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Evinrude E-TEC Series
BRP Evinrude E-TEC Series User Manual
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2
Table of Contents
Safety Information
4
Table of Contents
4
Safety Information
4
Table of Contents
6
Models Covered in this Manual
8
Identifying Model and Serial Numbers
8
Model Designation
9
Typical Page - a
10
Typical Page - B
11
Typical Page - C
12
Typical Page - D
13
Abbreviations Used in this Manual
14
Units of Measurement
14
List of Abbreviations
14
Engine Emissions Information
15
Manufacturer's Responsibility
15
Dealer's Responsibility
15
Owner's Responsibility
15
Epa Emission Regulations
15
Product Reference and Illustrations
16
Symbols
16
Electrical
16
Values
17
Notes
18
Service Specifications and Special Tools 1
19
Service Specifications and Special Tools
20
Technical Data
20
Standard Torque Specifications
22
Special Tools
23
Diagnostics
23
Universal
23
Electrical / Ignition
24
Fuel/Oil Systems
25
Powerhead
26
Gearcase
27
Trim and Tilt
29
Shop Aids
30
Notes
34
Installation and Predelivery
35
Boat Rigging
36
Remote Controls
36
Battery Installation
38
Battery Switches and Multiple Batteries
39
Auxiliary Battery Charge Isolator
40
Battery and Switch Wiring Diagrams
41
Fuel System Requirements
43
Oiling System Set-Up
45
Cable and Hose Installation
48
Outboard Installation
53
Hull Preparation
53
Transom Measuring and Drilling
54
Lifting the Outboard
58
Steering Systems
58
Outboard Mounting
60
Outboard Rigging
61
Cable, Hose, and Wire Routing
61
Control Cable Installation
62
Electrical Harness Connections
64
Water Pressure Gauge
65
Canbus Connections
65
Fuel and Oil Priming
67
Fuel Requirements
67
Fuel System Priming
68
Oil Requirements
68
Oil Injection Rate
69
Break-In Oiling
69
Systemcheck Low Oil Warning
70
Oil Supply Priming
70
Before Start-Up
72
Running Checks
73
Systemcheck Operation
73
Fuel System
73
Emergency Stop / Key Switch
73
Start-In-Gear Prevention
73
Tachometer Pulse Setting
74
Water Pump Overboard Indicator
74
Operating Temperature
74
Break-In
74
Idle Speed
74
Propellers
75
Propeller Selection
75
Propeller Hardware Installation
76
Final Adjustments
77
Tilt Limit Switch Adjustment
77
Trim Sending Unit Adjustment
78
Trim Tab Adjustment
79
Dual-Outboard Alignment
80
Maintenance
81
Inspection and Maintenance Schedule
82
Anti-Corrosion Protection
83
Sacrificial Anodes
83
Testing Procedure - Continuity
83
Metallic Component Protection
83
Exterior Finishes
83
Cooling System
84
Flushing
84
Water Intake Screens
85
Additional Maintenance
85
Lubrication
85
Steering System
85
Swivel Bracket and Trailering Bracket
86
Tilt Tube
86
Throttle and Shift Linkage
86
Propeller Shaft
87
Gearcase Lubricant
87
Trim and Tilt
88
Fuel and Oil Systems
89
Fuel Filter
89
Oil Filters and Oil Reservoir
90
Air Silencer
90
Hoses and Connections
90
Battery and Battery Connections
89
Spark Plugs
91
Indexing
91
Exhaust Pressure Fitting
92
Operation Test
92
Cleaning
92
Storage
93
Fuel System Treatment
93
Internal Engine Treatment
93
Additional Recommendations
94
Pre-Season Service
94
Outboard Mounting Bolts
94
Gearcase Lubricant
94
Battery(S)
94
Power Trim and Tilt
94
Operational Checks
94
Submerged Engines
95
Engine Dropped Overboard (Not Running)
95
Engine Dropped Overboard (Running)
95
Engine Dropped Overboard (in Salt Water)
95
Prolonged Submersion (Fresh or Salt Water)
95
Notes
96
Maintenance Notes Notes
97
Default Chapter
97
Engine Management Module (Emm)
97
Description
98
Emm Functions
98
Emm Connections
98
Sensors and Functions
99
Internal Sensors
99
External Sensors
100
Internal Functions
103
Emm Inputs and Outputs Diagram
104
Shutdown Mode
105
Warning System
105
Initiation
105
Recovery
105
Emm Diagnostics
106
Led Indicators
106
Diagnostic Software Program
107
Communication
107
Program Information
108
Service Codes (Faults)
108
Static Tests
109
Dynamic Tests
110
Oil Control
111
Timing Verification
111
Tps Calibration
112
Fuel Injector Servicing
112
Fuel Control Adjustment
112
Reports
113
Software Replacement
113
Emm Transfer
113
Systemcheck Engine Monitor
114
Gauges
114
System Self-Test
114
Service Mode
114
Engine Running
114
System Analysis
115
Electrical Connections
116
Ground Circuits
118
Test Procedure
118
Fuse
118
Emm Diagnostics
119
Led Indicators
119
Software Programs
119
Diagnostic Procedures
120
Symptoms
121
Specialized Test Procedures
122
Dynamic Tests
122
Testing with Timing Light
122
Inductive Amp Meter Test
123
Engine Monitoring Information
123
Voltage Testing
124
Start Circuit
124
Electric Starter Operation
124
Starter Solenoid Activation
125
Start Circuit Diagram
127
Ignition and Electrical Circuits
128
Ignition Output
129
Wiring Inspection
129
Ignition Voltage
129
System Voltage
130
Static Spark Test
130
Running Ignition Tests
131
Ignition Primary Circuit Resistance Test
132
Crankshaft Position Sensor (Cps) Test
132
Fuel Delivery
133
Manifold Pressure Test
133
Vapor Separator Checks
134
Fuel Delivery to Lift Pump
134
Fuel Injector Operation
134
Static Tests
134
Dynamic Tests
135
Exhaust Valve
136
Electrical and Ignition
137
Service Chart
138
Dash Connections, Instrument Harness
140
Sensor Resistance Tests
141
Capacitor Test
142
Ignition Coil Tests
143
Stator Tests
143
Charging System Tests
144
Systemcheck Circuit Tests
147
Remote Control Switch Tests
149
Key Switch Test
149
Neutral Start Circuit Test
150
Neutral Start Switch Test
150
Emergency Stop Switch Test
151
Tachometer Circuit Tests
151
Electric Starter Tests
152
Starter Solenoid Test
152
Load Current Draw Test
152
Tilt/Trim Relay Test
153
Operation
153
Test Procedure
154
Exhaust Valve Relay Tests
154
Emm Servicing
155
Removal
155
Installation
156
Flywheel and Stator Servicing
156
Flywheel Removal
156
Stator Service
158
Flywheel Installation
158
Timing Adjustments
159
Timing Pointer
159
Timing Verification
161
Tps Calibration
161
Spark Plugs
162
Inspection
162
Indexing
162
Electric Starter Servicing
163
Removal
163
Disassembly
163
Cleaning and Inspection
166
Assembly
167
Installation
169
Connector Servicing
170
Table of Contents
175
Service Chart
176
Components
179
Fuel Lift Pump
179
Fuel Filter
179
Vapor Separator
180
Fuel Circulation Pump
181
Fuel Manifolds
181
Fuel Injectors
182
Fuel System Hose Routing
183
Direct Injection Electrical Circuits
184
Injector / Circulation Pump Circuits Diagram
185
Fuel Component Tests
186
Fuel Injectors
186
Fuel Supply
187
Fuel Component Servicing
191
Relieving Fuel System Pressure
191
In-Line Fuel Filter
192
Optional Fuel Filter
192
Fuel Lift Pump
193
Vapor Separator
193
Fuel Manifolds
194
Fuel Injectors
195
Intake Manifold
198
Removal
198
Disassembly
198
Inspection
199
Assembly
199
Installation
199
Oiling System
201
Service Chart
202
Components
203
Oil Tank
203
Oil Injection Pump
203
Oil Pressure Sensor
204
Electrical Circuit (55 V)
204
Oil Injection Pump Diagram
205
Oiling System Electrical Diagram
206
Systemcheck, I-Command and Emm Oiling System Warnings
207
Cylinder and Crankcase
207
Oil Supply and Distribution Diagrams - V6
208
Oil Supply and Distribution Diagrams - V4
210
Oil Recirculation System
212
Recirculation Hose Routings and Check Valve Diagrams - V6
213
Recirculation Hose Routings and Check Valve Diagrams - V4
215
Priming
217
Oil Hose Connections
217
Oil Distribution Manifold Priming
217
Oiling Rates
219
Oil Injection Rate
219
Xd100 Outboard Oil Decal
219
Break-In Oiling
219
Oiling System Tests
220
Oil Injection Pump Static Test
220
Oil Injection Pump Voltage Test
220
Oil Injection Pump Circuit Resistance Test
221
Oil Supply Vacuum Test
222
Oil Injection Pump Function Test
222
Oil Injection Fittings Flow Test
223
Low Oil Sending Unit Test
223
Oil Component Servicing
224
Oil Distribution Hoses
224
Oil Injection Pump
225
Cooling System
227
Hose Routing and Water Flow Diagrams
228
Engine Temperature Check
230
Software Method
230
Pyrometer Method
230
Idle Operating Temperature Troubleshooting (below Range)
231
Components
232
General Description
232
Water Pump and Intakes
232
Water Supply Tube
232
Adapter/Inner Exhaust Housing
233
Pressure Relief Valve
233
Thermostats
233
Block Venting
233
Operation
234
Cylinder Block / Cylinder Head Cooling
234
Vapor Separator and Emm Cooling
234
Thermostat Servicing
235
Disassembly
235
Inspection
235
Assembly
235
Pressure Relief Valve Servicing
235
Inspection
236
Assembly
236
Powerhead
237
Service Chart
238
General
240
Cylinder Compression Testing
240
Retaining Ring Pliers
240
Removal
241
Disassembly
243
General
243
Crankcase
244
Cylinder Head
245
Connecting Rods and Pistons
245
Crankshaft
247
Cleaning
249
Inspection
250
Cylinder Head
250
Crankshaft
250
Cylinder Bore
251
Pistons
251
Piston Rings
251
Bearings
252
Assembly
252
Crankshaft
252
Pistons and Connecting Rods
254
Cylinder Head
256
Crankshaft and Connecting Rods
257
Crankcase
260
General
261
Upper Mount Servicing
263
Installation
264
Powerhead Views
268
V4 Starboard - Hose Routings
268
V4 Port - Hose Routings
269
V4 Starboard
270
V4 Port
271
V4 Front
272
V4 Rear
273
Top - Hose Routings
274
V4 - V6 Top
275
V6 Starboard - Hose Routings
276
V6 Port - Hose Routings
277
V6 Starboard
278
V6 Port
279
V6 Front
280
V6 Rear
281
Notes
282
Powerhead Notes Notes
283
Default Chapter
283
Midsection
283
Service Chart
284
Tilt Tube
287
Removal
287
Installation
288
Exhaust Housing
289
Removal
289
Disassembly
290
Cleaning and Inspection
291
Assembly
291
Installation
294
Stern Bracket
295
Removal
295
Disassembly
295
Assembly
297
Exhaust Relief Muffler Assembly
300
Gearcase
301
Service Chart
302
Gearcase Types
307
Propeller
308
Shift Interrupt Switch
308
Lubricant
309
Leak Test
310
Removal and Installation
310
Water Pump
313
Disassembly
316
Pre-Disassembly Inspection
316
Propeller Shaft Bearing Housing Removal
317
Pinion Gear and Driveshaft Removal
318
Driveshaft Service
322
Shift Housing, Gear and Propeller Shaft Removal
325
Water Intake Screens
325
Shift Rod Adjustment
316
Gearcase Housing Inspection
325
Bearing and Seal Removal
326
Shift Housing
326
Pinion Gear Bearing
327
Driveshaft Bearing Housing
328
Propeller Shaft Bearing Housing
328
Bearing and Seal Installation
329
Shift Housing
329
Pinion Gear Bearing
331
Driveshaft Bearing Housing
332
Propeller Shaft Bearing Housing
333
Driveshaft Shimming
334
Assembly
336
Water Intake Screens
336
Shift Housing, Gear, and Propeller Shaft Installation
336
Shift Rod Housing Installation
336
Pinion Gear and Driveshaft Installation
337
Propeller Shaft Bearing Housing and Gear Installation
342
Counter Rotation
343
Propeller Shaft Bearinghousing Removal
343
Shift Housing, Gear and Propeller Shaft Removal
343
Shift Housing Service
344
Propeller Shaft Bearing Housing and Forward Gear
347
Propeller Shaft Bearing Housing Seals and Bearings
352
Propeller Shaft Bearing Housing and Gear Installation
354
Notes
356
Gearcase Notes Notes
357
Service Chart
358
System Description
360
Manual Adjustment
360
Trailering Bracket and Tilt Support
360
Modes of Operation (Three Piston System)
361
Trim-Out / Tilt-Up Mode
361
Tilt-Down / Trim-In Mode
362
Impact Relief
363
Shallow Water Drive Tilt Relief
364
Thermal Expansion Relief
364
Manual Release - up
365
Manual Release - down
366
Routine Inspections
367
General
367
Reservoir Fluid
367
Manual Release Valve
367
Stern Brackets
367
Troubleshooting
368
Three Piston System
368
Single Piston System
371
Electrical Circuit Tests
372
Relay Testing
372
Trim and Tilt Motor Current Draw Tests
372
Trim and Tilt Motor no Load Test
373
Trim Gauge Test
374
Trim Sender Test
374
Removal and Installation
375
Servicing - Three Piston System
378
Disassembly
378
Tilt Piston Removal
380
Tilt Piston Identification
381
Tilt Piston Assembly
382
Tilt Rod Assembly
382
Trim Rod Removal
384
Trim Rod Assembly
385
Manifold and Reservoir Installation
386
Trim Rod Installation
387
Tilt Rod Installation
387
Motor Installation
388
Servicing-Single Piston System
390
Disassembly
390
Safety
390
Assembly
391
Adjustments
392
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
393
Marine Products and the Safety of People Who Use Them
395
Outboard Shift Systems and Safety
396
Outboard Speed Control System and Safety
397
Outboard Steering Control System and Safety
398
Outboard Fuel, Electrical System, and Safety
400
Outboard Mounting System and Safety
403
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
405
Outboard Emergency Stop System and Safety
406
Summing up
408
Marine Products and the Safety of People Who Fix Them
409
Handling Outboards
409
Handling Lead/Acid Batteries
413
Gasoline - Handle with Care
414
Hazardous Products
415
Safety Awareness Test
416
Index
417
Trouble Check Chart
425
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BRP Evinrude E-TEC Series Specifications
General
Brand
BRP
Model
Evinrude E-TEC Series
Category
Outboard Motor
Language
English
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