 1. Serial number 006828

MODELS COVERED IN THIS MANUAL

Evinrude/Johnson XD100 Oil

Minimum Fuel Lift Pump Pressure

HP 200 225 250

750 CCA (940 MCA) below 32°F (0°C)

Maximum Temperature 190°F (88°C)

Water pressure 15 to 17 psi @ 5000 RPM

Ignition Features EMM Controlled

“M2” Type Gearcase: 38.9 fl. oz. (1150 ml)

Fluid Capacity 21 fl. oz. (622 ml)

Trim Range 0° to 21°

Tilt Range 22° to 75°

Tilt UP Stall Pressure 1500 psi (10342 kPa)

Tilt IN Stall Pressure 800 psi (5516 kPa)

Evinrude/Johnson XD100 Oil

Minimum Fuel Lift Pump Pressure

750 CCA (940 MCA) below 32°F (0°C)

Maximum Temperature 190°F (88°C)

Water pressure 18 to 25 psi @ 5000 RPM

Ignition Features EMM Controlled

“M2” Type Gearcase: 38.9 fl. oz. (1150 ml)

Fluid Capacity 21 fl. oz. (622 ml)

Trim Range 0° to 21°

Tilt Range 22° to 75°

Tilt UP Stall Pressure 1500 psi (10342 kPa)

Tilt IN Stall Pressure 800 psi (5516 kPa)

STANDARD TORQUE PRODUCT REFERENCE

INSPECTION AND MAINTENANCE SCHEDULE

A HPF Pro Gearcase Lubricant

LIFTING THE OUTBOARD RIGGING

1. Shift cable casing guide extended to midpoint DP0811

Extend the control cables and lubricate them with

Fasten appropriate chain hoo k to eye of too l.

Cable Retainer Clip Installation Cable, Hose, and Wire Routing

1. Straight section DP0818

1. Grommet retaining bracket 003964

1. Alternate fuel hose location 003970

1. Fuel supply hose 000095 003974

Remove contro l ca ble t runnion co vers and cable

1. Alternate fuel hose location 003971

The main wiring harness, battery cables, oil t ank

Push and pull on th e shift cable and observe the

Adjust shift cable trun nion to align with cente r of