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BRP EVINRUDE E-TEC E90DSLAA Series User Manual

BRP EVINRUDE E-TEC E90DSLAA Series
422 pages
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Printed in the United States.
© 2012 BRP US Inc. All rights reserved.
TM, ® and the BRP logo registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
BRP US Inc.
Technical Publications
P.O. Box 597
Sturtevant, Wisconsin 53177 United States
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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™

Table of Contents

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BRP EVINRUDE E-TEC E90DSLAA Series Specifications

General IconGeneral
BrandBRP
ModelEVINRUDE E-TEC E90DSLAA Series
CategoryEngine
LanguageEnglish

Summary

REFERENCE INFORMATION

SAFETY NOTICE

Provides critical safety warnings and instructions for servicing the outboard.

SERVICE SPECIFICATIONS AA MODELS

Provides detailed technical specifications for 40-60 HP E-TEC models.

SERVICE SPECIFICATIONS AB MODELS

Provides detailed technical specifications for 40-60 HP E-TEC models (AB).

SERVICE SPECIFICATIONS AA MODELS (75-90 HP)

Provides detailed technical specifications for 75-90 HP E-TEC models.

ROUTINE SERVICE

INSPECTION AND MAINTENANCE SCHEDULE

Outlines recommended inspection and maintenance tasks for prolonging outboard life.

ENGINE MANAGEMENT MODULE (EMM)

ENGINE MONITOR AND WARNING SYSTEMS

Describes how the engine monitor system warns the operator of critical conditions.

DIAGNOSTIC SOFTWARE FUNCTIONS

Covers using Evinrude Diagnostics software for troubleshooting and adjustments.

ELECTRICAL AND IGNITION

SENSOR TESTS

Covers testing procedures for crankshaft position, throttle position, engine temperature, and air temperature sensors.

STATOR TESTS

Details stator resistance and voltage output tests for charging system diagnostics.

CHARGING SYSTEM TESTS

Covers testing the 12V and 55V charging circuits and battery performance.

ELECTRIC START CIRCUIT AND TESTS

Explains start circuit operation and provides tests for the starter solenoid and voltage drop.

REMOTE CONTROL SWITCH AND EMERGENCY STOP TESTS

Covers testing of key switches, neutral start, and emergency stop switches.

TIMING ADJUSTMENTS AND TPS CALIBRATION

Covers adjusting timing pointer, verifying timing, and calibrating the throttle position sensor.

FUEL SYSTEM

FUEL SYSTEM TESTS

Covers tests for fuel system pressure, regulator, injectors, and pumps.

FUEL COMPONENT SERVICING

Details procedures for servicing fuel filter, lift pump, vapor separator, and fuel manifolds.

OILING SYSTEM

OIL CONTROL SETTINGS

Explains how to set oil injection rate and oil type using Evinrude Diagnostics software.

OILING SYSTEM TESTS

Details tests for oil injection pump voltage, resistance, function, and flow.

COOLING SYSTEM

COMPONENTS

Describes water pump, exhaust housing, water supply tube, and pressure relief valve.

ENGINE TEMPERATURE CHECK

Details methods for checking engine operating temperatures using software or pyrometer.

POWERHEAD

COMPRESSION TESTING

Details the procedure for testing cylinder compression and interpreting results.

POWERHEAD REMOVAL AND INSTALLATION

Covers the step-by-step process for removing and installing the powerhead.

CRANKSHAFT AND CONNECTING ROD SERVICE

Provides procedures for removing and handling crankshafts, connecting rods, and pistons.

POWERHEAD ASSEMBLY

Provides detailed instructions for assembling crankshaft, pistons, cylinder head, and other components.

GEARCASE

GEARCASE LEAK TEST

Details procedures for pressure and vacuum testing the gearcase for leaks.

GEARCASE SERVICE, 40-60 HP MODELS

Provides comprehensive procedures for gearcase removal, disassembly, and assembly.

GEARCASE SERVICE, 75-90 HP MODELS

Provides comprehensive procedures for gearcase removal, disassembly, and assembly.

TRIM AND TILT

ELECTRICAL CIRCUIT TESTS

Details testing procedures for trim/tilt relays, motor current draw, and trim gauge/sender.

TRIM AND TILT REPLACEMENT

Provides step-by-step instructions for removing and installing the trim and tilt unit.

MANUAL STARTER

RECOIL STARTER ASSEMBLY AND INSTALLATION

Provides step-by-step instructions for assembling and installing the recoil starter.

SAFETY

MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM

General safety guidelines for users and technicians working with marine products.

FUEL, ELECTRICAL SYSTEM, AND SAFETY

Addresses fire and explosion prevention, safe handling of gasoline, and electrical system safety.

TROUBLE CHECK CHART

OUTBOARD WILL NOT START

Lists possible causes and procedures for diagnosing outboard starting issues.

OUTBOARD HARD TO START

Provides troubleshooting steps for engines that are difficult to start.

OUTBOARD WILL NOT SHUT OFF

Covers diagnosis and procedures for an outboard that fails to shut off.

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