40-90 HP

BRP US Inc.
Technical Publications
250 Sea Horse Drive
Waukegan, Illinois 60085 United States
† 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.

© 2010 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
8 OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
9 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
10 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
11 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
12 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
GEARCASE SERVICE, 40 – 65 HP MODELS . . . . . . . 296
GEARCASE SERVICE, 75 – 90 HP MODELS . . . . . . . 318
13 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
14 MANUAL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
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
SAFETY NOTICE
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This publication is written for qualified, factory- DO NOT perform any work until you have read
trained technicians who are already familiar with and understood these instructions completely.
the use of Evinrude/Johnson Special Tools. The
included information is not a substitute for work Torque wrench tightening specifications must
experience. It is an organized guide for reference, strictly be adhered to.
repair, and/or maintenance. Should removal of any locking fastener (lock tabs,
The following symbols and/or signal words locknuts, or patch screws) be required, always
may be used in this document: replace with a new one.
When replacement parts are required, use

DANGER
Evinrude/Johnson Genuine Parts or parts with
Indicates a hazardous situation which, if equivalent characteristics, including type, strength
not avoided, will result in death or serious and material. Use of substandard parts could
injury. result in injury or product malfunction.
Always wear EYE PROTECTION AND APPRO-

WARNING PRIATE GLOVES when using power tools.
Indicates a hazardous situation which, if Unless otherwise specified, engine must be OFF
not avoided, could result in death or seri- when performing this work.
ous injury
Always be aware of parts that can move, such as
flywheels, propellers, etc.
CAUTION Some components may be HOT. Always wait for
Indicates a hazardous situation which, if engine to cool down before performing work.
not avoided, could result in minor or mod- If you use procedures or service tools that are not
erate personal injury. recommended in this manual, YOU ALONE must
decide if your actions might injure people or dam-
age the outboard.
NOTICE Indicates an instruction which, if
not followed, could severely damage engine This document may be translated into other lan-
components or other property. guages. In the event of any discrepancy, the
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.
SAFETY NOTICE
1
DANGER
Contact with a rotating propeller is likely to result in serious injury or death. Assure the
engine and prop area is clear of people and objects before starting engine or operating boat.
Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and
the propeller can continue to turn even after the engine is off. Remove propeller before ser-
vicing and when running the outboard on a flushing device.
DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to
accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled,
can cause serious brain damage or death.
WARNING
Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172
kPa).
The motor cover and flywheel cover are machinery guards. Use caution when conducting
tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and
clothing away from rotating parts.
During service, the outboard may drop unexpectedly. Avoid personal injury; always support
the outboard’s weight with a suitable hoist or the tilt support bracket during service.
To prevent accidental starting while servicing, disconnect the battery cables at the battery.
Twist and remove all spark plug leads.
The electrical system presents a serious shock hazard. DO NOT handle primary or secondary
ignition components while outboard is running or flywheel is turning.
Gasoline is extremely flammable and highly explosive under certain conditions. Use caution
when working on any part of the fuel system.
Protect against hazardous fuel spray. Before starting any fuel system service, carefully
relieve fuel system pressure.
Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular
phones in the vicinity of a fuel leak or while fueling.
Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and
causing an explosion.
Always work in a well ventilated area.
Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak.
Definite resistance to tightening must be felt when reusing a locking fastener. If replacement
is indicated, use only authorized replacement or equivalent.
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
 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 outboard
maintenance performed to maintain emission lev-
1
els within prescribed certification standards.
INSTRUCTIONS
The owner/operator is not to, and should not allow
Failing to follow these instructions when
anyone to, modify the outboard in any manner
installing a certified engine in a vessel violates
that would alter the horsepower or allow emis-
federal law (40 CFR 1068.105 (b)), subject to
sions levels to exceed their predetermined factory
fines or other penalties as described in the
specifications.
Clean Air Act.
Tampering with the fuel system to change horse-
Maintenance, replacement, or repair of the emis-
power or modify emission levels beyond factory
sion control devices and systems may be per-
settings or specifications will void the product war-
formed by any marine SI (spark ignition) engine
ranty.
repair establishment or individual.
Manufacturer’s Responsibility EPA Emission Regulations

All new 1999 and more recent Evinrude/Johnson
Beginning with 1999 model year outboards, man-
outboards are certified to the EPA as conforming
ufacturers of marine outboards must determine
to the requirements of the regulations for the con-
the exhaust emission levels for each outboard
trol of air pollution from new watercraft marine
horsepower family and certify these outboards
spark ignition outboards. This certification is con-
with the United States of America Environmental
tingent on certain adjustments being set to factory
Protection Agency (EPA). An emissions control
standards. For this reason, the factory procedure
information label, showing emission levels and
for servicing the product must be strictly followed
outboard specifications, must be placed on each
and, whenever practical, returned to the original
outboard at the time of manufacture.
intent of the design. The responsibilities listed
above are general and in no way a complete list-
Dealer’s Responsibility ing of the rules and regulations pertaining to the
When performing service on all 1999 and more EPA requirements on exhaust emissions for
recent Evinrude/Johnson outboards that carry an marine products. For more detailed information on
emissions control information label, adjustments this subject, you may contact the following loca-
must be kept within published factory specifications:
tions.
VIA U.S. POSTAL SERVICE:
Replacement or repair of any emission related
Office of Mobile Sources
component must be executed in a manner that
Engine Programs and Compliance Division
maintains emission levels within the prescribed
Engine Compliance Programs Group (6403J)
certification standards.
401 M St. NW
Dealers are not to modify the outboard in any Washington, DC 20460
manner that would alter the horsepower or allow
VIA EXPRESS or COURIER MAIL:
emission levels to exceed their predetermined
factory specifications. Office of Mobile Sources
Engine Programs and Compliance Division
Exceptions include manufacturer’s prescribed Engine Compliance Programs Group (6403J)
changes, such as altitude adjustments, for exam- 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 II 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: II = 2011
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. Model and serial number 002224 1. Serial number 002225
8
MODELS COVERED IN THIS MANUAL
MODELS COVERED IN THIS MANUAL

This manual covers service information on all 52.7 cubic inch (.86 L), 2-Cylinder; and 79 cubic inch (1.29 1
L), 3-Cylinder Evinrude E-TEC models.
Model Displacement Gearcase Height Color Description
E40DRLIIS .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Manual Tilt, Tiller Steering, Rope Start
E40DTLIIA .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Tiller Steering, Electric Start
E40DPLIIS .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Remote Steering, Electric Start
E40DSLIIA .86 L, 52.7 ci 12:32 / 0.375 F 20" White Power Tilt, Remote Steering, Electric Start
E65WDRLIIA .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Manual Tilt, Tiller Steering, Rope Start
E65WDRYIIA .86 L, 52.7 ci 12:32 / 0.375 F 22.5" Blue Manual Tilt, Tiller Steering, Rope Start
E75DPLIIS 1.29 L, 79.0 ci 13:26 / 0.50 S 20" Blue Power Tilt, Steel Steering Arm
E75DSLIIA 1.29 L, 79.0 ci 13:26 / 0.50 S 20" White Power Tilt, Stainless Steering Arm
E90DPLIIS 1.29 L, 79.0 ci 13:26 / 0.50 S 20" Blue Power Tilt, Steel Steering Arm
E90DSLIID 1.29 L, 79.0 ci 13:26 / 0.50 S 20" White Power Tilt, Stainless Steering Arm
E90DPXIIS 1.29 L, 79.0 ci 12:27 / 0.444 O 25" White Power Tilt, Stainless Steering Arm
E90WDELIIA 1.29 L, 79.0 ci 13:26 / 0.50 S 20" Blue Manual Tilt, Steel Steering Arm, Commercial Model
E90WDEXIIA 1.29 L, 79.0 ci 12:27 / 0.444 O 25" White Manual Tilt, Steel Steering Arm, Commercial Model
9
SERVICE SPECIFICATIONS
40 – 65 HP E-TEC Models
40 HP – 5000 to 6000 RPM
Full Throttle 50 HP – 5500 to 6000 RPM
Operating Range RPM 60 HP – 5500 to 6000 RPM
65 HP – 5500 to 6000 RPM
40 HP (30 kw) @ 5500 RPM
50 HP (37 kw) @ 5750 RPM
Power
60 HP (45 kw) @ 5750 RPM
65 HP (45 kw) @ 5750 RPM
Idle RPM in Gear 800 ± 50 EMM Controlled
Idle RPM in Neutral 750 ± 50 EMM Controlled
Test Propeller P/N 382861
Weight (RL) Models: 232 lbs. (105 kg)
(may vary depending
(PL) Models: 240 lbs. (109 kg)
ENGINE
on model)
Evinrude/Johnson XD100, XD50, XD30; or

Lubrication
NMMA TC-W3 certified
Engine Type In-line, 2 Cylinder, Two-Cycle
Displacement 52.7 cu. in. (864 cc)
Bore 3.601 in (91.47 mm)
Stroke 2.588 in. (65.74 mm)
3.6005 to 3.6015 in. (91.45 to 91.48 mm)
Standard Bore
To bore oversize, add piston oversize dimension to standard bore
Top Crankshaft Journal 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Center Crankshaft Journal 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Bottom Crankshaft Journal 1.5747 to 1.5752 in. (40.0 to 40.01 mm)
Rod Crankpin 1.3757 to 1.3762 in. (34.94 to 34.96 mm)
Piston Ring End Gap, Both 0.011 to 0.023 in. (0.28 to 0.58 mm)
Fuel/Oil Control EMM Controlled
Starting Enrichment EMM Controlled
Minimum (High) Fuel Pressure 24 to 28 psi (165 to 193 kPa)
Minimum Fuel Lift
3 psi (21 kPa)
FUEL
Pump Pressure
Maximum Fuel Inlet Vacuum 4 in. Hg.
Minimum Octane 87 AKI (R+M)/2 or 90 RON
®
2+4 Fuel Conditioner, Fuel System Cleaner
Additives Use of other additives may result in engine damage.
See Fuel Requirements on p. 131 for additional information
10
1
Minimum Battery
ELECTRICAL
640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C)
Requirements
25-Amp fully regulated. Refer to Predelivery and Installation Guide for multiple battery
Alternator
applications.
Tachometer Setting 6 pulse (12 pole)
Engine Fuse P/N 967545 – 10 A
Thermostat 143°F (62°C)

COOLING
Maximum Temperature 212°F (100°C)
Water pressure 12 to 14 psi @ 5000 RPM
Type Capacitor Discharge

Firing Order 1-2
Ignition Timing EMM Controlled
IGNITION
RPM Limit in Gear 6250

RPM Limit in Neutral 1800
Crankshaft Position Sensor Air
Fixed
Gap
Refer to Emission Control Information Label
Spark Plug
Champion † QC10WEP @ 0.028 ± .003 in. (0.71 mm)
Gear Ratio 12:32 (.375)
GEARCASE
HPF XR Gearcase Lube

Lubricant
HPF Pro in high performance or commercial applications
Capacity 22 fl. oz. (650 ml)
Shift Rod Height 20 in. (L) Models: 21.38 (543 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
Lubrication Evinrude/Johnson Biodegradable TNT Fluid
Fluid Capacity 15.2 fl. oz. (450 ml)
Trim Range 0° to 15°
Tilt Range 16° to 65°
11
Full Throttle
4500 to 5500 RPM
Operating Range RPM
75 HP (56 kw) @ 5000 RPM
Power
90 HP (67.1 kw) @ 5000 RPM
Idle RPM in Gear 700 ± 50 EMM Controlled
Idle RPM in Neutral 600 ± 50 EMM Controlled
(L) Models: P/N 386246
Test Propeller
(X) Models: P/N 387388
Weight (L) Models: 320 lbs. (145 kg)
(may vary depending
on model)
(X) Models: 335 lbs. (152 kg)
ENGINE
Evinrude/Johnson XD100, XD50, XD30; or

Lubrication
NMMA TC-W3 certified
Engine Type In-line, 3 Cylinder, Two-Cycle
Displacement 79.1 cu. in. (1296 cc)
Bore 3.601 in (91.47 mm)
Stroke 2.588 in. (65.74 mm)
3.6005 to 3.6015 in. (91.45 to 91.48 mm)
Standard Bore
To bore oversize, add piston oversize dimension to standard bore
Top Crankshaft Journal 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Center Crankshaft 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 1.3757 to 1.3762 in. (34.94 to 34.96 mm)
Piston Ring End Gap, Both 0.011 to 0.023 in. (0.28 to 0.58 mm)
Fuel/Oil Control EMM Controlled
Starting Enrichment EMM Controlled
Minimum (High) Fuel Pressure 24 to 28 psi (165 to 193 kPa)
Minimum Fuel Lift
3 psi (21 kPa)
FUEL
Pump Pressure
Maximum Fuel Inlet Vacuum 4 in. Hg.
Minimum Octane 87 AKI (R+M)/2 or 90 RON
®
2+4 Fuel Conditioner, Fuel System Cleaner
Additives Use of other additives may result in engine damage.
See Fuel Requirements on p. 131 for additional information
12
1
Minimum Battery
ELECTRICAL
640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C)
Requirements
25-Amp fully regulated. Refer to Predelivery and Installation Guide for multiple battery
Alternator
applications.
Tachometer Setting 6 pulse (12 pole)
Engine Fuse P/N 967545 – 10 A
Maximum Temperature 212°F (100°C)

COOLING
Thermostat 143°F (62°C)
Water pressure 19 to 21 psi @ 5000 RPM
Type Capacitor Discharge

Firing Order 1-2-3
Ignition Timing EMM Controlled
IGNITION
RPM Limit in Gear 6250

RPM Limit in Neutral 1800
Crankshaft Position Sensor Air
Fixed
Gap
Refer to Emission Control Information Label
Spark Plug
Champion † QC10WEP @ 0.028 ±.003 in. (0.71 mm)
20 in. (L) Models: 13:26 (.500) 2:1
Gear Ratio
25 in. (X) Models: 12:27 (.444) 2.25:1
GEARCASE
Lubricant HPF XR Gearcase Lube

20 in. (L) Models: 31.6 fl. oz. (935 ml)
Capacity
25 in. (X) Models: 32.8 fl. oz. (970 ml)
20 in. (L) Models: 21.25 (539.75 mm) ± one-half turn
Shift Rod Height
25 in. (X) Models: 26.25 (666.75 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
Lubrication Single Piston System–Evinrude/Johnson Biodegradable TNT Fluid
Fluid Capacity 21 fl. oz. (620 ml)
Trim Range 0° to 15°
Tilt Range 16° to 65°
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 any time, without notice, in specifications and
models and also to discontinue models. The right
No. 6 7–10 0.58–0.83 0.8–1.1 is also reserved 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 equip same on models manufactured prior to
No. 10 24–36 2–3 2.7–4.0 date of such change. Specifications used are
No. 12 36–48 3–4 4.0–5.4 based on the latest product information available
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 not depict actual 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 might not be found on all models 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 orientation. This manual often identifies parts
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 more screws on the same part, DO NOT
tighten screws completely, one at a time.
WARNING
Torque wrench tightening specifications
must be strictly adhered to. Replace any
locking fastener (locknut or patch screw)
if its locking feature becomes weak. Defi-
nite resistance to turning must be felt
when reusing a locking fastener.
If replacement is specified or required
because the locking fastener has become Nautical Orientation 006411
weak, use only authorized Evinrude/
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SYSTEMCHECK HARNESS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
I-COMMAND NETWORK CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
WATER PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BATTERY AND BATTERY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OETIKER CLAMP SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
STEERING FRICTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
THROTTLE FRICTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TILT LIMIT SWITCH ADJUSTMENT (75 – 90 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TRIM SENDING UNIT ADJUSTMENT (40 – 60 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TRIM SENDING UNIT ADJUSTMENT (75 – 90 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TRIM TAB ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DUAL-OUTBOARD ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ENGINE FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
RUNNING THE OUTBOARD USING A HOSE AND FLUSHING ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TILLER HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SWIVEL BRACKET AND TRAILERING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
THROTTLE AND SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
FUEL AND OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
OIL FILTERS AND OIL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
AIR SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
HOSES AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
FUEL SYSTEM TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INTERNAL ENGINE TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ADDITIONAL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
PRE-SEASON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SUBMERGED ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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)
Biodegradeable TNT Fluid (Single ram hydraulic systems)
C Triple-Guard Grease
D Starter Bendix Lube Only
16
ROUTINE SERVICE
LIFTING THE OUTBOARD
LIFTING THE OUTBOARD RIGGING

OUTBOARD CONNECTIONS
WARNING IMPORTANT: For complete outboard rigging
and remote control installation information, refer to 2
To avoid personal injury, make sure the lift- the Predelivery and Installation Guide included
ing capacity of the hoist is at least twice with the service manual set.
the weight of the outboard.
Common Practices – All Models
DO NOT allow the lift hook or chain from
the hoist to come in contact with any part Control Cable Identification
of the engine during lifting.
IMPORTANT: Identify control cable function
before rigging outboard.
Use correct Lifting Fixture to lift outboard:
Identify each control cable:
Model Lifting Fixture • Put the control handle into NEUTRAL position.
P/N 396748 with The throttle cable casing guide will retract com-
40–90 HP
1 1/8 in. screws pletely and the shift cable casing guide will go to
the midpoint of its travel.
With recoil starter removed, Place lifting tool on
flywheel and seat the three screws completely.
1
Refer to RECOIL STARTER REMOVAL on
p. 363.
2
1
2
1. Shift cable casing guide extended to midpoint DP0811
2. Throttle cable casing guide retracted
Extend the control cables and lubricate them with

Triple-Guard grease.
1. Lifting fixture 002098

2. 1 1/8 in. screws
NOTICE Use only the 1 1/8 in. (short)

screws, P/N 398067, included with the tool to
avoid damage to electronic components under
the flywheel.
Fasten appropriate chain hook to eye of tool.

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 link-
age pins, clips should be locked and must not be CAUTION
bent or deformed.
To prevent accidental starting while servic-
For proper installation, review the following steps: ing, disconnect the battery cables at the
• Place washer on pin. battery. Twist and remove all spark 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.
Apply soapy water to the inside surfaces of grom-
met and install cables and fuel line as shown:
1 3
1
2 4
2 5
1. Straight section DP0818
2. Angled section DP0817
1. Throttle cable 001998

• Push the clip towards the hole while lifting on 2. Shift cable
the curved end with the pliers. 3. Main wiring harness
• Be sure retainer clip fully engages the pin. 4. Battery cable
5. Fuel line
• Lock the retainer by moving the angled section
behind the straight section.
Place the grommet into position in the lower
engine cover.
Locked Retainer Clip DP0817a

1. Angled section behind straight section
002104
When grommet is in place and all cables have

been installed, tighten a tie strap around the out-
side of the grommet to form a watertight seal
around the cables.
18
ROUTINE SERVICE
NOTICE After installation, make sure there If there are not enough threads on the shift cable
is enough clearance for all cables to avoid for the adjustment, or if the gearcase does not
binding or chafing through all engine steering shift fully into FORWARD or REVERSE, refer to
and tilting angles. SHIFT ROD ADJUSTMENT on p. 300, or SHIFT
ROD ADJUSTMENT on p. 323.
Control Cable Installation With remote control lever in NEUTRAL, pull firmly 2
Refer to Control Cable Identification on p. 17. on throttle cable casing to remove slack.
Remove cable retainer from anchor block. Apply With engine throttle lever against stop, place the
Triple-Guard grease to both anchor block pockets. cable trunnion into the upper anchor pocket and
adjust the trunnion nut so the casing fits onto the
throttle lever pin.
1
1. Cable retainer 002099
IMPORTANT: DO NOT secure cables to throttle 1. Throttle lever pin 002101

2. Trunnion nut
and shift lever pins until all cables, wires, and
hoses have been routed and grommet has been
installed in the lower engine cover.
Make sure the remote control is in NEUTRAL, and 1

throttle is in the IDLE position.
Pull firmly on shift cable casing to remove slack.

With outboard in NEUTRAL, place the cable trun-
nion into the lower anchor pocket. Adjust the trun-
nion nut so the casing fits onto the shift lever pin.
1. Throttle lever stop – 3 Cylinder models 005111
1
2 1
1. Shift lever pin 002100

2. Trunnion nut
1. Throttle lever stop – 2 Cylinder models 005114
19
ROUTINE SERVICE
IMPORTANT: Move control handle to FOR- the seal only. DO NOT fill connectors with Electri-
WARD and pull back slowly to NEUTRAL. Make cal Grease.
sure the engine throttle lever is against the stop. If
not, remove slack by adjusting cable trunnion.
After grommet has been installed in lower engine

cover, install the washers and retainer clips on the
throttle and shift lever pins. Refer to Cable
Retainer Clip Installation on p. 18.
1
Install cable retainer and screw. Tighten screw to 1. Seal 42079A
a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
Arrange connectors in flywheel cover.
002103
SystemCheck Harness 001999
Connections Install electrical cover and secure with screws.

Place the wiring harness through notch in lower
motor cover and route to the recess in the fly-
wheel cover. Secure the cable with a tie strap as
shown:
2
1
002102
NOTICE BE SURE all harnesses and wires

1. Recess 002011
are not pinched, cannot contact flywheel, and
2. Tie strap do not interfere with moving throttle or shift
linkages.
Before installing electrical connectors, check that
the seal is in place. Clean off any dirt from con-
nectors. Apply a light coat of Electrical Grease to
20
ROUTINE SERVICE
I-Command Network Connections Connect the I-Command Engine Interface Cable

If the outboard will be used with I-Command, or to the EMM CANbus connector.
other NMEA 2000 compliant CANbus instruments, 1
use the following connections to supply informa- 2
tion to the network:
Remove lower motor covers. Remove air silencer.

2
Route I-Command Engine Interface Cable around
the front of the throttle body, following the path of
the TPS wiring, and behind the battery cable.
Loosely install tie straps as shown.
NOTICE To prevent wire chafing, harness

1. I-Command network connector 006735
must be routed below the flywheel cover. 2. EMM CANbus connector
1 2 CYLINDER MODELS
To prevent interference with engine cover latch,
2 bundle excess wiring behind EMM cooling water
hose. Secure I-Command connectors to back side
3 of engine harness with tie strap.
1
2
2
2 Cylinder Models 006736

1. Flywheel cover
2. Harness routing
3. Tie straps
1
1. Engine harness 006738
2 2. EMM cooling water hose
3
3 Cylinder Models 006742

1. Flywheel cover
2. Harness routing
3. Tie straps
21
ROUTINE SERVICE
3 CYLINDER MODELS ALL MODELS

EMM CANbus connector cap is clipped to EMM Adjust harness routing as needed and secure with
cooling water hose. Remove clip from cap and tie straps.
install on I-Command harness connector.
Use an I-Command Ignition and Trim Harness to
1 connect the outboard to the key switch and trim/tilt
2 control. Seal unused SystemCheck connector
with 6-Pin Connector Seal, P/N 586076.
If connecting to an existing I-Command Classic

network, connect the purple wires between the I-
Command Ignition and Trim Harness and the I-
Command Engine Interface Cable. This connec-
tion supplies power to the network when the key
switch is on. I-Command Digital networks do not
use this connection.
1. Canbus harness connector 006743
2. EMM CANbus connector cap and clip 1
Install clip and connector to hose. 4

2
1
2
3
1. Trim/Tilt connector 006734

2. CANbus Ignition connector
3. SystemCheck connector (with seal)
4. Deutsch-style harness power connector
1. CANbus connectors 006744

2. EMM cooling water hose
22
ROUTINE SERVICE
Route I-Command Ignition Harness through wire Water Pressure Gauge

channel in flywheel cover. Install electrical cover.
To display engine water pressure, install a water
Make sure both harnesses are in front of the tab
pressure hose fitting in the cylinder block as
and tighten with tie strap.
shown.
1
Use Pipe Sealant with Teflon on the threads of the 2
hose fitting. Refer to installation instructions sup-
plied with gauge.
3
2
1
4
1. Electrical cover 006737
2. Wire channel
3. Tab
4. Tie strap
Use Evinrude Diagnostics software to adjust net- 1. Water pressure hose fitting 002461
work settings in the EMM. From the Settings
screen, select Engine Options. For an I-Command water pressure display, sev-
eral water pressure sensor kits are available.
Refer to the Evinrude/Johnson Genuine Parts
and Accessories catalog.
Engine Options Screen 008093
23
ROUTINE SERVICE
BATTERY AND BATTERY CONNECTIONS
BATTERY AND BATTERY Install a starwasher on the threaded battery post.

Stack cables from the outboard, then cables from
CONNECTIONS accessories. Finish this connection with a hex nut.
WARNING
Keep the battery connections clean, tight, 3
and insulated to prevent their shorting or
arcing and causing an explosion. If the bat-
tery mounting system does not cover the 2
connections, install protective covers.
Check often to see that connections stay
clean and tight. 1
Marine Style Battery Post DR5103
1. Starwasher
Check battery connections frequently. Periodically 2. Hex nut
remove battery to clean and service connections. 3. Terminal Insulator
• Confirm that battery meets the minimum engine
requirements. NOTICE Do not use wing nuts to fasten ANY
• Connections must be clean and tight. battery cables. Wing nuts can loosen and
• Observe all wiring connections prior to disas- cause electrical system damage not covered
sembly. under warranty.
Disconnect battery negative (–) cable first and the Tighten all connections securely. Apply Triple-
battery positive (+) cable last. Guard grease to prevent corrosion.
Clean all terminals, battery posts, and connectors WARNING
with a solution of baking soda and water. Use a
wire brush or battery terminal tool to remove cor- Battery electrolyte is acidic—handle with
rosion buildup. Rinse and clean all surfaces. care. If electrolyte contacts any part of the
body, immediately flush with water and
IMPORTANT: Connect the battery positive (+) seek medical attention.
cable to the battery positive (+) post FIRST. Con-
nect the battery negative (–) cable to the battery
negative (–) post LAST.
24
ROUTINE SERVICE
OETIKER CLAMP SERVICING
OETIKER CLAMP 1
SERVICING
Clamp Identification
Use Oetiker clamps for making hose connections. 2
These clamps provide corrosion resistance, mini-
mize the potential for abrasion of rigging compo-
nents, and provide solid, permanent connections.
The selection and installation of an Oetiker clamp

is essential in the proper sealing of hose connec-
tions. The clamp identification numbers appear on
the side of the clamp, near the top of the ear.
Refer to Clamp Selection chart for dimensions.
1. Clamp identification numbers 000093
WARNING
DO NOT re-use Oetiker clamps. Fuel leak-
age could contribute to a fire or explosion.
Clamp Selection
To select the correct size Oetiker clamp, measure Chose a clamp so that the outside diameter of the
the outside diameter of the hose when installed on hose is approximately in the middle of the clamp-
the fitting. ing range of the clamp.
,' 31 &ODPSLQJ5DQJH

+RVH PP

'LDPHWHU LQFK
008458
25
ROUTINE SERVICE
OETIKER CLAMP SERVICING
Clamp Installation Clamp Removal

A constant stress should be applied 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.
IMPORTANT: Use only Oetiker recommended

tools to close Oetiker stepless clamps.
Oetiker pincers are available in the Evinrude/
Johnson Genuine Parts and Accessories Catalog.
000108
Method 2: Lift end of stepless clamp with screw-

driver.
DP0886
• Position correct size clamp over hose.

• Install hose on fitting.
• Close clamp ear fully with Oetiker pincers (pli-
ers).
000090
Method 3: Use Oetiker pincers (pliers) to grip

clamp. Pull clamp off of connection and discard.
1 2
1. Open clamp 000092
2. Closed clamp
000091
26
ROUTINE SERVICE
ADJUSTMENTS
ADJUSTMENTS Throttle Friction Adjustment

Tiller models are equipped with a throttle friction
Steering Friction Adjustment adjustment knob located on the steering handle.
Tiller models are equipped with a steering friction Tighten the knob to reduce the effort required to
adjustment. Steering friction is not required when hold a throttle setting.
remote steering is used. 2
Turn the knob:
Adjust steering friction with outboard mounted to • clockwise to increase friction
boat by loosening or tightening the adjustment • counterclockwise to decrease friction
screw. Steering friction should be adjusted so a
slight drag is felt when turning. WARNING
WARNING Tighten knob only enough to hold throttle

at a constant engine speed. Overtighten-
Do not overtighten. The steering friction ing will prevent quick throttle change in
screw is not intended to allow “hands off” case of emergency.
steering.
002191
1. Steering friction adjustment—Manual tilt models 001256
1. Steering friction adjustment—Power tilt models 005116
27
ROUTINE SERVICE
ADJUSTMENTS
Tilt Limit Switch Adjustment Place the outboard in normal operating position.
(75 – 90 HP) Rotate the LOWER adjustment tab UP to reduce
the maximum tilt. Rotate the UPPER adjustment
WARNING tab DOWN to increase the maximum tilt position.
If the outboard does not clear all boat parts
when tilted fully or turned side to side,
safety related parts could be damaged in
the course of such outboard movement.
Injuries could result from loss of boat con-
trol.
2
Adjust the tilt limit switch on all new outboard
installations.
1
Check the clearance between outboard(s) and the
boat’s motor well and transom area. Tilt out- 1. Lower adjustment tab DR4268
board(s) to highest point of clearance and turn the 2. Upper adjustment tab
steering system lock to lock.
Check the adjustment by tilting the outboard fully.
If the outboard contacts the boat's motor well
when fully tilted, adjust the tilt limit cam to reduce Repeat this procedure until the tilt limit switch
full-tilt position. stops the outboard's upward travel before it con-
tacts the motor well.
NOTICE The tilt limit cam will not prevent
the outboard from overriding the adjustment if To prevent damage to equipment, provide addi-
the outboard is tilted manually. tional motor well clearance when needed. Con-
sider either changing the outboard mounting
position or modifying the boat if the possibility for
interference and damage exists.
WARNING
Adjusting the tilt limit cam will NOT pre-
vent the outboard from tilting fully and
contacting the motor well if the gearcase
hits an object at high speed. Such contact
could damage the outboard and boat and
injure boat occupants.
DR3916
28
ROUTINE SERVICE
ADJUSTMENTS
Trim Sending Unit Adjustment

WARNING
(40 – 60 HP)
The sending unit eccentric cam must be adjusted To avoid personal injury, do not adjust the
so that the gauge needle is aligned with the lowest sending unit eccentric cam while the
gauge mark with the outboard trimmed all the way engine is being tilted.
DOWN.
2
When the outboard is trimmed all the way DOWN,
the sending unit lever touches the eccentric cam
just forward of the top of the cam at the contact
point.
Loosen cam screw and rotate eccentric cam to

adjust full down gauge position:
• If the needle was above the lowest mark, move
the thick part of the cam TOWARD the contact
1
point. Tighten the screw, and recheck the gauge
reading.
• If the needle was below the lowest mark, move
1. Lowest gauge mark DR2827 the thick part of the cam AWAY from the contact
point. Tighten the screw, and recheck the gauge
Check if the gauge needle is above or below the reading.
lowest gauge mark. Tilt engine UP and engage 1
trailering lock. 3
4
1
1. Lever DR5090
2. Eccentric cam
1. Trailering lock 18954 3. Contact point
4. Cam screw
Tighten eccentric cam retaining screw and check

needle position at full trim DOWN.
29
ROUTINE SERVICE
ADJUSTMENTS
Trim Sending Unit Adjustment Observe the trim gauge. If the needle does not
show center position, tilt the outboard up and
(75 – 90 HP) adjust the sending unit by pivoting it up or down.
Tilt the outboard and engage the tilt support.
Temporarily install a thrust rod, P/N 436541, in the

number 3 hole.
1
1. Needle at center position 000662
Lower the outboard against the thrust rod to check

adjustment. Repeat adjustment, if necessary.
29072
After adjustment is correct, tilt the outboard up,
Loosen the sending unit screws, to allow the tighten the two sending unit screws, and remove
sending unit to pivot. 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 the trim limiter rod is left out, the bow could
plow into the water causing the boat to “bow
steer” resulting in a loss of control.
• If the trim limiter rod is set too far out, the pro-
peller could ventilate, resulting in poor accelera-
tion when the boat is coming onto plane.
1. Screws 27339
Set the trim limiter rod to prevent excessive trim
Disengage the tilt support. Lower the outboard down and provide good acceleration. The trim lim-
against the thrust rod. iter rod can be used to prevent the gearcase or
spray deflector from contacting the transom.
WARNING
When the outboard is returned to the cus-
tomer, the trim limiter rod must be
installed and in the same location as it
was when the motor was brought in for
service. Leaving the trim limiter rod out, or
changing the adjustment, could allow the
motor to unexpectedly trim in too far and
cause loss of control.
30
ROUTINE SERVICE
ADJUSTMENTS
Trim Tab Adjustment

WARNING
1
Improper trim tab adjustment can cause
difficult steering and loss of control.
2
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. 1. Trim tab screw COA3663
IMPORTANT: A single trim tab adjustment will Test the boat and, if needed, repeat the procedure
relieve steering effort under only one set of speed, until steering effort is as equal as possible.
outboard angle and load conditions. No single
adjustment can relieve steering effort under all Outboards with High Transom Heights
conditions. The trim tab may be above the surface of the
water when the outboard is trimmed out. Steering
If the boat pulls to the left or right when its load is effort might increase. Lower the trim setting to
evenly distributed, adjust the trim tab as follows: submerge the trim tab and to reduce steering
• With the remote control in NEUTRAL and the effort.
engine OFF, loosen the trim tab screw.
• If the boat pulled to the right, move rear of the Dual Standard Rotation Outboards
trim tab slightly to the right. Move both trim tabs equally and in the same
• If the boat pulled to the left, move rear of the direction.
trim tab slightly to the left.
Dual Outboards, One Counter and One
Tighten the trim tab screw as follows: Standard Rotation
• 40 – 90 HP: 35 to 40 ft. lbs. (47 to 54 N·m). Set both trim tabs to the center position.
31
ROUTINE SERVICE
ADJUSTMENTS
Dual-Outboard Alignment Alignment Adjustment

Dual outboards must be connected with a tie bar Various boat/motor combinations respond differ-
and adjusted to align the outboards for correct ently to dual-outboard alignments. Each applica-
water flow to the gearcases and propellers. tion must be thoroughly tested until the ideal
combination of performance, steering, and cooling
Incorrect outboard alignment could cause one or is found.
more of the following: A common practice is to set-up the outboards par-
• Propeller ventilation allel, or with a small amount of “toe-out,” and
• Reduction of top speed adjust inward until best results are achieved.
• Improper boat tracking • A typical set-up, with outboards mounted
• Engine overheat and powerhead damage directly on the transom, often runs best with a
slight amount of “toe-in.”
Follow the instructions provided by the tie-bar • Outboards mounted behind the transom on
manufacturer for tie bar installation and adjust- motor brackets usually require parallel align-
ment. ment or “toe-out.”
Measure Alignment Adjust the outboard alignments by adjusting tie
The “toe-in” (gearcase leading edges closer bar. Follow the tie bar manufacturer’s adjustment
together than propeller shaft centers) or “toe-out” procedures.
(gearcase leading edges farther apart than propel-
ler shaft centers) is determined as follows: Check steering operation. Make sure that the
• Position outboards straight with the anti-ventila- steering system operates properly at various trim
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 ventilation on one or both outboards may
• Measure between leading edges of gearcase. indicate a misalignment of the gearcases. Reset
the outboard alignment and retest.
6340
32
ROUTINE SERVICE
OPERATIONAL CHECKS
OPERATIONAL CHECKS Fuel System

Perform running checks of the fuel system by fol-
DANGER lowing these steps:
• Squeeze fuel primer bulb until hard or activate
DO NOT run the engine indoors or without electric primer. Observe all fuel hoses and con-
adequate ventilation or permit exhaust nections. Repair any leaks. 2
fumes to accumulate in confined areas. • Start outboard. Inspect all hoses and connec-
Engine exhaust contains carbon monoxide tions. Repair any leaks or misrouted hoses
which, if inhaled, can cause serious brain immediately.
damage or death.
Emergency Stop / Key Switch
Check emergency stop function. With outboard
WARNING running at IDLE, pull safety lanyard from emer-
gency stop switch. Outboard must stop immedi-
Contact with a rotating propeller is likely to ately.
result in serious injury or death. Assure
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 that control can be easily moved into
peller, even when the engine is off. Blades all gear and throttle settings. Do not shift remote
control when outboard is not running.
can be sharp and the propeller can con-
tinue to turn even after the engine is off.
Start-In-Gear Prevention
WARNING
CAUTION
Make certain that the starter will not oper-
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 feature is required by
ing system and/or powerhead 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 restart the outboard. Outboard should not
Turn key switch to ON. Warning horn should 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
Turn key switch to ON. Try to restart the outboard. Outboard should not
start.
The Evinrude E-TEC screen should apeear, fol-
lowed by the tachometer display.
33
ROUTINE SERVICE
COOLING SYSTEM
Tachometer Pulse Setting COOLING SYSTEM

(SystemCheck)
Regularly inspect cooling system components for
Confirm accuracy of tachometer reading.
corrosion, damage, leaks, or restrictions:
• Adjust dial on back of tachometer to required
setting (the outboard should not be running). • water intake screens
• water pump
Outboard Model Tachometer Setting • all internal water passages
40–90 HP 6 Pulse or 12 Pole • thermostats
• all external water hoses and fittings
• vapor separator cooling passages and fittings
Water Pump Overboard Indicator • EMM cooling passages and fittings
A steady stream of water should flow from the • overboard water pressure indicator.
overboard indicator.
Water Intake Screens
Inspect condition of water intake screens. Clean
or replace as needed.
Confirm function of overboard water pressure indi-
cator.
2
1
1
1. Water pump overboard indicator 008469
Operating Temperature 1. Water intake screen 001212

2. Overboard indicator 008470
An outboard run at idle speed should achieve a
temperature based on the engine’s thermostatic
control. In general, the powerhead temperature
should reach at least 104°F (40°C) after five min-
utes of idling. Check that the powerhead reaches
idle temperature. Refer to SERVICE SPECIFICA-
TIONS on p. 10.
Idle Speed
Make sure the outboard idles within the specified
idle RPM range. If the outboard is run on a flush-
ing device, the idle speed and quality may not be
representative of actual in water use.
34
ROUTINE SERVICE
COOLING SYSTEM
Engine Flushing Turn water supply on.

Flush the outboard with fresh water following each Run outboard at IDLE only until full operating tem-
use in brackish, salt, or polluted water to minimize perature is reached.
the accumulation of scale and silt deposits in cool-
ing system passages. Leave the outboard in VERTICAL (DOWN) posi-
tion long enough for the powerhead to drain com- 2
The outboard can be flushed on the trailer or at pletely.
dockside; running or not running.
Reinstall propeller.
IMPORTANT: The outboard must be located in
a well ventilated area with appropriate ground Flushing — Outboard Not Running
drainage during the flushing procedure. Outboard can be in VERTICAL (DOWN) or
TILTED (UP) position.
Keep water inlet pressure between 20 to 40 psi
(140 to 275 kPa). Thread garden hose into flushing port.
Flushing — Outboard Running Turn water supply ON.
WARNING Flush outboard for at least five minutes.
To prevent injury from contact with rotat- Turn off water supply and remove garden hose.
ing propeller, remove the propeller before
flushing. Leave the outboard in VERTICAL (DOWN) posi-
tion long enough for the powerhead to drain com-
pletely.
Place outboard in VERTICAL (DOWN) position in
a well ventilated area.
Thread garden hose into flushing port.
002024
35
ROUTINE SERVICE
COOLING SYSTEM
Running the Outboard Using a Install flushing adapter onto gearcase water inlet
screens.
Hose and Flushing Adapter
WARNING
To prevent injury from contact with rotat-
ing propeller, remove the propeller before
running engine with a flushing adapter. 1
A flushing adapter may be used to provide cooling

water when running the outboard to:
• Flush the engine
• Run for an extended period of time, such as
when performing diagnostic work 1. Flushing adapter 008342
• Run the engine on a dynamometer
• Prepare the outboard for storage. A steady stream of water should flow from the
overboard indicator while the engine is running.
IMPORTANT: The outboard must be located in
a well ventilated area with appropriate ground Monitor engine water pressure gauge when:
drainage. • Engine speed is above 3000 RPM
• Running engine on a dynamometer.
Keep water inlet pressure between 20 to 40 psi
(140 to 275 kPa). Refer to SERVICE SPECIFICATIONS on p. 10 for
water pressure requirements.
Be sure water supply is sufficient to run the engine
above idle speed. NOTICE Engine will overheat if normal water
pressure is not maintained. Temporarily install
Water Supply Requirements an engine water pressure gauge if not
Model Water Flow @ WOT equipped with one.
40–65 HP 4 to 6.5 GPM 1 (15 to 24 LPM 2)
75–90 HP 7.5 to 9 GPM (28 to 34 LPM)
1. GPM: Gallons per minute
2. LPM: Liters per minute
36
ROUTINE SERVICE
LUBRICATION
LUBRICATION Tiller Handle

Lubricate the tiller handle grease fittings with Tri-
Steering System ple-Guard grease.
WARNING
Failure to regrease as recommended
2
could result in steering system corrosion.
Corrosion can affect steering effort, mak-
ing operator control difficult.
1 1
Grease the stainless steel output end of the steer-
ing cable with Triple-Guard grease.
Use an appropriate cleaning solvent to remove

corrosion and dirt from output end of cable before 1. Tiller handle fittings – Standard handle 008196
coating it with grease. Make sure wiper nut is
installed and not damaged.
1 1
2
1
1. Tiller handle fittings – Long handle 008197
1. Steering cable DR29546

2. Wiper nut
37
ROUTINE SERVICE
LUBRICATION
Swivel Bracket and Trailering Tilt Tube

Bracket Lubricate the tilt tube grease fittings with Triple-
Lubricate the swivel bracket with Triple-Guard Guard grease.
grease.
Apply grease until the grease begins to flow from
the upper or lower swivel bracket areas.
Coat the pivot points of the trailering bracket with

Triple-Guard grease.
1
1 1
2 1. Tilt tube fittings DR38798
1 Throttle and Shift Linkage

Disconnect the battery cables at the battery.
Remove clips and washers from throttle and shift

lever pins. Carefully, remove casing guides from
2-Cylinder models DR31329
1. Grease fitting pins.
2. Tilt support
IMPORTANT: DO NOT disturb cable trunnion
adjustments.
Shift remote control into FULL THROTTLE/

1 REVERSE position to fully extend the plastic cas-
ing guides.
Apply Triple-Guard grease to:

2 3 • Cable attachment pins of both the throttle and
shift levers
• Inner casings of both the throttle and shift
cables.
3-Cylinder models DR5073
1. Grease fitting
2. Pivot points
3. Lower swivel bracket area
1 2
1. Attachment pins, throttle and shift cables 002214

2. Inner casings, throttle and shift cables
38
ROUTINE SERVICE
LUBRICATION
Shift the remote control to the NEUTRAL/IDLE Gearcase Lubricant

position.
Draining
Install control cables.
WARNING
Check proper throttle and shift function.
Gearcase lubricant may be under pressure 2
Propeller Shaft and/or hot. If plug is removed from a
Debris from the water can become lodged around recently operated outboard, take precau-
propeller shaft. Frequent inspection can minimize tions to avoid injury.
potential gearcase damage.
IMPORTANT: Always check the fill level of the
WARNING gearcase lubricant at the upper plug before
When servicing the propeller, always shift removing the lower, drain/fill plug. A tie strap can
the outboard to NEUTRAL, turn the key be used to check lubricant level.
switch OFF, and disconnect the battery
cables at the battery.
Remove propeller. Refer to Propeller Hardware

Installation on p. 294.
Inspect bushing and blade surfaces. Replace

damaged or worn propellers.
1
Clean propeller shaft. Inspect propeller shaft
seals. Replace damaged or worn seals.
Apply Triple-Guard grease to entire length of pro- 1. Tie strap 000072
peller shaft prior to installing propeller.

If lubricant level is low, refer to GEARCASE LEAK
Reinstall propeller hardware and propeller. TEST on p. 295.
Remove the lubricant level plug, then the lubricant
drain/fill plug, and drain the lube from the gear-
case into a container.
2
1. Lubricant level plug 001993
2. Lubricant drain/fill plug
39
ROUTINE SERVICE
LUBRICATION
Inspection Remove the lubricant level plug and the lubricant

Inspect the lubricant and the magnets 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 indicate normal wear of the gears, bearings,
gearcase with HPF PRO lubricant through the
or shafts within the gearcase. Metal 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 lubricant for water contamination.
can cause air pockets and the gearcase may not
Water can make the lubricant milky in appear-
fill completely.
ance. However, normal aeration can also cause
the same appearance. Clean plug seal area and install the lubricant level
plug and new seal, then the lubricant drain/fill plug
To check for water contamination, put lubricant
and new seal. Tighten plugs to a torque of 60 to
into a glass container. Allow the oil to settle 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, refer to GEARCASE LEAK
TEST on p. 295.
2
Overheated lubricant will have a black color and
burned odor.
Internal gearcase inspection is recommended

when lubricant is contaminated or shows signs of
failure.
Filling 1. Lubricant level plug 27023

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

recommended lubricants. IMPORTANT: The recommended gear lubri-
cants are formulated for marine applications. Do
Secure the gearcase in a vertical position. not use automotive gear lubricants, engine oils, or
any other oil or grease.
40
ROUTINE SERVICE
LUBRICATION
Trim and Tilt • Single Ram System–Add Evinrude/Johnson

Biodegradable TNT Fluid, as needed, to bring
CAUTION level to the bottom of the fill plug threads.
Correct fluid level must be maintained to
ensure operation of the impact protection
built into the unit. 2
Check reservoir fluid level at least every three 1
years or 300 operating hours.
• 40–60 HP: System capacity is approximately
15.2 fl. oz. (450 ml).
• 75–90 HP: System capacity is approximately 21
fl. oz. (620 ml).
• Tilt the outboard and engage the tilt support. Single Ram System, 40 - 60 HP 008018
1. Filler cap
1. Tilt support bracket, 40-60 HP 18954

Single Ram System, 79 - 90 HP 008017
1. Filler 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 unit at least five complete cycles to
purge all air from the system. When cycling the
unit, hold the trim switch ON an additional 5 to
1 10 seconds after the unit reaches the end of its
travel before activating the switch in the oppo-
site direction.
• Remove filler cap and check fluid level.
41
ROUTINE SERVICE
SPARK PLUGS
SPARK PLUGS plug with the OPEN side of the ground electrode
facing the fuel injector.
Spark plugs should be removed and examined
periodically. Replace worn, fouled or damaged
spark plugs.
Use only recommended spark plugs with the cor-
rect gap setting.
Spark Plug, Champion 2 1
QC10WEP @ 0.028 ± 0.003 in. (0.71 mm)
1. Ink mark 000758
• Remove spark plugs and inspect condition. 2. Open side
• Set spark plug gap on new, replacement spark

Apply Triple-Guard grease to the gasket surface
plugs.
of the spark plug. Install spark plug and tighten to
• Mark spark plugs for ground electrode orienta-
a torque of 15 ft. lbs. (20 N·m).
tion.
• Apply Electrical Grease to the ribbed portion of If the mark is in unshaded area do not tighten any-
the spark plug ceramic and to the opening of more.
the spark plug cover to prevent corrosion.
• Install spark plugs using “indexing” procedure.
Removal 1 2
Remove ignition coil above spark plug to gain
access. When reinstalling coils, tighten screws to
Spark Plug Indexing Diagram 002106

1. Unshaded area
2. Shaded area
If the mark is in the shaded area, reset torque

wrench to 30 ft. lbs. (41 N·m) and continue to turn
until the mark is in the unshaded area.
006521
If the mark does not reach the unshaded area
before the torque of 30 ft. lbs. (41 N·m) is reached,
the spark plug cannot be indexed for that cylinder.
Indexing Try another spark plug and repeat the steps
Spark plug indexing positions the ground elec- above.
trode of the spark plug opposite the fuel injector
nozzle.
Put an ink mark on the ceramic of the spark plug

in line with the OPEN side of the ground elec-
trode. This mark will be used to orient the spark
42
ROUTINE SERVICE
FUEL AND OIL SYSTEMS
FUEL AND OIL SYSTEMS Air Silencer

The air silencer maximizes air flow while minimiz-
Routine replacement of filters reduces the possi-
ing noise.
bility of foreign material restricting the incoming
fuel or oil supplies.
Replacement filter elements are available through
2
Evinrude/Johnson Genuine Parts.
Fuel Filter
Evinrude E-TEC 40–90 HP outboards are
equipped with an in-line fuel filter. Refer to FUEL
COMPONENT SERVICING on p. 142.
40 - 65 HP 002227
1. In-line fuel filter 002145
Oil Filters and Oil Reservoir

Perform visual inspections to identify oiling system 75 - 90 HP 002158
leaks. Make certain the oil tank is filled and oil
supply is not contaminated. Routine cleaning of the air silencer is recom-
mended to remove any accumulation of debris.
Hoses and Connections

Check condition of all hoses and connections in
both the fuel and oil systems:
• Visually inspect all components.
• Observe all clamps, hoses, and connections
while outboard is running.
• Replace all damaged components.
• Repair all leaks.
WARNING
Failure to check for fuel leakage could
allow a leak to go undetected, resulting in
fire or explosion.
43
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 fresh or salt water.
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 equipped with three sacrificial

anodes. 1
1. Meter lead to anode 000677
1 The meter should show little or no resistance. If

resistance is high, check the following:
• Remove the anode 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 products 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 anodes and metal components film of anti-corrosion protection.
below water level. Erosion of anodes is normal
and indicates the anodes are functioning properly. Exterior Finishes
IMPORTANT: Anodes that are not eroding may Maintain the outboard’s exterior finish to prevent
not be properly grounded. Anodes and the mount- corrosion and reduce oxidation:
ing screws must be clean and tight for effective • Use automotive wax to protect the outboard’s
corrosion protection. exterior finish from oxidation
• Clean regularly using clean water 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.
• Do not paint or apply protective coatings to
anodes or anode fasteners.
• Avoid using metal-based antifouling paint on the
boat or outboard.
44
ROUTINE SERVICE
STORAGE
STORAGE Software Control Method

Winterization can also be run using Evinrude
IMPORTANT: DO NOT start outboard without a Diagnostics software. With the outboard running,
water supply to the outboard’s cooling system. start the process at the Settings/Adjustments
Cooling system and/or powerhead damage could screen and follow the instructions.
occur. 2
Fuel System Treatment
Stabilize the boat’s fuel supply with Evinrude/
Johnson 2+4 Fuel Conditioner following the
instructions on the container. 1
Internal Engine Treatment
Remove the propeller, attach garden hose to
flushing port and turn on water.
Evinrude E-TEC models are designed to be self-

winterizing using either of the following methods: 1. Winterization start button 008077
IMPORTANT: Engine MUST be in NEUTRAL

throughout these procedures.
Throttle Control Method

• Advance throttle control to 1/2 throttle (50%)
position and then start the outboard. All four
SystemCheck lights will turn on and the out-
board will run at idle speed.
• After approximately 15 seconds, the System-
Check lights will go off. Move throttle to IDLE
position. SystemCheck lights will light again.
• Wait another 15 seconds. SystemCheck lights 008119
will go off. At this point, advance throttle to
FULL (in neutral). SystemCheck lights will flash, After the outboard shuts itself off, turn key switch
indicating that outboard is in winterize mode. OFF, then detach garden hose.
• Outboard will automatically go to fast idle and
fog itself. Allow outboard to run until it shuts IMPORTANT: When finished, leave the out-
itself off (about one minute). board in vertical position long enough to com-
pletely drain the powerhead.
IMPORTANT: If SystemCheck lights do not
flash, or outboard runs above fast idle, immedi-
ately turn off outboard and start the procedure
again.
45
ROUTINE SERVICE
PRE-SEASON SERVICE
Additional Recommendations PRE-SEASON SERVICE

• Fill oil reservoir.
• Inspect the fuel filter. If there is debris in the fuel If the outboard was removed from the boat for
filter, it must be replaced. storage, make sure it is reinstalled with factory
specified hardware. Refer to the Predelivery and
• Replace gearcase lubricant.
Installation Guide.
• Remove and inspect propeller.
• Clean and grease propeller shaft. Outboard Mounting Bolts
• Blow water from gearcase speedometer pickup • Check and re-tighten outboard mounting bolts
system (gearcase speedometer models only). to a torque of 40 ft. lbs. (54 N·m).
• Lubricate all grease fittings and linkages.
• Inspect outboard, steering system, and con- Gearcase Lubricant
trols. Replace all damaged and worn compo- • Check the lubricant level.
nents. Refer to manufacturer’s and lubrication • Inspect gearcase for leaks. If leak is apparent,
recommendations. pressure and vacuum test gearcase.
• Touch up painted surfaces as needed. Coat • Repair gearcase as needed.
outer painted surfaces with automotive wax.
• Remove battery(s) from boat. Store in a cool, Battery(s)
dry location. Periodically charge battery(s) while • Replace batteries that cannot be charged.
stored. Refer to manufacturer’s maintenance
recommendations when servicing batteries. Power Trim and Tilt
• Store outboard in upright (vertical) position. • Remove filler cap and check fluid level.
• Check for fuel leakage. • Inspect the power trim and tilt unit for leaks.
Repair as needed.
WARNING
Failure to check for fuel leakage could Operational Checks
allow a leak to go undetected, resulting in • Refer to OPERATIONAL CHECKS on p. 33
fire or explosion. • Steering system
• Remote controls
• All other accessories and instrumentation
Check Oil Injection Tank

• Inspect the oil tank for leaks.
Check Fuel System
• Inspect entire fuel system for leaks before start-
ing outboard.
• Repair all leaks.
Water Pump
• Make sure a steady stream of water flows from
overboard indicator.
WARNING
Failure to check for fuel leakage could
allow a leak to go undetected, resulting in
fire or explosion.
46
ROUTINE SERVICE
SUBMERGED ENGINES
SUBMERGED ENGINES Prime oil system and fuel system. Refer to FUEL
SYSTEM PRIMING on p. 136 and Oil Supply
Once an outboard has been submerged in fresh Priming on p. 165. Make sure all oil injection
or salt water, it must be serviced within three (3) hoses are clean and filled with oil.
hours of recovery. Immediate service can mini-
Make sure high pressure fuel system does not
mize the corrosive affect that air has on the pol-
ished surfaces of the crankshaft, connecting rods, contain water. Flush as needed. 2
and internal powerhead bearings. Inject a small amount of outboard lubricant into
spark plug holes and install new spark plugs.
IMPORTANT: If outboard cannot be started or
Refer to Spark Plug Indexing on p. 42.
serviced immediately, it should be resubmerged in
fresh water to avoid exposure to the atmosphere. Reinstall all removed or disconnected parts.
Engine Dropped Overboard Use Evinrude Diagnostics software to:
(Not Running) • Initiate Break-in
• Check fuel pump operation
• Check injector operation (fuel and oil)
Rinse powerhead with clean water. • Check timing (once outboard is running at full
operating temperature)
Remove spark plug leads and spark plugs.
Run outboard below 1500 RPM for one-half hour.
Place outboard in horizontal position (cylinder
heads down). Slowly rotate flywheel in a clock- Engine Dropped Overboard
wise rotation to work all water out of powerhead.
(Running)
IMPORTANT: If sand or silt may have entered Follow the same procedures as Engine Dropped
the outboard, DO NOT attempt to start it. Disas- Overboard (Not Running). However, if there is
semble and clean. any binding when the flywheel is rotated, it may
indicate a bent connecting rod and no attempt
Disassemble all electrical connectors. Clean con- should be made to start the outboard. Powerhead
nectors and terminals, and treat with water dis- must be disassembled and serviced immediately.
placing electrical spray. Apply Electrical Grease to
terminals prior to reassembly. Coat all exposed Engine Dropped Overboard
solenoid terminals and engine grounds with Black
Neoprene Dip. (In Salt Water)
Follow the same procedures used for Engine
Clean and inspect all electrical components. Dropped Overboard (Not Running) and Engine
Replace damaged or corroded components prior Dropped Overboard (Running). Disassemble
to returning the outboard to service. Electric start- and clean outboards that have been submerged in
ers should be disassembled, cleaned, flushed salt water for prolonged periods of time. Clean or
with clean water, and treated with water displacing replace electrical components as necessary.
electrical spray prior to reassembly.
Disconnect fuel supply hose from outboard. Drain

Prolonged Submersion
and clean all fuel hoses, filters, and fuel tanks. (Fresh or Salt Water)
Outboards that have been dropped overboard and
Disconnect oil supply hose and oil return hose not recovered immediately, must be serviced
from outboard. Drain and clean all oil hoses, fil- within three hours of recovery. Follow the same
ters, and oil tank assemblies. procedures used for Engine Dropped Overboard
Refill fuel tank with fresh fuel and oil tank with rec- (Not Running) and Engine Dropped Overboard
ommended oil. (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
LOWER COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
LOWER COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 3
LOWER COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
LATCH HANDLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
TRIM SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
49
UPPER COVER SERVICE
UPPER COVER SERVICE LOWER COVER SERVICE

Latch Hook Installation Lower Cover Removal
Insert threaded bracket into pocket. Remove lower engine cover screws.
1
1
1
1. Bracket 006468
1. Lower cover screws 002168

Apply Ultra-Lock to screw threads. Place hook
into position with opening toward the front. Tighten
Loosen port side cover slightly, and disconnect
screws to a torque of 60 to 84 in. lbs. (7 to 9.5
trim/tilt switch connector. Then, remove port and
N·m).
starboard covers.
006469
1. Trim/tilt switch connector 002169
50
LOWER COVER SERVICE
Lower Cover Installation Start the top front screw next and draw cover
halves together.
Installation of lower motor covers will be easier if
the following steps are performed in order:
• Install air silencer on throttle body.
• Place starboard cover on outboard and route
fuel hose and battery cable through grommet
notch. 1
• Insert trim cable grommet into port side cover.
• Connect trim/tilt switch connector. 3
• Place port side cover into position on outboard.
1. Start this screw second 002165
1 Install remaining cover screws and tighten all

screws to 24 to 36 in. lbs. (3 to 4 N·m).
2
1
1. Trim cable grommet 002216
2. Trim/tilt switch connector
1
Start the screw above the exhaust relief grommet

first. Tighten just enough to hold the grommet in
place.
1
1. Lower cover screws 002168
1. Start this screw first 002157

2. Exhaust relief grommet
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 006470
Install nut on switch. Tighten nut to a torque of 10
Apply Ultra-Lock to screw threads. Place spring to 16 in. lbs. (1 to 2 N·m).
washer and hook into position and tighten screw
to a torque of 180 in. lbs. (20 N·m).
3
1
006747
1. Spring washer 006471 Install electrical connector. Refer to CONNECTOR

2. Hook SERVICING on p. 116.
3. Screw
006748
52
ENGINE MANAGEMENT MODULE (EMM)

TABLE OF CONTENTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
EMM FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
EMM CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
LED INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
EMM INPUTS AND OUTPUTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INTERNAL SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
EMM TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
55 V CIRCUIT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4
12 V CIRCUIT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5 V CIRCUIT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
BAROMETRIC PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
EXTERNAL SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ENGINE TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
LOW OIL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
CRANKSHAFT POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
NEUTRAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INTERNAL EMM FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
ENGINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
S.A.F.E. WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SHUTDOWN MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DIAGNOSTIC SOFTWARE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
STATIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
DYNAMIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
STORED SERVICE CODES (FAULTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
HARD FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PERSISTENT FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
STATIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DYNAMIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
OIL CONTROL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
TILLER/REMOTE PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
TPS CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
IDLE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
FUEL INJECTOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
REPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SOFTWARE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
EMM TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
EMM SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
53
DESCRIPTION
DESCRIPTION
1
The Engine Management Module (EMM) is a
water-cooled engine controller. It controls many
outboard systems including alternator output for
2
the 12 V and 55 V circuits. Operating voltage is
supplied to the EMM by the stator.
This section discusses the functions of the EMM

and its various internal and external sensors. It 3
also describes using Evinrude Diagnostics soft-
ware to retrieve and adjust service information
stored in the EMM
1. J1-A connector 006487
2. J1-B connector
EMM Functions 3. J2 connector
The EMM controls the following processes and

functions: LED Indicators
• Alternator output; 55 V and 12 V The EMM has four LED indicators located next to
• Fuel and ignition timing and duration the electrical connectors that provide useful infor-
• Fuel injector activation mation about the status of the system.
• Oil injector pump activation
• Electric fuel pump control IMPORTANT: LED 1 is toward the top of the
outboard (Closest to EMM J1-B connector).
• Idle speed control
• RPM limiter
• Electrical circuit monitoring 1
• Service code creation and storage
• Warning system activation
• ROM verification, self-test
• Choke-less cold starting
• Output of diagnostic data
• Tachometer signal
• RPM profile and engine hours
• Oiling ratios
• Exhaust water valve activation (60 - 65 HP) 1. LED indicators 002429
(Cooling hose removed for clarity) 006467
EMM Connections
When the ignition key is turned ON, LEDs 3 and 4
IMPORTANT: EMM connections and wiring should light, indicating that sensor circuits and the
must be clean and tight. Improper electrical con- stop circuit are working.
nections can damage the EMM. DO NOT run the
As the outboard is being started, all four LEDs
outboard with loose or disconnected wiring. should light and then go off in sequence. If any of
Make sure EMM connections are clean and tight. the LEDs does NOT light during starting, refer to
• Engine wire harness to EMM connectors; J1-A, EMM LED INDICATORS on p. 77.
J1-B, J2 When the outboard is running, all LEDs should be
• Stator to EMM connections; one 6-pin AMP and off. If any LED is lighted while the outboard is run-
J2 connector. ning, refer to EMM LED INDICATORS on p. 77.
54
EMM INPUTS AND OUTPUTS DIAGRAM
EMM INPUTS AND OUTPUTS DIAGRAM

9 8 7 4 5 6
3
A B 12
ABC
A B
1 2
1 2
4
INPUTS
J1-A
J1-B
+ 1
2
3
2 4
17
J2
1
OUTPUTS
2 1
30 40
20
A
C
B
50
10
60
0
x 100
RPM
70 11
3550
IT
EX
U
P
DO G ES
WN PA TE R
EN
MENU
18 10
14 15 13 12 16
008026
1. Engine Management Module (EMM) 7. Low Oil Switch 13. Fuel Injector
2. Battery (12 volt) 8. Air Temperature Sensor (AT) 14. Tachometer/SystemCheck Gauge
3. Stator 9. Engine Temperature Sensor 15. I-Command (CANbus) Display
4. Crankshaft Position Sensor (CPS) 10. Fuel Pump (high pressure) 16. Diagnostic Connector
5. Throttle Position Sensor (TPS) 11. Oil Injection Pump and Manifold 17. LED Indicators
6. Neutral Switch 12. Ignition Coil 18. Exhaust Water Valve (60–65 HP)
55
INTERNAL SENSORS
INTERNAL SENSORS If sensor reads less than -71°F (-57.4°C) or

greater than 313°F (156°C), a sensor circuit fault
Sensor inputs and internal EMM controllers are is 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 the EMM Service Code Chart at the
back of this manual for a complete list of all EMM LED 3: ON (Running)
engine fault codes.
Internal sensors are NOT serviceable. Repro-

55 V Circuit Sensor
gramming or replacement may be required to Monitors the EMM’s 55 V alternator circuit.
resolve internal EMM 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 voltage is less than 45 V, the EMM:
Activates S.A.F.E.
Stores service code 25 Activates S.A.F.E.
EMM LED 4: ON (Running) Stores service code 17
Engine Monitor TEMP display: ON EMM LED 1: ON (Running)
If EMM temperature exceeds 212°F (100°C) or
the circuit fails, the EMM: 12 V Circuit Sensor
Activates SHUTDOWN Monitors the EMM’s 12 V alternator circuit.
Stores service code 29
If battery voltage exceeds 15.5 volts, the EMM:
EMM LED 4: FLASHING
Engine Monitor TEMP display: FLASHING Stores service code 27
EMM LED 1: ON (Running)
Engine Monitor LOW BATTERY display: ON
IMPORTANT: The outboard will not restart until
the engine cools below 212°F (100°C)and the
EMM temperature returns to normal. Refer to If battery voltage is less than 12.5 V, the EMM:
SHUTDOWN MODE on p. 62. Stores service code 26
If EMM temperature is less than -22°F (-30°C) or EMM LED 1: ON (Running)
the circuit fails, the EMM: Engine Monitor LOW BATTERY display: ON
56
EXTERNAL SENSORS
5 V Circuit Sensor EXTERNAL SENSORS

Monitors the EMM’s 5 V sensor circuit.
Sensor inputs and internal EMM controllers are
If sensor voltage is less than 4.75 volts, the EMM: used to control outboard operation. Use Evinrude
Diagnostics software to troubleshoot the sensors.
Stores service code 78 Refer to the EMM Service Code Chart at the
EMM LED 3: OFF (Cranking) back of this manual for a complete list of all
EMM LED 3: ON (Running) engine fault codes.
The EMM provides a 5 V DC signal for sensor cir-

Barometric Pressure Sensor cuits. It monitors all sensor voltage inputs and
Supplies the EMM with barometric pressure read- compares them to predetermined acceptable
ing to compensate for changes in altitude and air ranges. Inputs that fall outside of the acceptable
density. range create service codes. 4
If the BP sensor reads less than 13.3 KPa or Air Temperature Sensor
greater than 119.0 KPa, or the sensor or circuit
The air temperature sensor monitors the air tem-
fails, the EMM:
perature at the throttle body.
If the AT sensor voltage is out of the expected
range, or the sensor or circuit fails, the EMM:
If the BP sensor reads less than 70 KPa, the
EMM: Stores service code 47, 48, or 49
Stores a service code 45
If the BP sensor reads greater than 105 KPa, the
EMM: Engine Temperature Sensor
Stores service code 46 Monitors cylinder head temperature.
75 - 90 HP MODELS
If cylinder head temperature exceeds 212° F
(100° C) below 3500 RPM, the EMM:
Activates S.A.F.E.
Engine Monitor TEMP display: ON
If cylinder head temperature exceeds 194° F

(90° C) above 3500 RPM, the EMM:
Activates S.A.F.E.
57
EXTERNAL SENSORS
If cylinder head temperature exceeds 212° F If cylinder head does not reach operating temper-
(100° C) above 3500 RPM, or 230° F (110° C) ature (104°F / 40°C below 2300 RPM) in 10 min-
below 3500 RPM, the EMM: utes, the EMM:
Activates SHUTDOWN Stores service code 58
Stores service code 31 EMM LED 3: OFF (Cranking)
EMM LED 4: FLASHING EMM LED 3: ON (Running)
Engine Monitor TEMP display: FLASHING
Low Oil Switch
40 - 65 HP MODELS The low oil switch monitors the oil level in the oil
If cylinder head temperature exceeds 212° F tank.
(100° C), the EMM:
If the oil level falls below one-quarter capacity, the
Activates S.A.F.E. EMM signals:
Engine Monitor LOW OIL display: ON
When the oil level falls below one-quarter, the
EMM begins counting oil pump pulse cycles.
If cylinder head temperature exceeds 248°F When it reaches:
(120°C), the EMM:
• 40 – 65 HP: 4800 pulses
Activates SHUTDOWN • 75 – 90 HP: 6000 pulses
Stores service code 31 the EMM:
EMM LED 4: FLASHING
Activates S.A.F.E.
Engine Monitor TEMP display: FLASHING
ALL MODELS Engine Monitor NO OIL display: ON
The outboard will not restart after a temperature
related SHUTDOWN until the engine temperature
To recover from S.A.F.E. mode, the oil pump must
returns to normal. Refer to SHUTDOWN MODE
cycle for a minimum of three pulses with the oil
on p. 62.
level above one-quarter.
If sensor values are less than -15°F (-26.1°C) or
If outboard has been run for more than 3 hours
greater than 332°F (166.5°C), the EMM:
with NO OIL faults (codes 34 & 117), the EMM
Activates SHUTDOWN
EMM LED 4: FLASHING
Engine Monitor NO OIL display: FLASHING
If sensor values are below -4°F (-20°C), the EMM:
58
EXTERNAL SENSORS
Throttle Position Sensor Crankshaft Position Sensor

The throttle position sensor receives a voltage sig- Ribs spaced on the flywheel mark crankshaft posi-
nal from the EMM. As the throttle lever is rotated, tion. As the ribs pass the magnetic field of the
the EMM receives a return voltage signal through CPS, an AC voltage signal is generated. The
a second wire. This signal increases as the TPS EMM uses this signal to identify crankshaft posi-
lever is advanced. A third wire provides a ground tion and speed, generate a tachometer signal, and
circuit back to the EMM. control fuel and ignition timing.
If TPS voltage is greater than 0.78 volts when the If the sensor is damaged or the signal is intermit-
key is turned to ON, or the recoil starter is pulled, tent (10 occurrences), the EMM:
the EMM:
Creates service code 11 EMM LED 2: OFF (Cranking)
4
If the outboard starts, the code is stored.
If code 11 is present as both a Hard Fault and a Approximate air gap between CPS and flywheel
Stored Fault, refer to Control Cable Installation encoder ribs is 0.073 inch (1.85 mm).
on p. 19. For tiller models, refer to Throttle Cable Use the Evinrude Diagnostics software Monitor
Adjustment on p. 276, or Throttle Cable Adjust- screen to check CPS operation. The software
ment on p. 287. should show an RPM reading while the outboard
If the TPS or TPS circuit fails (below 0.14 volts or is cranking. If the CPS or its circuit fails, no RPM
above 4.92 volts), the EMM: reading will appear and the outboard cannot run.
Stores service code 12 Neutral Switch

Limits engine RPM to IDLE The powerhead mounted neutral switch controls a
EMM LED 3: OFF (Cranking) ground signal from the EMM to indicate shift link-
EMM LED 3: ON (Running) age position. This allows the EMM to control idle
Engine Monitor CHECK ENGINE display: ON speed variations and start in gear protection. Fuel
and ignition functions are turned off if the neutral
switch is not closed.
IMPORTANT: When a TPS circuit fault has
been detected, the outboard will not accelerate If the starter is cranked while the outboard is in
above idle speed. To reset, stop the outboard and gear, or if the switch fails, the EMM:
correct the fault.
If the TPS circuit reads below 0.2 volts, the EMM: EMM LED 3: OFF (Cranking)
Stores service code 13 Engine Monitor CHECK ENGINE display: ON
EMM LED 3: ON (Running) The Monitor screen of the diagnostics software
displays switch position, NEUTRAL or IN GEAR.
Make sure switch is operating properly.
If the TPS circuit reads above 4.85 volts, the

EMM:
59
INTERNAL EMM FUNCTIONS
INTERNAL EMM Exhaust Water Valve Activation

(60 - 65 HP)
FUNCTIONS During acceleration, the EMM opens a valve that
ROM Verification injects water into the exhaust housing. This water
changes the tuning of the exhaust, allowing the
The EMM performs a self-test of programming engine to develop more midrange horsepower as
every time it is turned ON. Service code 15 indi- the boat comes on plane.
cates a programming (software) issue. Repro-
gram the EMM with the correct software program Two conditions must be met to activate the valve:
to correct the problem. • Throttle opening above 80%
• RPM between 2500 to 4600.
Idle Controller
The idle controller reacts to engine operating con- The valve may not activate if the engine is accel-
ditions. Fuel and ignition timings are altered to erated slowly.
maintain a specific RPM when engine is cold or
warm. The controller is inactive when TPS is Engine Monitor and Warning
advanced from idle position. Systems
Refer to ENGINE MONITOR SYSTEM on p. 61.
RPM Limiter
This feature of EMM programming prevents Refer to S.A.F.E. WARNING SYSTEM on p. 62.
engine damage due to excessive RPM. At 6250 Refer to SHUTDOWN MODE on p. 62.
RPM, fuel and ignition to the cylinders is shut off.
Normal operation resumes when engine RPM Fault Code Creation and Storage
returns to the specified range.
Refer to the EMM Service Code Chart at the
Neutral RPM Limiter back of this manual for a complete list of all
engine fault codes.
This feature prevents engine damage due to
excessive RPM if accelerated in NEUTRAL. Neu-
tral engine speed is limited to 1800 RPM.
60
ENGINE MONITOR SYSTEM
ENGINE MONITOR The EMM activates the warning horn and gauge
displays as follows:
SYSTEM • LOW OIL means that oil in the tank is at reserve
level (about 1/4 full).
All remote controlled outboards must be equipped • NO OIL indicates the oil tank is empty.
with an engine monitoring system to warn the • WATER TEMP or HOT indicates an engine or
operator of conditions that could damage the out- EMM overheat condition.
board. • CHECK ENGINE or FAULT is used to indicate
The engine monitor system includes sensors on other fault conditions identified by the EMM.
the outboard and oil tank, a warning horn, a dash- Refer to the EMM Service Code Chart at the
mounted display, and related wiring. back of this manual for a complete list of all fault
The outboard’s EMM sends information about codes.
4
monitored functions to:
• SystemCheck gauges System Self-Test
• An I-Command or ICON display During engine start-up, pause with the key switch
• EMM LED indicators. in the ON position. The horn self-tests by sound-
ing a half-second beep. SystemCheck gauges
IMPORTANT: Operating the outboard without self-test by turning the indicator lights on simulta-
an engine monitor will void the warranty for fail- neously, then off in sequence.
ures related to monitored functions. For informa-
tion about boat mounted Information Display Note: The warning horn does NOT sound in an
System options, refer to the current Predelivery I-Command installation.
and Installation Guide included with the service
manual set.
Service Mode
SystemCheck goes into a service mode if the key
is left ON after self-test (engine NOT running). All
light circuits and sensors are active, but the horn
is not. Grounding the appropriate light circuit wire
will turn the light on, but the horn will not sound.
Refer to SystemCheck CIRCUIT TESTS on
p. 107.
Engine Running
All warning circuits are active when the engine is
running. The horn circuit is active when engine
Typical I-Command and SystemCheck gauges 007988
speed exceeds 500 RPM.
Engine monitor warnings activate the horn for 10

seconds and the appropriate gauge light for a
minimum of 30 seconds. If the failure is momen-
tary (for example, oil moving in the tank), the light
will remain ON for the full 30 seconds before
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.
61
S.A.F.E. WARNING SYSTEM
S.A.F.E. WARNING SHUTDOWN MODE

SYSTEM Outboard “shutdown” will occur if specific faults
are detected by the EMM:
The S.A.F.E. (Speed Adjusting Failsafe Electron-
ics) warning system alerts the operator and pro- Code 29 Excessive EMM temperature
tects against engine damage from the following Code 31 Excessive engine temperature
abnormal conditions: Code 33 Excessive NO OIL condition
Code 17 Alternator 55 V below expected range Code 57 High RPM with low TPS setting
Code 18 Alternator 55 V above expected range
Code 25 EMM temperature above expected Code 57 occurs when the EMM detects abnor-
range mally high RPM relative to the TPS position. This
condition could be caused by uncontrolled fuel
Code 34 Oil injector open circuit
entering the combustion cycle. Before removing
Code 40 Cylinder head temperature above the code and STARTING the outboard, find and
expected range–low speed repair the cause.
Code 43 Cylinder head temperature above • Perform Fuel System Pressure Test on p. 137.
expected range–high speed Check for external fuel leakage that could allow
Code 117 NO OIL detected fuel and/or vapor to enter the engine through
the air intake.
Activation • Check for internal fuel leakage from a leaking
injector or vapor separator vent hose.
When one of these conditions occurs, the EMM
interrupts fuel injector and ignition operation, WARNING
reducing engine speed to 1200 RPM. The warning
horn sounds and an Engine Monitor message dis- If the engine shuts OFF and the “CHECK
plays. When S.A.F.E. is active, the engine will run ENGINE” light or EMM SENSOR FAULT
normally below 1200 RPM. Above 1200 RPM, the LED is flashing, the engine cannot be
engine will shake excessively. restarted. A hazardous fuel condition may
exist which could result in a fire or explo-
Recovery sion.
The engine will operate in S.A.F.E. as long as the
fault condition exists. To recover normal operation, Recovery
two conditions must be met:
To recover from shutdown mode, the EMM must
• Sensor or switch readings must be back within NOT detect the related fault at start-up. The out-
limits board will not restart until the cause of the stored
• The EMM must be reset—stop and restart service code is resolved (code 29 and 31) and the
code is cleared using diagnostics software (code
33 and 57). Then, the EMM must be turned OFF
and ON again.
IMPORTANT: Shutdown related to code 57 or

33 requires the removal of the stored service
code. Use Evinrude Diagnostics software to clear
a code 57 or 33.
62
DIAGNOSTIC SOFTWARE FUNCTIONS
DIAGNOSTIC ROPE START MODELS

Diagnostic communications on non-running rope
SOFTWARE FUNCTIONS start models requires a power supply to the EMM.
The EMM stores valuable information about the Use Diagnostic Power Supply Tool, P/N 587005,
outboard and its running history. This information to supply power to the EMM. The power supply
can be used for troubleshooting, for checking uses internal 9-volt batteries.
parts information, and for making adjustments to
the system. Disconnect the tiller handle harness connector
from the engine harness. Connect Power Supply
Use Evinrude Diagnostics software, version 4.5 or Tool to the engine harness connector. Turn toggle
higher, and a laptop computer to access program switch to the ON position to power the EMM.
information.
2 4
IMPORTANT: For software help, refer to the
“Help” menu in the software.
Communication
Locate the diagnostic connector on the engine. 1
Remove the cover and install the Diagnostic Inter-
face Cable (P/N 437955).
1. Power supply tool 007279

2. Engine harness connectors
1 2
IMPORTANT: Static tests require more power
than the internal batteries of the tool can provide.
Static tests performed using only the internal
power supply batteries will produce false results.
Use Accessory Power Cable Kit, P/N 5008092, to

connect an external 12 volt battery to the Power
1. Diagnostic connector 004973 Supply Tool when performing these static tests:
2. Cover
• Fuel pump
Connect the 9-pin connector of the interface cable • Fuel injector
directly to the computer’s serial port. • Ignition coil
• Oil injector
The EMM must turn ON before it will communicate
with the computer.
ELECTRIC START MODELS

Power is normally supplied to the EMM when the
key switch is ON. Switched B+ (12 V) enters the
EMM at pin 28 (purple) of the EMM J1-B connec-
tor. 1
The EMM is also turned ON when it begins to
receive AC voltage from the stator while the out-
board is being cranked.
1. External power connector 007280
63
If Diagnostic Power Supply Tool, P/N 587005, is The serial number and cylinder location displayed
not available, a Battery Cable, P/N 584348, can on the Injector Coefficients screen must match the
be connected to the engine mounted solenoid. actual cylinder placement for each injector.
Use accessory Key Switch Assembly,
P/N 176408, to control power to the EMM.
1 2
1. Accessory key switch 007281

2. Battery cable Injector Coefficients Screen 008079
007282
Static Information Dynamic Information

Static information is viewed when the outboard is Dynamic information is viewed while the outboard
NOT running. This includes manufacturing infor- is running. Changes in data, such as voltages or
mation. temperatures, are shown as they happen.
The outboard model and serial numbers displayed

on the Identity screen must match the identifica-
tion label on the outboard swivel bracket.
Monitor Screen 008080
Identity Screen 008078
64
Stored Service Codes (Faults) Persistent Faults

Service codes are stored if an abnormal condition The Persistent Faults screen keeps a history of all
occurs while the outboard is running. previously stored codes, including code number,
the number of times the event occurred, and oper-
The Stored Faults screen of the diagnostics soft- ating hours of the last occurrence.
ware shows the code number, the number of
times the event occurred, and operating hours of Persistent faults cannot be erased.
first and last occurrences.
Static Tests
Static Tests allow diagnostic testing of system
components while the outboard is NOT running.
Stored Faults Review Screen 008098
Hard Faults
A hard fault is a service code that currently exists. Static Tests Screen 008082
Hard faults become stored faults only if the out- Ignition Test
board is running. Use the diagnostics software to test each ignition
circuit. Refer to Static Ignition Test on p. 81.
Fuel Test
Use the diagnostics software to test each fuel
injector circuit. Refer to Fuel Injector Static Test
on p. 84.
Oil Injector
Use the diagnostics software to test the oil injec-
tion pump circuit. Refer to OILING SYSTEM
TESTS on p. 166.
Fuel Pump
Use the diagnostics software to test the fuel pump
Hard Faults Review Screen 008081 circuit. Refer to Fuel Pump Static Test on p. 84.
Water Injector
This test activates the exhaust water valve sole-
noid (60 - 65 HP). Refer to Exhaust Water Valve
Static Test on p. 86.
65
Overheat Prime Oil

This test is used to check the “ENG TEMP” or This test is used to cycle the oil injection pump for
“HOT” circuit of the Engine Monitoring system. priming the oiling system. Perform this test with
outboard running to activate oil injection pump.
Oil Fault
This test is used to check the “NO OIL” circuit of Oil Control Settings
the Engine Monitoring system.
Set Oil Type
Check Engine The TC-W3 oil type setting is the standard setting
This test is used to check the “CHECK ENGINE” for all outboards. Set TC-W3 for:
circuit of the Engine Monitoring system. • Operation with all TC-W3 outboard oils includ-
ing XD30, XD50, or XD100
Tachometer • Applications requiring maximum lubrication
This test is used to check operation of the tachom- • Extreme applications (racing or harsh condi-
eter circuit. tions).
Dynamic Tests The XD100 setting provides an option to run the

Dynamic tests are performed with the outboard outboard at a reduced oil injection rate. This set-
running. ting REQUIRES the use of Evinrude XD100 out-
board lubricant and is not recommended for all
applications.
Use the XD100 setting for:
• Conventional use (runabouts, cruisers)
• Moderate applications.
Dynamic Tests Screen 008083
Ignition Test
This test momentarily disables the ignition and
fuel injection circuits to one cylinder. By dropping 1. Oil control setting 008084
one cylinder, RPM and running quality changes
can be observed. Refer to DYNAMIC TESTS on CAUTION
p. 76.
Running an Evinrude E-TEC outboard on
Fuel Test other grades of oil while set to the XD100
This test momentarily disables one fuel injector oil ratio will result in increased engine
circuit. By dropping one cylinder, RPM and run- wear and shortened outboard life.
ning quality changes can be observed. Refer to
DYNAMIC TESTS on p. 76.
66
Powerhead Break-In Ignition Timing

Use the diagnostics software to start break-in oil- Use the Ignition Timing screen to check and
ing after a powerhead rebuild. The break-in oiling adjust EMM timing. EMM timing must be synchro-
program runs for two hours of outboard operation, nized to crankshaft position.
above 2000 RPM.
Refer to TIMING ADJUSTMENTS on p. 113.
1. Break-in oil setting 008084
Tiller/Remote Programming 008085

This feature controls the start in gear protection
function of the neutral switch. Tiller operated mod- Check timing after any of the following proce-
els, including remote models with an installed tiller dures:
conversion kit, MUST be set to TILLER. • Powerhead replacement
• Crankshaft replacement
• Flywheel removal or replacement
• CPS replacement
• EMM replacement
• EMM software replacement
1
IMPORTANT: Make sure the timing pointer is
set and the outboard reaches operating tempera-
ture before making adjustments.
1. Starter mode setting 008084
67
TPS Calibration Fuel Injector Servicing

TPS Calibration synchronizes throttle plate open- All E-TEC fuel injectors use software program-
ing with throttle position sensor voltage. ming to compensate for variations in fuel flow.
Each injector and its location on the outboard is
Refer to TPS Calibration on p. 114. identified by the EMM. DO NOT install an injector
without updating the compensation software.
To install a service injector, click the “Replace”

button on the Injector Coefficients screen and
select the file for the replacement injector. Refer to
Fuel Injector Service on p. 146.
1
1. TPS Calibration button 008086
Perform TPS Calibration after replacing or adjust-

ing any throttle body or throttle linkage parts.
Idle Speed Control

Use the Idle Adjust function to increase or
decrease IN GEAR IDLE speed. This adjustment 008100
offsets the basic EMM programming and will not
set an absolute fixed speed. After the offset is
changed, the EMM continues to control engine
operation normally. Engine idle speed is not fixed.
1. Idle adjustment 008084
68
Reports Software Replacement

Engine reports provide service records and can Engine Management Software is loaded into the
be used to document the running history of an out- EMM at the factory. Periodically, a new program
board. Reviewing this information can help iden- may be available to enhance the operation 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 window of the diagnos- vided with the program.
tics software to print engine data, or to export the
information to a computer file.
1
4
1. Print button 008087 008095

2. Print/Export options
IMPORTANT: Software replacement requires
the use of Bootstrap Tool, P/N 586551. Install tool
between engine and boat harness key/stop switch
connectors as instructed by update program.
002383
Engine Report data files 008096
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 new EMM is being installed,
refer to EMM Transfer on p. 70.
Select EMM Data Transfer from the Utilities menu.
Select the Collect EMM data to FILE option and Removal
follow the instructions provided with the program.
Disconnect cooling hoses from EMM.
1 Disconnect J1-A, J1-B, and J2 connectors.

2 Remove three EMM retaining screws and wash-
ers. Remove EMM.
1. Select EMM Data Transfer 006642

2. Select Collect EMM data to FILE 2
IMPORTANT: Whenever the EMM is replaced,
EMM timing must be synchronized to crankshaft
position. Refer to TIMING ADJUSTMENTS on
p. 113. 1. Cooling hose connections 006476
2. EMM mounting screws
Remove EMM from behind oil tank bosses.
006477
70
EMM SERVICING
Installation
Installation is the reverse of removal. Pay close
attention when performing the following tasks.
Make sure isolator mounts are placed in slots in of

EMM case. Slide EMM into position.
1 1
1. Isolator mounts 006478
Apply Nut Lock to threads of EMM retaining

screws. Tighten to a torque of 30 to 42 in. lbs. (4
to 5 N·m).
Install harness connectors and cooling hoses.
Secure hoses with tie straps.
71
NOTES
NOTES
Bulletins
Instruction Sheets
Other
72
SYSTEM ANALYSIS
SYSTEM ANALYSIS
TABLE OF CONTENTS
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
VISUAL INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
OPERATIONAL INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
DYNAMIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
CYLINDER DROP TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
FUEL CONTROL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INDUCTIVE AMP METER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
EMM LED INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
KEY ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5
IGNITION OUTPUT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
REQUIRED IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
WIRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
CRANKSHAFT POSITION SENSOR (CPS) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
SYSTEM VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
STATIC IGNITION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
RUNNING IGNITION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
IGNITION CONTROL CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
CAPACITOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
FUEL DELIVERY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
FUEL PUMP STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
FUEL INJECTOR STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
RUNNING FUEL SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
EXHAUST WATER VALVE (60–65 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
EXHAUST WATER VALVE STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
EXHAUST WATER VALVE DYNAMIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
73
SYSTEM ANALYSIS
DIAGNOSTIC PROCEDURES
DIAGNOSTIC Operational Inspections

Run the outboard to confirm actual symptoms
PROCEDURES before performing any unnecessary procedures.
Inspection should include the following:
Visual Inspections • Make sure the outboard can be cranked easily,
Inspect wiring and electrical connections. Disas- with no mechanical binding.
semble and clean all corroded connections. • Check the EMM LED Indicators for system sta-
Replace damaged wiring, connectors, or termi- tus information. Refer to EMM LED INDICA-
nals. Repair any shorted electrical circuits. TORS on p. 77.
• Refer to ELECTRICAL HARNESS CONNEC- • Check the Evinrude Diagnostics software Hard
TIONS on p. 92. Faults and Stored Faults screens for current
• Refer to WIRING DIAGRAM at the back of this service codes. Correct any problems and clear
manual. the codes before further troubleshooting. Refer
• Refer to CONNECTOR SERVICING on p. 116. to Stored Service Codes (Faults) on p. 65.
Make sure all ground connections are clean and
tight. Refer to GROUND CIRCUITS on p. 94.
1. Main engine harness ground 002292 Stored Faults Review Screen 008098
2. Ground stud (battery)
Check the diagnostics software Profiles, History,
Inspect spark plugs for wear, oil fowling, or dam- and Persistent Faults screens for evidence of
age. A rich or lean running condition or evidence abnormal operation.
of internal engine damage could be identified by
the appearance of the spark plugs.
Check the fuse and the emergency stop switch

lanyard.
Profiles Screen 008088
74
SYSTEM ANALYSIS
DIAGNOSTIC PROCEDURES
Troubleshooting • Use the diagnostics software Dynamic Tests to

isolate a faulty cylinder. See DYNAMIC TESTS
Outboard will not crank, starter does not on p. 76.
operate: • Use an inductive timing light to check ignition
• Check condition of battery and cables (main and fuel injector circuits. Refer to Running Igni-
battery switch and cables). Make sure battery tion Tests on p. 82 and Running Fuel System
cables are not reversed. Tests on p. 85.
• Confirm that switched B+ is present at “A” termi- • Use the diagnostics software Fuel Control
nal (yellow/red wire) of starter solenoid with key Adjustment test to help identify a cylinder that
switch in the START position. may be too rich or too lean. Refer to Fuel Con-
• Check ground at “B” terminal harness connec- trol Adjustment on p. 76.
tion. • Use an inductive amp meter to monitor injector
• Refer to ELECTRIC START TESTS on p. 102. circuit current. Compare readings of all circuits
Repair starter or start circuit as needed. to identify possible failure.
Outboard cranks, will not start: • Check fuel quality and that fuel is present at
injectors.
• Check emergency stop switch and lanyard
• Use the diagnostics software Logging function 5
• Check powerhead mounted neutral switch
to record engine data as a problem is occurring.
• Check the EMM LED Indicators for system sta-
tus information. Refer to EMM LED INDICA-
TORS on p. 77.
• Use the Evinrude Diagnostics software Stored
Faults screen to check for current service
codes. If there are multiple stored sensor
codes, inspect all 5 V sensor circuits for broken
or grounded wiring.
• Perform a Static Ignition test using Evinrude
Diagnostics software and an inductive timing
light. Refer to Static Ignition Test on p. 81.
• If ignition test indicates steady spark, refer to
FUEL DELIVERY TESTS on p. 84.
Outboard runs, low on power, misfires:

Logging Screen 008097
• Check the EMM LED Indicators for system sta-
tus information. Refer to EMM LED INDICA-
• AFTER all the above inspections, if the cause of
TORS on p. 77.
a running quality problem still cannot be identi-
• Use the Evinrude Diagnostics software Monitor
fied, perform a compression test to check for
screen to check system (55 V) and TPS volt-
internal powerhead damage.
ages. System voltage should be steady, and
TPS voltage should be between 0.2 and 4.85 V. IMPORTANT: Remove a cylinder head or disas-
semble the engine only as a last resort.
IMPORTANT: Use a digital multimeter to check
voltage on external circuits only when necessary.
All EMM output currents are DC current.
75
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 software Dynamic used by itself to identify a faulty injector.
Tests to momentarily disable one cylinder while
the outboard is running. Evinrude Diagnostics software allows temporary
adjustments to the fuel flow characteristics of the
• The Dynamic Ignition test disables the ignition
injectors. Factory fuel flow settings are restored
and fuel injection circuits to a cylinder.
when power to the EMM is returned to OFF.
• The Dynamic Fuel test momentarily disables
one fuel injector circuit. Test the outboard at the RPM where the problem
is occurring.
By dropping one cylinder, RPM and running qual-
ity changes can be compared for each cylinder.
IMPORTANT: Test the outboard at the RPM

where the problem is occurring. Use the test pro-
cedures to identify inconsistencies in voltages and
cylinder performance. Once a circuit has been
identified as malfunctioning, inspect all related
wiring and connections. Check all voltage inputs
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 multimeter to check voltage changes 008089
on electrical circuits.
If the outboard run quality improves with a fuel
control adjustment, eliminate other possibilities
before replacing an injector:
• Refer to Fuel System Pressure Test on p. 137.
• Refer to Running Fuel System Tests on p. 85.
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 an inductive amp meter to monitor battery
charging and current flow. Identifying erratic
amperage in a circuit can be used to isolate a
Dynamic Test Screen 008083 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 function to tem-
porarily disable the idle controller.
76
SYSTEM ANALYSIS
EMM LED INDICATORS
EMM LED INDICATORS Starting

Starting mode occurs from the time the flywheel
The EMM LED indicators provide a quick refer-
begins to turn until the outboard is running for 2
ence to the status of several outboard systems.
seconds. During starting, all four LEDs should
Checking the LEDs FIRST when diagnosing an
light and then go off in sequence.
engine problem can save time.
LED 1 – CHARGING OKAY – Stator signal 30 V
For detailed code information, refer to the EMM
or higher.
Service Code Chart at the back of this manual.
LED 2 – CRANK POSITION OKAY – input from
IMPORTANT: LED 1 is toward the top of the CPS, EMM powered ON. For NO LIGHT, check
outboard (closest to EMM J1-B connector). for:
• Code 16 – CPS, intermittent loss of sync
1
LED 3 – SENSORS OKAY (5 V). For NO LIGHT,
check for:
• Code 12 – TPS circuit fault 5
• Code 13 – TPS below expected range
• Code 14 – TPS above expected range
• Code 19 – In Gear (tiller models)
• Code 23 – EMM temp. sensor circuit fault
• Code 24 – EMM temp. below expected range
• Code 41 – temp. sensor circuit fault
1. LED indicators 006467
• Code 42 – temp. below expected range
• Code 47 – AT sensor circuit fault
Key ON • Code 48 – AT sensor below expected range
• Code 49 – AT sensor above expected range
IMPORTANT: Diagnostic communications on • Code 58 – Operating temperature not reached
non-running rope start models requires that power • Code 78 – Sensor supply voltage fault
is supplied to the EMM. Refer to Communication
on p. 63. For FLASHING LIGHT, check for Code 57.
When the EMM is ON (engine not running), the LED 4 – LANYARD/STOP OKAY. For NO LIGHT,
following LEDs should light: check for:
• Grounded stop circuit.
LED 3 – Sensor Circuits working. FLASHING
LIGHT indicates Code 57 – engine will not start. For FLASHING LIGHT, check for:
• Code 29 – EMM temp. OVER range (flashing)
LED 4 – Stop Circuit not grounded–okay to start. • Code 31 – Engine temp. OVER range (flashing)
FLASHING LIGHT indicates severe overheat or • Code 33 – Engine shutdown, excessive no oil
no oil – engine in SHUTDOWN mode. condition
77
SYSTEM ANALYSIS
EMM LED INDICATORS
Running LED 3 – Sensor circuits (5 V), SENSOR FAULT.

For LIGHT ON, check for possible fault codes:
When the outboard is running, all of the LEDs
• Code 12 – TPS circuit fault
should be off. If a light is on, check for:
• 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 41 – temp. sensor circuit fault
• Code 42 – temp. below expected range
LED 2 – INJECTOR/IGNITION FAULT:
• Code 47 – AT sensor circuit fault
• Code 51 – cylinder no. 1 injector circuit open • Code 48 – AT sensor below expected range
• Code 52 – cylinder no. 2 injector circuit open • Code 49 – AT sensor above expected range
• Code 53 – cylinder no. 3 injector circuit open • Code 57 – high RPM with low TPS setting
• Code 61 – cylinder no. 1 injector circuit short • Code 58 – operating temp. not reached
• Code 62 – cylinder no. 2 injector circuit short • Code 78 – Sensor supply voltage fault
• Code 63 – cylinder no. 3 injector circuit short
• Code 81 – no. 1 ignition coil circuit open LED 4 – Engine overheat, EMM temperature or
• Code 82 – no. 2 ignition coil circuit open sensor, oil injection pump or sensor, NO OIL /
• Code 83 – no. 3 ignition coil circuit open OVERHEAT. For LIGHT ON, check for possible
• Code 90 – Water injection solenoid short fault codes:
• Code 91 – fuel pump circuit open • Code 25 – EMM overheat
• Code 93 – Water injection solenoid open • Code 29 – EMM overheat, critical (flashing)
• Code 94 – fuel pump circuit short • Code 31 – engine overheat, critical (flashing)
• Code 101 – No. 1 ignition timing circuit shorted • Code 33 – excessive NO OIL faults
• Code 102 – No. 2 ignition timing circuit shorted • Code 34 – oil injection pump circuit open
• Code 103 – No. 3 ignition timing circuit shorted • Code 40 – engine overheat, low rpm
• Code 43 – engine overheat
• Code 117 – Critical NO OIL detected
78
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
IGNITION OUTPUT Crankshaft Position Sensor

• Provides EMM with input.
TESTS • Outboard cranking speed exceeds 300 RPM
and a steady CPS signal is generated.
DANGER Alternator Output/System Voltage
The electrical system presents a serious • System voltage from EMM (white/red) provides
shock hazard. Allow outboard to sit for 55 VDC to the high pressure fuel pump, the oil
two minutes after running before handling injection pump, the fuel injectors, and the igni-
capacitor or 55 V electrical components. tion coils.
Failure to handle capacitor properly can
Capacitor
result in uncontrolled electrical discharge
• Connected to 55 V circuit (white/red) to stabilize
and possible electrical shock to humans.
current on 55 V circuit
DO NOT handle primary or secondary igni- • Negative terminal of capacitor must be
tion components while outboard is run- grounded.
ning or flywheel is turning.
Ignition Coil
5
• Primary circuits are powered by system (55 V)
Use the Evinrude Diagnostics software Stored
voltage
Faults screen to check for current service codes
before troubleshooting. Correct any problems and • EMM provides control signal to ignition coil
clear the codes FIRST. • Output from ignition coil secondary winding and
high tension spark plug wire.
Required Ignition Systems
Wiring Inspection
Following is a complete list of circuits required for
ignition output: Visually inspect all wiring, connections, and
grounds.
Stop Circuit
• Black/yellow wire NOT grounded (emergency Use a digital ohmmeter to test resistance on all
stop switch lanyard in place). ground circuits and connections. Ohmmeter read-
ings should be approximately 0.0 W.
Neutral Switch
• Powerhead mounted neutral switch provides a Check that all engine wire harness grounds have
continuity to the cylinder/crankcase.
switched ground circuit to EMM. The circuit
enables specialized control functions such as
neutral start protection and RPM limiting in
NEUTRAL.
Stator Output Voltage 1

• Provides A/C voltage to EMM J2 connector:
Outboard cranking, typical range is 20-40 VAC
(AC output voltage is related to cranking RPM);
Outboard running, approximately 55 VAC.
EMM
• Controls ignition grounds, injector grounds, and
1. Main engine harness ground 002292
engine timing.
Clean or repair all ground circuits, wiring, and con-
nections as needed.
79
SYSTEM ANALYSIS
Crankshaft Position Sensor (CPS) System Voltage Test

Test The ignition system is powered 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 software 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 outboard is cranking or running.
An RPM display higher than zero indicates a CPS
signal to the EMM.
Monitor Screen, System voltage 008080
Results:
• EMM ON (not running) - approximately 1 V less
Engine RPM and CPS Sync displays 008080
than battery voltage, system voltage is GOOD.
• EMM ON (not running) - no voltage, check 12 V
If the Monitor screen says “Check CPS Sync,” power to EMM. Repair connection or wiring.
refer to Crankshaft Position Sensor (CPS) Test • RUNNING - 55 V ± 2, system voltage is GOOD.
on p. 95. • RUNNING - less than 55 V ± 2, check stator
output to EMM. Repair connection or wiring.
Possible faulty stator or EMM. Refer to STATOR
TESTS on p. 97.
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. On a
non-running rope start engine, power is supplied
to the EMM by Diagnostic Power Supply Tool,
P/N 587005.
80
SYSTEM ANALYSIS
Static Ignition Test IMPORTANT: This test is operating the ignition

coil with 12 V battery power on the system voltage
Perform the static ignition test using Evinrude
(55 V) circuit. An inductive probe with low sensitiv-
Diagnostics software and an inductive timing light.
ity may not be able to detect the signal.
IMPORTANT: DO NOT perform static tests
using Diagnostic Power Supply Tool, P/N 587005,
with internal 9 volt batteries only. This will produce
false results. Refer to Communication on p. 63.
1
IMPORTANT: DO NOT use a spark checker 2
tool. Radio Frequency Interference (RFI) gener-
ated by the arcing current can cause erratic EMM
operation.
The outboard must NOT be running and the emer-

gency stop switch lanyard must be installed.
1. Timing light pick-up
2. Spark plug lead
006492
5
Results:
No spark on one or more cylinders:
• Inspect or replace spark plugs
• Refer to Ignition Control Circuit Tests on
p. 83
• Refer to Ignition Coil Tests on p. 83
Steady spark on all cylinders:
• Refer to Running Ignition Tests on p. 82 and
DYNAMIC TESTS on p. 76.
Static Tests Screen 008082
Connect timing light pickup to the secondary cir-

cuit (spark plug lead) of the cylinder being tested.
Activate test and observe timing light strobe for
consistent flash.
81
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 at a specific speed (RPM) • Refer to FUEL DELIVERY TESTS on p. 84
should be steady • Check for internal engine damage.
• Refer to System Voltage Test on p. 80.
Steady voltage, erratic strobe, engine misfires:
Use an inductive timing light to monitor the spark • Inspect or replace spark plugs
signal through each of the secondary circuit • Check CPS air gap and resistance.
(spark plug lead) wires. • Refer to Ignition Control Circuit Tests on
p. 83
Start outboard and observe timing light strobe. • Refer to Ignition Coil Tests on p. 83.
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. 80
• Refer to Ignition Control Circuit Tests on
p. 83
1
2 • Refer to Ignition Coil Tests on p. 83.
IMPORTANT: If a running problem occurs at
about 1200 RPM, the outboard may be in S.A.F.E.
Refer to S.A.F.E. WARNING SYSTEM on p. 62.
1. Timing light pick-up 006492

2. Spark plug lead
82
SYSTEM ANALYSIS
Ignition Control Circuit Tests With EMM OFF, remove the EMM J1-B connector
and test the continuity of each ignition control cir-
Use a digital multimeter to test the following:
cuit (orange). Check resistance between J1-B
• System voltage supply to ignition coil. connector and ignition coil connector. Refer to
• Ignition control signal from EMM. engine wiring diagram.
• Engine harness resistance.
If circuits test good, replace EMM.
Disconnect ignition coil connector.
Ignition Coil Tests
Supply voltage test:
There are no simple ignition coil tests available.
Use an appropriate adapter to connect the red
Before replacing an ignition coil, be sure:
meter lead to pin 3 (white/red) of the engine har-
ness connector and the black lead to ground. With • 55 V is supplied to the white/red wire of the igni-
EMM ON, voltage should be approximately 1 V tion coil connector
less than battery voltage. • A control signal is present on the orange wire of
the ignition coil connector. Refer to Ignition
Control signal test: Control Circuit Tests on p. 83.
Set meter to the Hz scale to check ignition control • The black wire of the ignition coil connector pro- 5
signal. vides continuity to ground.
• The secondary spark plug lead provides conti-
Use an appropriate adapter to connect the red nuity.
meter lead to pin 2 (orange) of the engine harness
connector and the black lead to ground. Activate If all of the above tests are good, and a cylinder
diagnostics software Static Ignition test and does not have spark, replace the ignition coil with
observe meter for consistent reading (approxi- a known good coil.
mately 2 Hz).
Capacitor Test
If control signal is present, connect black meter
lead to pin 1 (black) and repeat test to confirm IMPORTANT: Make sure the capacitor is dis-
harness ground. charged before testing. Make a momentary con-
nection between the two terminals to ground any
stored energy.
Remove capacitor from electrical harness.

Use an ohmmeter set on the high ohms scale to
test the capacitor. Connect the meter leads to the
capacitor terminals:
• If the capacitor is working correctly, it will store
energy from the meter. The resistance reading
will increase until it goes to (nearly) infinity.
• If the capacitor is shorted, the reading will
006609 immediately show full continuity.
• If there is an open circuit in the capacitor, the
Harness resistance test: meter will show no continuity.
If control signal is NOT present, calibrate multime-
ter to low ohms scale. Use appropriate adapters If the resistance reading starts as a negative num-
on meter leads to avoid damaging harness con- ber, or the reading goes down in value, the capac-
nectors. itor already retains some stored energy. Ground
the capacitor and test again.
83
SYSTEM ANALYSIS
FUEL DELIVERY TESTS
FUEL DELIVERY TESTS Voltage should be 55 V when the outboard is

cranking or running.
• The EMM controls the fuel pump ground (brown
WARNING wire). Use an ohmmeter to check continuity
Protect against hazardous fuel spray. between pin 2 of fuel pump connector and
Before starting any fuel system service, ground. Use the fuel pump static test to activate
carefully relieve fuel system pressure. the control function of the EMM. Resistance
should drop as EMM connects the control circuit
to ground.
Refer to Relieving Fuel System Pressure on
• Refer to Circulation Pump Resistance Test on
p. 142.
p. 139.
Check the Evinrude Diagnostics software Stored
If the pump runs:
Faults screen for current service codes before
troubleshooting. Correct any problems and clear
the codes FIRST. • Refer to Running Fuel System Tests on p. 85.
Inspect all fuel hoses, filters, and connections. Fuel Injector Static Test
Check quality of fuel supply. Use the Evinrude Diagnostics software Fuel Injec-
tor Static Test to activate each fuel injector. Listen
Fuel Pump Static Test for an audible click from each injector when it is
Use the Evinrude Diagnostics software Fuel Pump actuated. If the injector activates, the EMM and
test to activate the electric fuel pump. If the pump injector circuits are not at fault.
runs, the EMM and fuel pump circuit are not at
fault. IMPORTANT: Do NOT perform static tests using
Diagnostic Power Supply Tool, P/N 587005, with
IMPORTANT: Do NOT perform static tests using internal 9 volt batteries only. This will produce
Diagnostic Power Supply Tool, P/N 587005, with false results. Refer to Communication on p. 63.
internal 9 volt batteries only. This will produce
Static Tests Screen 008082 IMPORTANT: This test is operating the injectors
with 12 V battery power on the system voltage
If the pump does not run: (55 V) circuit. Battery must be fully charged and
• Check voltage at pin 1 of fuel pump connector. connections must be clean and tight. Injector acti-
Voltage should be slightly less than 12 V with vation should be carefully confirmed.
KEY ON, or when fuel pump test is activated.
84
SYSTEM ANALYSIS
FUEL DELIVERY TESTS
Results: Results:
No injectors actuate: No light activation on any injector wires (outboard
• Use the Monitor screen of the diagnostics soft- cranks and starter turns flywheel):
ware to make sure voltage is present on the • Check stator input to EMM, CPS operation, and
system voltage circuit. all grounds and wiring connections.
• Refer to Running Fuel System Tests on p. 85. • Eliminate all other possibilities to isolate a faulty
EMM.
Some injectors actuate; some do not:
• For non-working injectors, test the resistance of Irregular or no light activation on some injector
injector circuit between the injector connector wires:
and injector control wire at the EMM. • Test the resistance of individual injector circuits
• See Fuel Injector Resistance Test on p. 139. 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. 85. • Make sure all grounds are clean and tight.
• See Fuel Injector Resistance Test on p. 139.
Running Fuel System Tests 5
Run or crank the outboard. Steady light activation on all injector wires and
consistent voltage readings, EMM injector control
Use the Evinrude Diagnostics software Monitor function is good:
screen to check system voltage. If voltage is low, • Use the diagnostics software Dynamic Fuel Test
or drops as RPM increases, refer to Stator Volt- to isolate a faulty cylinder. See DYNAMIC
age Output Test on p. 97. TESTS on p. 76.
Use an inductive timing light to monitor the injec-
tor control wire (connector pin 2) for each injector.
Make sure the pickup is attached to only one wire.
Flashes on the timing light indicate current in the
circuit is being switched by the EMM. The
Dynamic Tests screen allows the control signal to
be turned off to a particular injector.
IMPORTANT: Some timing 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.
• Refer to Fuel Injector Pressure Test on p. 138.

85
SYSTEM ANALYSIS
EXHAUST WATER VALVE (60–65HP)
EXHAUST WATER VALVE Disconnect the water valve outlet hose.
(60–65HP)
During rapid acceleration, the EMM opens a valve
that injects water into the exhaust. This water 1
changes exhaust tuning, boosting midrange
horsepower as the boat comes on plane.
If the valve is plugged or not working, the operator

may not notice a problem during slow accelera-
tion. During rapid acceleration, the outboard will
be low on power around 3200 rpm, depending on
boat and load. 1. Water valve outlet hose 004293
If the valve is stuck open, the outboard may be Start the outboard. No water should flow from the
low on top speed power (above 4600 RPM). hose. If water appears, check for debris in valve
assembly.
Exhaust Water Valve Static Test
Use Evinrude Diagnostics software to test the With the outboard idling, activate the dynamic
water valve solenoid electrical circuit. The water water valve test and check for water flow. A
valve is a 55 volt coil. The static test, which oper- steady stream of water should flow from the hose
ates on 12 VDC, will not activate the water valve. while the test is running.
Monitor the voltage at pin 2 (blue/red wire) of the Water should flow at a rate of 18 to 25 ounces /
the water valve connector. Voltage should drop minute (550 to 750cc / minute).
while the static test is active.
1
1

1. Water valve test button
1. Water valve test button
Results:
• No water flow—check for debris in valve
Exhaust Water Valve assembly and water supply line. Refer to
Dynamic Test EXHAUST WATER VALVE TEST on p. 106.
Use the diagnostics program to perform a • Water appears—make sure fitting into exhaust
dynamic test of the water valve while the outboard housing is clear.
is running.
86
ELECTRICAL AND IGNITION

TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
IGNITION SYSTEM CIRCUIT DIAGRAM, 40 – 65 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
IGNITION SYSTEM CIRCUIT DIAGRAM, 75 – 90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
ELECTRICAL HARNESS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
GROUND CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
SENSOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
CRANKSHAFT POSITION SENSOR (CPS) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
THROTTLE POSITION SENSOR (TPS) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
ENGINE TEMPERATURE SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
AIR TEMPERATURE SENSOR (AT) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
STATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
STATOR RESISTANCE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
STATOR VOLTAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 6
CHARGING SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
ELECTRIC START CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
ELECTRIC START TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
REMOTE CONTROL SWITCH TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
TILT/TRIM RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
EXHAUST WATER VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
SYSTEMCHECK CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
TACHOMETER CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
FLYWHEEL AND STATOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
STATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
IGNITION COIL SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
IGNITION COIL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
IGNITION COIL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
TIMING ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
TIMING POINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
TIMING VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
TPS CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
ELECTRIC STARTER SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
STARTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
STARTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CONNECTOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
DEUTSCH CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
AMP CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
PACKARD CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
87
SERVICE CHART
SERVICE CHART
5 to 8 in lbs.
(.6 to .9 N·m)
120 to 140 in lbs.

(13.5 to 16 N·m)
100 to 115 ft. lbs.

A (136 to 156 N·m)
168 to 192 in lbs.

(19 to 21 N·m) N
A F
84 to 106 in lbs. F
(9.5 to 12 N·m) 60 to 84 in lbs.
(7 to 9.5 N·m)
T
F
60 to 84 in lbs.
(7 to 9.5 N·m)
IMPORTANT:
DO NOT lubricate TPS
to throttle shaft surface
24 to 36 in lbs.
(2.7 to 4 N·m)
F
24 to 36 in lbs.
(2.7 to 4 N·m)
F
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
24 to 36 in lbs. D Moly Lube
(2.7 to 4 N·m) E Red Ultra Lock
F Blue Nut Lock
N Starter Bendix Lube
008029 T Liquid Neoprene
88
SERVICE CHART
24 to 36 in lbs.
(2.7 to 4 N·m)
B
J
15 to 30 ft. lbs.
(20 to 41 N·m)
60 to 84 in lbs.
(7 to 9.5 N ·m)
6
30 to 42 in lbs.
(3.4 to 4.8 N·m)
24 to 36 in lbs.
(2.7 to 4 N·m)
7 to 10 in. lbs.
(0.8 to 1.1 N·m)
60 to 84 in. lbs.
(7 to 9.5 N ·m)
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
J Thermal Grease
T Liquid Neoprene
X See Service Manual Text 002249
89
IGNITION SYSTEM CIRCUIT DIAGRAM, 40 – 65 HP

1
5
3 1
1
321
1 1
2 2
2
1 23
8 + 2
123
26 18 10
10 1
27 19 11
11 2
28 20 12
12 3
29 13
13 4
30
31
21
22 14
14 5 J1-A
23 15
15 6
32 7
33 24 16
16
34 25 17
17
8
9
4
1
20 14 8 2
21 15 9 3
22 16
6 543 21 23 17
10
11
4
5
J1-B 321
24 18
25 12 6
26 19 13 7
6 5 4 3 2 1
9
1
10
2
11
3
12
4
13
5
J2
14
6
15
7
16
8
6
1. Key switch (stop circuit) 4. EMM 7. Ignition coil

2. Neutral switch 5. Crankshaft position sensor 8. Main harness ground
3. Stator 6. Capacitor
90

1
5
3 1
1
321
1 1
2 2
2
1 23
8 + 2
123 6
26 18 10
10 1
27 19 11
11 2
28 20 12
12 3
29 13
13 4
30
31
21
22 14
14 5 J1-A
23 15
15 6
32 7
33 24 16
16
34 25 17
17
8
9
4
1
20 14 8 2
21 15 9 3
22 16
6 543 21 23 17
10
11
4
5
J1-B 321
24 18
25 12 6
26 19 13 7
6 5 4 3 2 1
7
9
1
10
2
11
3
12
4
13
5
J2
14
6
15
7
16
8
6
321
1. Key switch (stop circuit) 4. EMM 7. Ignition coil

2. Neutral switch 5. Crankshaft position sensor 8. Main harness ground
3. Stator 6. Capacitor
91
ELECTRICAL HARNESS CONNECTIONS
ELECTRICAL HARNESS EMM J1-A Connector

CONNECTIONS
Inspect wiring and electrical connections. Disas-
semble and clean all corroded connections.
Replace damaged wiring, connectors, or termi-
nals. Repair any shorted electrical circuits. Refer
to wiring diagrams and reference charts for spe-
cific wiring details.
Refer to CONNECTOR SERVICING on p. 116.
Engine Harness to Stator

001875
Connector
Pin
Description of Circuit Wire Color
No.
1 vacant
2 Diagnostic connector Red
3 Diagnostic connector White
4 vacant
5 vacant
6 Crankshaft position sensor (CPS) Yellow
7 Ground, CPS (digital) White
8 Bootstrap connector (programming) Blk/Orange
9 Stop circuit Blk/Yellow
002025
10 Throttle position sensor (TPS) 5 V Red
11 vacant
Pin 12 vacant
Description of Circuit Wire Color
No. 13 CANbus, NET-L Blue
1 Stator winding (yellow) Yellow/White 14 CANbus, NET-H White
2 Stator winding (yellow) Yellow 15 12 V to EMM (fused) Red/Purple
3 Stator winding (orange) Orange/White 16 Tachometer Gray
4 Stator winding (orange) Orange 17 CHECK ENGINE signal, SystemCheck Tan/Orange
5 Stator winding (brown) Brown/White 18 TPS Green
6 Stator winding (brown) Brown 19 Engine temperature sensor Pink/Black
20 Air temperature sensor Pink/Blue
21 CANbus, NET-S Red
22 CANbus, NET-C Black
23 vacant
24 LOW OIL signal, SystemCheck Tan/Black
25 WATER TEMP signal, SystemCheck Tan
26 TPS ground (analog) Black
27 Engine temp. sensor ground (analog) Black
28 Switched B+ to EMM Purple
29 LOW OIL switch Tan/Black
30 vacant
31 vacant
32 Neutral switch (shift linkage) Yellow/Red
33 vacant
34 vacant
92
ELECTRICAL HARNESS CONNECTIONS
EMM J1-B Connector EMM J2 Connector
001876 001877
Pin Pin
Description of Circuit Wire Color Description of Circuit Wire Color
No. No.
1 Injector, cylinder 2, 75–90 HP Purple 1 Stator winding, 1S Yellow
1 Injector, cylinder 2, 40–65 HP Green 2 Stator winding, 2S Brown
2
2
Injector, cylinder 3, 75–90 HP
Exhaust water valve, 60–65 HP
Green
Blue/Red
3
4
Stator winding, 3S
Fuel pump control
Orange
Brown
6
3 vacant 5 System Ground Black
4 vacant 6 +12 V out Red
5 vacant 7 System Ground Black
6 NO OIL signal, SystemCheck Tan/Yellow 8 System Ground Black
7 Ignition, cylinder 3, 75–90 HP Orange/Green 9 Stator winding, 1F Yellow/White
7 vacant, 40–65 HP 10 Stator winding, 2F Brown/White
8 Injector, cylinder 1 Blue 11 Stator winding, 3F Orange/White
9 vacant 12 Fuel pump (flyback) White/Red
10 vacant 13 +55 V, out White/Red
11 vacant 14 +12 V out Red
12 vacant 15 vacant
13 vacant 16 vacant
14 Injector ground Black
15 vacant
16 vacant
17 vacant
18 vacant
19 Ignition, cylinder 2, 75–90 HP Orange/Purple
19 Ignition, cylinder 2, 40–65 HP Orange/Green
22 vacant
23 Oil solenoid Blue
24 vacant
25 vacant
26 Ignition, cylinder 1 Orange/Blue
93
GROUND CIRCUITS
GROUND CIRCUITS FUSE

All ground circuits are essential to reliable out- The engine harness 12 V (B+) circuit is protected
board performance. Make sure all ground connec- by one automotive style 10 amp minifuse.
tions are clean and tight. Refer to wiring diagrams
for specific wiring details. The fuse is located on the port side of the power-
head, in the flywheel cover.
EMM Ground Tests
1
Use an ohmmeter to check continuity of ground
circuits. Calibrate the ohmmeter on the high ohms 2
scale. Resistance readings for all ground circuits
should be 0 W.
• System/power supply grounds: Check continu-
ity between terminal pins 5, 7, and 8 of EMM J2
connector and the main harness ground.
• Injector circuit grounds: Check continuity
between terminal pins 14, 20, and 21 of the 1. Fuse 005004
EMM J1-B connector and the main harness 2. Spare fuse
ground.
• Sensor circuit grounds: Check continuity IMPORTANT: Repeat failures of fuse could be
between terminal pins 26 and 27 of the EMM the result of faulty connections or accessories.
J1-A connector and the appropriate sensor The 12 V accessory circuit (purple wire from ter-
ground connections. Refer to wiring diagrams. minal “A” of key switch) is often used to power
accessories.
1. Main harness ground 002292

2. Ground stud (battery)
Additional Ground Tests

Check connections and continuity at the following
locations:
• Starter solenoid terminal B and main harness
ground.
• Trim and Tilt module ground at main harness
ground.
94
SENSOR TESTS
SENSOR TESTS (1.85 mm). The acceptable clearance is 0.036 to

0.110 in. (1 to 2.8 mm).
All sensor circuits are dependent on wiring and
connections, EMM supplied current (5 V), and
sensor resistance. The supplied current flows 1
through the wiring circuit and sensor before
returning to the EMM.
IMPORTANT: Use Evinrude Diagnostics soft-

ware to monitor sensor circuit voltages or values.
Crankshaft Position Sensor (CPS)

Test
Use the Evinrude Diagnostics software CPS Sync 1. CPS gap 006527
and engine RPM displays to confirm a valid CPS
signal while the outboard is cranking or running. Throttle Position Sensor (TPS) Test
An RPM display higher than zero indicates a CPS
signal to the EMM. Use Evinrude Diagnostics software to monitor
TPS voltage while the outboard is running. Volt-
Disconnect the crankshaft position sensor. age should change evenly as sensor lever is
moved. 6
Use a digital multimeter to measure sensor resis-
tance between the yellow and white wires. The Remove the electrical connector from the throttle
complete circuit can be tested by measuring position sensor.
between pins 6 and 7 of the EMM J1-A connector.
Sensor Resistance tance.
560 ± 10% @ 77°F (25°C)
Sensor Resistance between “A” and “B”
3000 to 7000 @ 77°F (25°C)
Sensor Resistance between “A” and “C”

4000 to 8000 @ 77°F (25°C)
1
1
1. CPS Connector 002286
The CPS is mounted to the throttle body housing

and requires no adjustment. Air gap or clearance
to flywheel is fixed at approximately 0.073 in.
1. TPS 002289
95
SENSOR TESTS
Connect red meter lead to terminal “A” and black Air Temperature Sensor (AT) Test
meter lead to terminal “C.” Rotate the sensor lever
Remove the electrical connector from the air tem-
through its range of travel. Resistance reading
perature sensor.
must change evenly as the sensor lever is moved.
Connect red meter lead on terminal “B” and black
tance.
meter lead to terminal “C.” Rotate the sensor
lever. Resistance reading must change evenly as AT Sensor Resistance
the sensor lever is moved. 680 ± 5.25% @ 212°F (100°C)
10000 ± 1.5% @ 77°F (25°C)
Engine Temperature Sensor Test 32654 ± 3.0% @ 32°F (0°C)
Remove the electrical connector from the engine
temperature sensor.

tance.
Engine Temperature Sensor Resistance
1
680 ± 5% @ 212°F (100°C)
10000 ± 1% @ 77°F (25°C)
32654 ± 2.5% @ 32°F (0°C)
1. AT sensor 006613
1
1. Engine temperature sensor 006612
96
STATOR TESTS
STATOR TESTS To check for a grounded winding, connect one

meter lead to ground and alternately connect the
The stator consists of 3 windings (4 poles each) other meter lead to each stator wire. Meter should
on a 5 inch diameter core and generates an out- read no continuity. If meter reads continuity,
put voltage of 55 VAC (1100 watts maximum). replace stator.
This voltage is converted by the EMM to provide
12 VDC for battery charging (3 to 5 A at 500 RPM Stator Voltage Output Test
and 25 A from 3000 RPM to WOT) and 55 VDC
for fuel injector, and fuel and oil pump operation. ELECTRIC START MODELS
Use a digital multimeter to check stator output
Stator Resistance Tests voltage. Set meter to read 110 VAC output.
Use a digital multimeter to check resistance of sta-
WARNING
tor windings.
To prevent accidental starting of outboard,
Disconnect EMM J2 connector from EMM. disconnect crankshaft position sensor
Stator Winding Resistance Specification (CPS).
Yellow & Yellow / white
.670 ± 0.020 @ 73°F (23°C) Disconnect CPS.
Brown & Brown / white
.670 ± 0.020 @ 73°F (23°C) Disconnect stator (6-pin) connector from the 6
engine harness (6-pin) connector.
Orange & Orange / white
.670 ± 0.020 @ 73°F (23°C) Connect Stator Test Adaptor tool, P/N 5005799, to
stator connector.
1 Connect meter leads to terminals of adaptor tool.
With a fully charged battery, crank outboard (300

RPM minimum) and observe meter reading:
• 30 VAC at 300 RPM
• 40 VAC at 400 RPM
• 55 VAC above 500 RPM
1. EMM J2 Connector 002462
Connect meter leads to the following pins:

• Yellow/white and yellow (pins 9 and 1)
• Brown/white and brown (pins 10 and 2)
• Orange/white and orange (pins 11 and 3) 1
IMPORTANT: A reading of less than 2 ohms is

acceptable. Make sure meter is calibrated to read 1. Stator Test Adaptor 002396
1 ohm or less.
97
CHARGING SYSTEM TESTS
ROPE START MODELS CHARGING SYSTEM

Use a Peak Reading Voltmeter, P/N 507972, to
check stator output voltage. Set meter to the TESTS
50 VAC scale.
12 V Charging Circuit
WARNING To test the operation of the regulator in the EMM,
To prevent accidental starting of outboard, you must be able to run the outboard continuously
disconnect crankshaft position sensor at approximately 5000 RPM, such as in a test tank
(CPS). or on a marine dynamometer.
The test consists of monitoring the system’s

Disconnect CPS. Remove spark plugs. Make sure response to a partially discharged battery. Use a
outboard is in NEUTRAL. Refer to SPARK variable load tester to discharge the battery.
PLUGS on p. 42.
IMPORTANT: The regulator requires voltage to
Disconnect stator (6-pin) connector from the operate. Before proceeding, make sure there is at
engine harness (6-pin) connector. least 7 V on the positive terminal of the starter
solenoid.
Connect Stator Test Adaptor tool, P/N 5005799, to
stator connector. Disconnect the battery cables at the battery.
Connect meter leads to terminals of adaptor tool. Use an inductive amp meter or connect a 0 to
50 A ammeter in series between the red wire of
Rotate the flywheel with the starter rope, using a
engine wire harness (alternator output from EMM)
long, steady pull.
and the positive (B+) battery cable terminal of
Stator output voltage should be approximately starter solenoid.
30 VAC.
Fluke † model 334 or 336, Snap-On † model MT110
or EETA501, and various other amp meters
should be available through local tool suppliers.
Reconnect the battery cables.
1. Stator Test Adaptor 006750
IMPORTANT: Index all spark plugs. Refer to

Spark Plug Indexing on p. 42.
98
CHARGING SYSTEM TESTS
Following the manufacturer’s directions, connect Start and run the outboard at approximately 5000
the variable load tester (carbon pile) across the RPM. Use the variable load tester to draw the bat-
battery terminals. Stevens model LB-85 and tery down at a rate equivalent to the stator’s full
Snap-On model MT540D are examples of testers output.
available. • The ammeter should indicate nearly full output,
approximately 25 A @ 5000 RPM.
WARNING
Decrease the battery load toward 0 A.
Excessive battery discharge rates might • Ammeter should show a reduced output. As the
overheat battery causing electrolyte gas- current draw decreases, the battery voltage
sing. This might create an explosive atmo- should stabilize at approximately 14.5 V.
sphere. Always work in a well ventilated
• If results vary, check stator BEFORE replacing
area.
the EMM. Refer to STATOR TESTS on p. 97.
4
55 V Alternator Circuit
2 Check battery ground cable for continuity.
With the key switch ON, check battery voltage at

1 battery (12 V).
Then, use Electrical Test Probe Kit, P/N 342677, 6

5 and a digital multimeter set to read 55 VDC to
3 check voltage on white/red wires at J2 connector
of EMM. Voltage at EMM connector should be 0.5
to 1 V less than battery.
Variable Load Test Diagram

1. Red wire (alternator output from EMM)
002077 1
2. Starter solenoid 2
3. Battery cable terminal (B+)
4. Variable load tester
5. Ammeter
1. J2 connector 007261
2. Test probe
With outboard running at 1000 RPM, voltage on

white/red wires should be 55 V. Voltage readings
at a specific speed (RPM) should be steady.
If there is any other reading, refer to STATOR

TESTS on p. 97. Inspect the stator wiring and
connections. Inspect the capacitor wiring, connec-
tions, and capacitor. Repair the wiring or replace a
Battery Charging Graph 002076
faulty capacitor, stator, or EMM.
99
ELECTRIC START CIRCUIT

Start Circuit Diagram
1
2
3
4
5
6 7
13
11
9
B M 1 2
M C S
A 8
4 5
FUSE
1 2
12
A B
A B 9
26 18 10
10 1
6 27
28
19 11
11 2
3
20 12
12
29 13
13 4
30 21
5 J1-A
31 22
23
14
14
15
15 6 10
32 7
16
15 NEG 33
34
24
25
16
17
17
8
9
–
J1-B
14
9
1
10
2
11
3
12
3 2 13
4
J2
5
14
6
15
7
16
8
+
1
008049
1. Marine battery 9. PURPLE wire (switched B+)

2. RED wire (POS) 10. Engine Management Module (EMM)
3. BLACK wire (NEG) 11. YELLOW/RED wire, start
4. Starter solenoid 12. Neutral Safety Switch (remote control)
5. Fuse (10 amp) 13. Neutral Safety Switch (engine)
6. RED/PURPLE wire 14. RED starter motor cable
7. Key switch connectors 15. Electric starter motor
8. Ignition switch
100
Start Circuit Operation Instrument Wire Harness

The starter must engage and turn the flywheel. Contains the following circuits:
The outboard must crank a minimum of 300 RPM • Red/purple wire provides 12 V to key switch ter-
to start. minal “B”.
• Purple wire provides switched 12 V to engine
Starter performance depends on the following: wire harness.
• Proper battery and cable capacity. • Yellow/red wire from terminal “S” of key switch
• Clean, tight cable connections. provides switched 12 V to solenoid (terminal
• Solenoid activation through the key switch and “A”) (key switch in START position).
neutral safety switch.
Key Switch, ON position
Refer to Predelivery and Installation Guide for 12 V is applied to the accessory circuit. Key
battery, terminal, and cable requirements. switch ON:
• Switches 12 V to terminal “A” of key switch and
Solenoid Wiring
to the purple wires of the wire harnesses.
The positive (B+) battery cable connects to a large
• Provides 12 V input to terminal 28 of EMM J1-B
terminal of the starter solenoid. This terminal also
connector. EMM turns ON.
provides the 12 V power supply to the engine har-
ness (red wire) and the 10 A fuse. The red/purple 1 2
wire from the fuse holder (10 A) provides 12 V to
terminal “B” of key switch. B B B
6
M M M M M M
The negative (B–) battery cable connects to the
C A C A C
A
main ground stud on the starter housing. S S S
Engine Wire Harness

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

• Yellow/red wire provides switched 12 V to sole-
4 5 6
noid (terminal “A”).
• Yellow/green wire provides 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)
101
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 engine wire harness yellow/red wire and
solenoid (terminal “A”). IMPORTANT: Disconnect all wiring from sole-
noid terminals before proceeding with this test.
1
B
Use a digital multimeter to measure resistance.
M M Put one meter lead on the starter positive (+)
A C
S
cable terminal and the other lead on the battery
positive (+) cable terminal:
• Meter must not show continuity (high reading).
• If meter shows continuity (low reading), replace
B
M
the solenoid.
C
M
S
A 1 2
POS
4 5 6
+
3 2 1
2 3
1. Ignition switch, START position – Continuity 000691R AB
between terminals “B” and “A”; “B” and “S”
2. Terminal “S”, 12 V
3. Neutral safety switch
3 4
1. Battery positive cable (B+) terminal 002073
2. Starter positive (+) cable terminal
3. “A” terminal (yellow/red)
4. “B” terminal (yellow/green)
Apply B+ to terminal “A” of solenoid and ground

(NEG) to terminal “B” of solenoid. Measure resis-
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 meter shows no continuity (high reading),
replace the solenoid.
After re-installing the solenoid, coat all wires and

terminals with Black Neoprene Dip.
102
ELECTRIC START TESTS
Starter Voltage Drop Test • Observe voltage reading.
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 crankshaft position sensor • Activate starter motor and observe voltage
(CPS). reading.
Use a digital voltmeter to measure the voltage No Load Current Draw Test
drop on each section of the start circuit. Securely fasten starter in a vise or suitable fixture
before proceeding with this check.
If any voltage reading is greater than 0.5 VDC
check that connections are clean, tight and free of Use a battery rated at 500 CCA (60 amp-hr) or
corrosion. Clean or replace any corroded or dam- higher that is in good condition and fully charged.
aged cables or connections.
Use an inductive ammeter or connect a 0 to 100
STEP 1: Connect voltmeter positive (+) lead to amp ammeter in series with a heavy jumper
the terminal for the negative (–) battery cable at between the battery positive (+) terminal and the
powerhead. Connect voltmeter negative (–) lead starter positive (+) terminal.
to negative (–) battery post.
• Activate starter motor and observe voltage Fluke model 334 or 336, Snap-On model MT110
or EETA501, and various other ammeters should
6
reading.
be available through local tool suppliers.
V–
NEG V
Attach or hold a vibration tachometer, such as a
1
Frahm † Reed tachometer, to the starter.
3 –
2 4
+
1. Negative battery cable 008464

2. Positive battery cable 24083
3. Solenoid
4. Starter cable
Complete the circuit with a heavy jumper between
the battery negative (–) terminal and the starter
STEP 2: Connect positive (+) lead to battery posi-
frame.
tive (+) terminal. Connect negative (–) lead to
starter solenoid terminal. Monitor the starter RPM and current draw.
• Activate starter motor and observe voltage • At 10,500 RPM the ammeter should show a
reading. maximum of 30 A.
STEP 3: First, activate starter motor. Connect
positive (+) lead to starter solenoid terminal. Con-
nect negative (–) lead to opposite starter solenoid
terminal.
103
REMOTE CONTROL SWITCH TESTS
REMOTE CONTROL Neutral Start Circuit Test

Use an ohmmeter or continuity light to test the
SWITCH TESTS continuity of the circuit while positioning the
remote control in NEUTRAL, FORWARD, and
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 cable to allow proper remote control shift
switch operation. Replace switch if results are action while outboard is not running. Disconnect
incorrect with any of the following tests. the instrument harness connector from the key
switch harness connector.
IMPORTANT: Disconnect battery and key
switch wiring before proceeding with the following Make sure the remote control handle is in NEU-
tests. TRAL. Connect meter between terminal 5
(red/purple wire) and terminal 2 (yellow/red wire).
Stop/Ground Terminals (M) – Connect meter Turn the key switch to START. Meter must indicate
between the two “M” terminals. Meter must indi- continuity.
cate NO continuity at START or ON.
Move the remote control handle to FORWARD
Turn key switch OFF. Meter must indicate continu- and turn the key switch to START. Meter must
ity. NOT indicate continuity.
Accessory Terminal (A) – Make sure the key 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) and “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 choke function or terminal

“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 shift cable and instru-

ment harness connector to key switch harness
connector.
1. OFF 000443R
2. ON
3. START
104
REMOTE CONTROL SWITCH TESTS
Neutral Start Switch Test Emergency Stop Switch Test

Use an ohmmeter or a continuity light to test neu- This switch can be part of the key switch or
tral start switch operation. installed as a separate switch. Either style con-
nects the “M” terminals of the key switch.
IMPORTANT: All wiring must be disconnected
from the switch before proceeding with this test. The emergency stop switch function grounds the
stop circuit wire (black/yellow) when the lanyard
Disassemble the remote control and remove the clip is removed. One “M” terminal is the ground
neutral start switch. wire (black) and one “M” terminal is the stop circuit
wire (black/yellow).
Connect one meter lead to each terminal of the
switch. 4 1 2
• Meter must indicate continuity when the plunger
is depressed
• Meter must indicate no continuity when the
plunger is released.
1
6
2
3
1. Lanyard and clip assembly 000444
2. Emergency stop switch, separate from key switch
3. Stop circuit wire (black/yellow)
4. Ground wire (black)
TYPICAL 3224
1. Plunger Install the clip on the emergency stop switch or
2. Neutral start switch
key switch. Start the outboard. Pull the clip from
the switch. The outboard must stop running.
Replace switch if results are incorrect.
105
TILT/TRIM RELAY TEST
TILT/TRIM RELAY TEST The meter must indicate battery voltage (12 V)
with B+ connected to either terminal.
The tilt and trim (TNT) module contains the cir-
cuitry and relays required for power trim and tilt
3
operation.
1
1
1. Tilt and trim module 006754 6

5
The tilt and trim switch provides B+ input to
green/white or blue/white wire of the TNT module. Tilt and Trim Module Diagram 002063
1. Green/white wire
2. Blue/white wire
Operation 3. B+, red wire
4. B–, black wire
The relay activates when B+ input from the switch 5. TNT motor connector
is supplied to terminal 86 of the internal relays. 6. TNT switch connector
Terminal 87a connects to ground (B–).
Terminal 87 connects to B+.

EXHAUST WATER VALVE
Terminal 30 connects TNT motor.
TEST
Disconnect electrical connector from water valve
Terminals 87a and 30 are connected when relay is solenoid. Use an ohmmeter to measure solenoid
not activated. This supplies ground (B–) connec- resistance.
tion to TNT motor.
Terminals 87 and 30 are normally open. B+ is

applied to terminal 30 when relay is activated.
This supplies ground B+ connection to TNT motor.
1
Refer to Tilt and Trim Module Diagram.
Test Procedure
Make sure red and black wires are connected to
12 V battery power supply.
Set voltmeter to 12 VDC scale. Connect test leads

1. Water valve electrical connector 004297
to terminals “A” and “B” of TNT motor connector.
Use a wire jumper to alternately connect B+ to ter- Water Valve Solenoid Resistance
minals “1” and “2” of tilt and trim switch connector.
295 ± 20 @ 77°F (25°C)
106
SystemCheck CIRCUIT TESTS
SystemCheck CIRCUIT instrument harness terminal 1 (purple wire) and

terminal 2 (black wire).
TESTS
Make sure the SystemCheck engine monitor can
warn the operator during a “NO OIL,” “WATER
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 before performing the following tests.
Refer to the Engine Wiring diagram and the 1. Test adapter(s) 42761
2. Connector, SystemCheck gauge
MWS Instrument Wiring diagram in the back of
this manual.
• If battery voltage is present, replace the gauge.
IMPORTANT: Use jumper wires made 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.
6
If the lights worked, but the warning horn did not
sound for one-half second, turn the key switch
OFF. Disconnect the warning horn 2-pin connec-
tor. Substitute a known good warning horn. Turn
the key switch ON.
• If the substitute horn beeps, the original horn is
defective and must be replaced.
• If the substitute horn does not beep, check for
battery voltage between instrument harness 2-
42811 pin connector, terminal 2 (purple wire) and
ground with the key switch ON. Also, check the
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 and pin 1 of the 2-pin connec-
running. The gauge warning lights for NO OIL, tor.
WATER TEMP, CHECK ENGINE, and LOW OIL • If battery voltage is present at the purple wire
must all light at once, then turn off in sequence, and the tan/blue wire has continuity between
and the warning horn must sound for one-half
second.
If the gauge lights do not turn on, turn the key

switch OFF. Disconnect the gauge 8-pin connec-
tor from the back of the gauge and turn the key
switch ON. Test for battery voltage between
107
SystemCheck CIRCUIT TESTS
the two connectors, replace SystemCheck WATER TEMP/ HOT Circuit Test
gauge.
The tan wire of engine harness and the MWS har-
ness receives a signal from the EMM. The EMM
receives information from the temperature sensor
on the cylinder head.
Using a jumper wire, connect tan wire (pin 6) of

the engine harness connector to a clean engine
ground.
2 1
1. Purple wire DRC6280
2. Tan/blue wire
002079
Turn the key switch OFF and reconnect all discon-
nected circuits.
Turn the key switch ON. After the normal self-test
sequence, the gauge WATER TEMP / HOT indi-
CHECK ENGINE Circuit Test cator should stay on.
Separate the 6-pin SystemCheck connector of • If LED is not on, test circuit for continuity. Test
MWS instrument harness from engine harness. for continuity of both the engine harness (tan
Black wire (pin 3) must be grounded. wire) and the MWS instrument harness (tan
Using a jumper wire, connect tan/orange wire (pin wire).
2) to a clean engine ground. Turn the key switch OFF and reconnect all discon-
Turn the key switch ON. After the normal self-test nected circuits.
sequence, the CHECK ENGINE light should stay IMPORTANT: To test the temperature sensor
on. itself, refer to Engine Temperature Sensor Test
• If the CHECK ENGINE light is not on, test circuit on p. 96.
for continuity. Check continuity of the MWS
instrument harness (tan/orange wire).
• Check continuity of the engine wire harness
between terminal 2 (tan/orange wire) of the Sys-
temCheck connector and pin 17 of the EMM J1-
A connector.

nected circuits.
108
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 engine 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.
2
1
3
002079
If the LOW OIL light does not turn on after con-

necting the terminal to ground, test circuit for con-
1. Purple lead
2. Black lead
006551
6
3. Gray lead
tinuity.
Turn the key switch OFF and reconnect all discon- Connect the red meter lead to the tachometer pur-
nected circuits. ple wire and the black meter lead to the tachome-
ter black wire (key ON, outboard NOT running).
NO OIL Circuit • If meter shows battery voltage, go to next step.
• If meter shows less than battery voltage, check
Separate the 6-pin SystemCheck connector of
the purple, red/purple, and black wiring circuits;
MWS instrument harness from engine harness.
fuse, key switch, and battery connections.
Black wire (pin 3) must be grounded.
Disconnect gray and black wires at tachometer.
Using a jumper wire, connect tan/yellow wire (pin
Set Fluke 29 Series II meter, or equivalent, to Hz
5) to a clean engine ground.
scale. Connect meter between gray wire and
Turn the key switch ON. After the normal self-test black wire. With outboard running at 1000 RPM,
sequence, the NO OIL light should stay on. meter should indicate 90 to 105 Hz.
• If the NO OIL light is not on, test circuit for conti- • If meter reads 90 to 105 Hz, replace tachome-
nuity. Test for continuity of the MWS instrument ter.
harness (tan/yellow wire). • If meter reads low or no signal, confirm output
• Test for continuity of the engine wire harness on gray wire at pin 16 of EMM J1-A connector.
between terminal 5 (tan/yellow wire) of the Sys- – Reading OK – Check condition of tachometer
temCheck connector and pin 24 of the EMM J1- circuit (gray wire). Repair as needed.
A connector. – Reading not OK – Check connection at EMM;
replace faulty EMM.
nected circuits.
109
FLYWHEEL AND STATOR SERVICING
FLYWHEEL AND STATOR Disconnect wiring harness and remove wiring

from cover.
SERVICING
IMPORTANT: Weak flywheel magnets can
cause low alternator output and affect outboard
performance. Weak flywheel magnets can also
cause low readings on ignition test equipment,
such as a peak-reading voltmeter, which might
cause unnecessary parts replacement.
1
An accurate test of alternator output can help
determine the flywheel’s condition. Refer to
CHARGING SYSTEM TESTS on p. 98. 1. MWS harness 002086
Flywheel Removal Remove fuse holder from flywheel cover.

WARNING
To prevent accidental starting while ser-
vicing, disconnect the battery cables at
battery.
Remove the recoil starter assembly (rope start

1
models). Refer to RECOIL STARTER REMOVAL
on p. 363.
Remove the electrical cover from flywheel cover.

1. Fuse holder 002094
1
Lift flywheel cover to remove.
002087
110
FLYWHEEL AND STATOR SERVICING
Use Flywheel Holder, P/N 771311, or equivalent, Stator Service

and a 1 5/16 in. socket to remove flywheel nut.
Disconnect stator harness connector.
Discard flywheel nut.
Remove three allen head screws to remove stator.
002088
1. Stator screws 006486
Apply Moly Lube grease to the threads of the
puller pressing screw, P/N 307637, and the center To install stator, position stator on cylinder block.
hole of the crankshaft. Apply Nut Lock to screw threads. Install screws
Assemble the following components from Univer-
and tighten in crossing pattern to a torque of 84 to 6
106 in. lbs. (9.5 to 12 N·m).
sal Puller Set, P/N 378103:
• Body, P/N 307636 Flywheel Installation
• Screw, P/N 307637
• Handle, P/N 307638 CAUTION
• Three screws P/N 309492
• Three washers, P/N 307640 To avoid injury, keep hands and fingers
clear from underside of flywheel. Flywheel
Put the puller on flywheel with body flat side up. can snap toward stator with great magnetic
Attach the puller body with the three shoulder force.
screws and washers. Hold puller body with han-
dle, and tighten pressing screw until flywheel Install the outer edge of flywheel key parallel with
releases. Turn the center screw and lift the fly- centerline of crankshaft.
wheel off of the crankshaft.
1
1
1. Flywheel key DRC2116

1. Universal puller 002089
111
IGNITION COIL SERVICING
Thoroughly clean the crankshaft and flywheel

tapers with Cleaning Solvent and let dry.
IGNITION COIL
SERVICING
Ignition Coil Removal
Remove spark plug lead from ignition coil and dis-
connect ignition coil electrical connector.
Remove two ignition coil retaining screws.
Do not lose the rubber washers between coil and

bracket.
1
002093 1
Align the flywheel keyway and install flywheel.

Coat the threads of flywheel nut with Triple-Guard
grease. Install the washer and nut and tighten to a
torque of 100 to 115 ft. lbs. (136 to 156 N·m).
1. Screws 008187
Ignition Coil Installation

Install one rubber washer on each screw and
install screw through ignition coil.
Install remaining rubber washers on screws

between coil and bracket.
002090
Replace flywheel cover and recoil starter (rope

start models).
IMPORTANT: Check ignition timing after fly-

wheel removal or replacement. Refer to TIMING 1
ADJUSTMENTS on p. 113.
1. Rubber washers 008188
Install coil 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 and connect

ignition coil electrical connector.
112
TIMING ADJUSTMENTS
TIMING ADJUSTMENTS the tool. Mark the flywheel directly across from the
pointer. Label this mark “A.”
Timing Pointer
WARNING
To prevent accidental starting while servic-
ing, disconnect the battery cables at the
battery. Twist and remove all spark plug
leads. 1
The timing pointer must be adjusted to indicate

top dead center (TDC) of the number 1 piston.
This reference to the position of the number 1 pis- 1. Timing pointer 006552
ton is used to synchronize the electronic timing
controlled by the EMM with the mechanical posi- Rotate the flywheel clockwise until the piston
tion of the number 1 piston. contacts the tool. Mark the flywheel directly across
from the pointer. Label this mark “B.” Rotate fly-
Always check timing pointer adjustment before
wheel counterclockwise slightly to release tool
using the Evinrude Diagnostics software Timing
Verification procedure.
then remove it from spark plug hole. 6
Use a flexible measuring device, such as a piece
Remove spark plugs. Rotate the flywheel clock-
of string, to find the exact center between marks
wise to approximately 30° ATDC.
“A” and “B.” Measure along the edge of the fly-
Install Piston Stop Tool, P/N 342679, into the wheel. Mark and label the center point “C.”
spark plug hole of the number 1 cylinder.
If mark “C” and the cast-in TDC boss on flywheel
are in alignment, the timing pointer is in the cor-
rect location.
1
If the pointer alignment is NOT correct, rotate the
flywheel clockwise to align the mark “C” with the
pointer. Hold the flywheel in this position. Loosen
the pointer retaining screw and adjust the pointer
1. Piston stop tool 006493
Rotate flywheel counterclockwise until the num-

ber 1 piston contacts the tool. Keep pressure on
the flywheel to position the piston firmly against
113
TIMING ADJUSTMENTS
location to align with the cast-in TDC boss on the Check ignition timing after any of the following
flywheel. Tighten retaining screw. procedures:
• Powerhead replacement
• Crankshaft replacement
• Flywheel removal or replacement
• CPS replacement
• EMM replacement
• EMM software replacement (reprogramming)
IMPORTANT: Make sure the timing pointer is
set and the outboard reaches operating tempera-
ture before making any timing adjustments.
TPS Calibration
2 3 4 1
Use Evinrude Diagnostics software to tell the
1. Mark “A’” 002092
2. Mark “B” EMM what throttle position sensor voltage is when
3. Mark “C” the throttle plates begin to open.
4. TDC boss
Set TPS Calibration after replacing or adjusting
Repeat the entire adjustment process to make any throttle body or throttle linkage parts.
sure pointer is aligned correctly.
Remove the lower engine covers and air silencer.
Install spark plugs. Refer to Spark Plug Indexing
on p. 42. Do NOT start the outboard.
Timing Verification On the Settings/Adjustments screen of the diag-

nostics software, click the “Set TPS Calibration”
Use Evinrude Diagnostics software to synchronize button.
the mechanical timing of the outboard with the
electronic timing of the EMM.
Start the outboard.
Use the Settings/Ignition Timing screen of the

diagnostics software and follow the on-screen
instructions.
1
1. TPS Calibration button 008086
While holding the throttle plates closed, advance

the throttle linkage until it stops. The Measured
TPS Calibration field on the screen will increase.
Click the Working button in the software to cali-

brate the TPS.
Ignition Timing Screen 008085 Install the air silencer and lower engine covers.
114
ELECTRIC STARTER SERVICING
ELECTRIC STARTER Starter Installation

Apply Triple-Guard grease to the threads of the
SERVICING two starter screws, the double-ended stud, and
also to the washers.
Starter Removal
Position the starter and install the screws and
IMPORTANT: Do not clean the starter drive washers. Tighten screws to a torque of 168 to 192
while the starter motor and drive are installed on in. lbs. (19 to 21 N·m).
the powerhead. The cleaning agent could drain
into the starter motor, washing dirt from the drive Attach starter positive (+) cable to post with lock
into the starter bearings and commutator. washer and nut; tighten securely.
Disconnect the battery cables at the battery. Install the battery negative cable (–) to the double-
ended stud.
Remove lower motor covers and air silencer.
Refer to Lower Cover Removal on p. 50. Coat connections with Black Neoprene Dip.
Remove the starter positive (+) cable from post on

starter. Remove the battery negative cable (–)
from the double-ended stud.
Remove two starter mounting screws and double- 6

ended stud. Remove the starter.
1 1
1. Black Neoprene Dip 008190

1 1
1. Screws 008189
115
CONNECTOR SERVICING
CONNECTOR Release terminal latch and gently pull on wire.
SERVICING
1
DEUTSCH Connectors
IMPORTANT: Electrical Grease is recom-
mended. Incorrect grease application can cause 2
electrical or warning system problems.
1. Terminal latch (plug) 42329
2. Terminal latch (receptacle)
To disconnect the connector, press the latch and
pull the connectors apart.
Terminal Installation
To connect the connector, confirm that the seal is Push terminal through seal until it locks into place.
in place. Clean off any old grease and dirt from Fill connector with Electrical Grease to 1/32 in.
connectors. Apply a light coat of Electrical Grease (0.8 mm) below ledge or end of plug.
to seal only. Push connectors together until
latched.
2
1
2
1 1. Ledge of plug 42330

2. End of plug
1. Latch 42079A
2. Seal
Push wedge in until latched. Wedge in 2-pin
Terminal Removal receptacle is not symmetrical; position latch shoul-
Use hook-end of Connector Service Tool, ders next to terminals.
P/N 342667, to pull out wedge from receptacle, or
Crimping Terminals
use other end of tool to pry out wedge from plug.
Use needle-nose pliers to remove wedge from Strip insulation back 3/16 in. (5 mm). Place termi-
3-pin receptacle. nal in 18-gauge 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. Capture all wire
strands in crimp; leave no loose strands. Crimp
1 wire securely. Do not solder. Crimp 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
116
CONNECTOR SERVICING
AMP Connectors
IMPORTANT: Always use the appropriate meter
test probes and adapters when testing compo-
nents fitted with these terminals. Electrical grease
is NOT used on AMP connectors. 1 2
SUPERSEAL 1.5
Disconnect
Lift latch. Pull connectors apart.
1. Locking tab, plug 002447
2. Locking tab, receptacle
Connect
Confirm the seal is in place. Push connectors Terminal Installation
together until latched.
Align terminal with connector housing. Push con-
1 nector and seal into housing until seated.
6
2
1. Latch 002448
2. Seal
1. Terminal and seal 002451

Terminal Removal
Use Secondary Lock Tool, P/N 777078, to release Align anti-backout device with connector housing
anti-backout device of connector housing. Next, and terminals. Use Secondary Lock Installer,
use Primary Lock Tool, P/N 777077, to release P/N 777079, to seat device in connector.
locking tab of connector housing. Release locking
tab and pull on wire to remove from 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
117
CONNECTOR SERVICING
SUPER SEAL POWER TIMER SERIES

The J1-A and J1-B connectors of the EMM are The J2 connector of the EMM is an AMP Power
AMP Super Seal connectors. Timer Series connector.
Disconnect Disconnect
Depress BOTH latches and pull connector from Use a screw driver to open latch. Pull connector
plug. from plug.
Connect Connect
Push connector into plug until latches engage. Push connector until seated in plug. Close latch
completely.
1
1
2
1. Latch 002118
1. J2 connector 002120
Terminal Removal 2. Latch (closed)
Open lock mechanism and remove terminal from

connector housing. Terminal Removal
Use Terminal Release Tool, P/N 351413, to
release BOTH locking mechanisms of connector.
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
118
CONNECTOR SERVICING
Terminal Installation Terminal Removal

Align terminal with connector housing and push A tab on the back side of the terminal engages a
terminal with seal into connector 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.
1. Latch 002456
2. Terminal with seal
1
Packard Connectors
IMPORTANT: Always use the appropriate meter
test probes and adapters when testing compo-
6
1. Tab DRC5940a
nents fitted with these terminals.
Disconnect
Install wire gasket on wires and feed wires
Lift latch(s). Remove connector.
through the correct terminal position of the con-
Connect nector housing. Terminal is crimped onto wire and
then pulled back into connector housing until lock-
Confirm the seal is in place. Push connector onto
ing tab engages and terminal is seated.
housing until latched.
002304
Crimping Terminals
DSC02124
Strip insulation back 3/16 in. (5 mm). Position end
of wire strands in terminal past the wire crimp area
and the end of insulation in the insulation crimp
area of the terminal.
Capture all wire strands in crimp; leave no loose

strands. Crimp wire and insulation securely using
crimping pliers.
119
NOTES
NOTES
Bulletins
Instruction Sheets
Other
120
FUEL SYSTEM
FUEL SYSTEM
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
FUEL SYSTEM HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
FUEL SYSTEM CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
FUEL SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
REGULATIONS AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
PORTABLE FUEL TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
FUEL FLOW REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
FUEL LIFT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
VAPOR SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
FUEL CIRCULATION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
FUEL MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
FUEL SYSTEM PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
VENT LINE CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
PRIMING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
FUEL SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7
FUEL SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
PRESSURE REGULATOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
VAPOR SEPARATOR VENT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
FUEL INJECTOR PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
FUEL INJECTOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
CIRCULATION PUMP RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
LIFT PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
LIFT PUMP VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
LIFT PUMP DIAPHRAGM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
ANTI-SIPHON VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
FUEL COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
RELIEVING FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
FUEL FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
FUEL LIFT PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
VAPOR SEPARATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
FUEL MANIFOLD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
FUEL INJECTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
INTAKE MANIFOLD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
121
FUEL SYSTEM
SERVICE CHART
SERVICE CHART
2-CYLINDER MODELS: INJECTORS, VAPOR SEPARATOR, FUEL PUMP
S
Tighten in 3 stages
5 ft. lbs.
1 (7 N·m)
A
10 ft. lbs.
2 (14 N·m)
24-36 in. lbs.
(2.7-4 N·m) A 24-26 Ft. lbs.
3
(33-35 N·m)
60-84 in. lbs

F (7-9.5 N·m)
60-84 in. lbs

(7-9.5 N·m)
60-84 in. lbs

(7-9.5 N·m)
24-36 in. lbs.

(2.7-4.0 N·m)
F
B Gasket Sealing Compound 002154a
C Adhesive 847
E Red Ultra Lock
F Blue Nut Lock
H Outboard Engine Lubricant
S STP † Oil Treatment
122
FUEL SYSTEM
SERVICE CHART
2-CYLINDER MODELS: REED PLATE ASSEMBLY AND THROTTLE BODY
25-35 in. lbs

(2.8-3.5 n·m)
60-120 in. lbs

(7-14 n·m)
Important: DO NOT lubricate

IMPORTANT:
DO
TPSNOTtolubricate
throttle TPS
shaft surface
7
10-14 in. lbs
(1.1-1.6 n·m)
10-14 in. lbs

(1.1-1.6 n·m)
10-18 in. lbs

(1.1-2.0 n·m)
60-120 in. lbs

(7-14 n·m)
002474
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
G Needle Bearing Grease
123
FUEL SYSTEM
SERVICE CHART
3-CYLINDER MODELS: INJECTORS, VAPOR SEPARATOR, FUEL PUMP
S
Tighten in 3 stages
5 ft. lbs.
1 (7 N·m)
A
10 ft. lbs.
2 (14 N·m)
24-36 in. lbs.
(2.7-4 N·m) A 3 24-26 Ft. lbs.
(33-35 N·m)
60-84 in. lbs

F (7-9.5 N·m)
60-84 in. lbs
(7-9.5 N·m)
60-84 in. lbs

(7-9.5 N·m)
24-36 in. lbs.

(2.7-4.0 N·m)
F
C Adhesive 847
E Red Ultra Lock
F Blue Nut Lock
H Outboard Engine Lubricant 002154b
S STP † Oil Treatment
124
FUEL SYSTEM
SERVICE CHART
3-CYLINDER MODELS: REED PLATE ASSEMBLY AND THROTTLE BODY
F
25-35 in. lbs
(2.8-3.5 n·m)
F
60-120 in. lbs
(7-14 n·m)
IMPORTANT:
DO NOT lubricate TPS
7
10-14 in. lbs
(1.1-1.6 n·m)
10-14 in. lbs
(1.1-1.6 n·m)
60-120 in. lbs 10-18 in. lbs

(7-14 n·m) (1.1-2.0 n·m)
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock 002155a
125
FUEL SYSTEM
FUEL SYSTEM HOSE ROUTING
FUEL SYSTEM HOSE ROUTING

2-CYLINDER MODELS
9
4
9 10 11 2
3
8
7 6
Fuel Supply
12
Fuel Return
1
002148
1. Fuel supply from boat fuel system

2. Fuel lift pump (2 to 8 psi)
3. Pulse hose from cylinder/crankcase
4. Fuel filter
5. Fuel supply to vapor separator
6. Vapor separator
7. Electric fuel circulation pump (20 to 30 psi)
8. Fuel supply manifold
9. Fuel injector(s)
10. Fuel return manifold
11. Vent hose to intake manifold
12. Pressure regulator (high pressure)
126
FUEL SYSTEM
3-CYLINDER MODELS
9
4
9 10 11 2
3
8
7 6
Fuel Supply
Fuel Return
12 7
1
5
002148a
1. Fuel supply from boat fuel system

2. Fuel lift pump (2 to 8 psi)
3. Pulse hose from cylinder/crankcase
4. Fuel filter
5. Fuel supply to vapor separator
6. Vapor separator
7. Electric fuel circulation pump (20 to 30 psi)
8. Fuel supply manifold
9. Fuel injector(s)
11. Vent hose to intake manifold
12. Pressure regulator (high pressure)
127
FUEL SYSTEM
FUEL SYSTEM CIRCUIT DIAGRAMS
FUEL SYSTEM CIRCUIT DIAGRAMS

2-CYLINDER MODELS
4 3 3
1 1
2 2
1 1
10 2 2
1
9
8
7
J1-A
2
20 14 8 1
21 15 2
9 3
22 16
10
6 543 21 23 17
11
4
5
J1-B
24 18
25 12 6
19 13 7
26
5 6 5 4 3 2 1
9
1
10
2
11
3
12
4
13
5
J2
14
6
15
7
16
8
6
006479
1. Stator 5. Capacitor 9. GREEN

2. EMM 6. WHITE/RED (55 V) 10. BROWN
3. Fuel injector 7. BLACK ground wires
4. Fuel circulation pump 8. BLUE
128
FUEL SYSTEM
3-CYLINDER MODELS
4 3 3 3
1
2
1 1 1 1
2 2 2
9 10
8
11
+
J1-A
2
7
1
20 14 8 2
21 15 9 3
22 16
6 543 21 23 17
10
11
4
5
J1-B
24 18
25 12 6
26 19 13 7
7
5 6 5 4 3 2 1
9
1
10
2
11
3
12
4
13 J2 J2
5
14
6
15
7
16
8
6 006756
1. Stator 5. Capacitor 9. PURPLE

2. EMM 6. WHITE/RED (55 V) 10. GREEN (2)
3. Fuel injector 7. BLACK ground wires 11. BROWN
4. Fuel circulation pump 8. BLUE
129
FUEL SYSTEM
FUEL SYSTEM REQUIREMENTS
FUEL SYSTEM Portable Fuel Tanks

REQUIREMENTS WARNING
Regulations and Guidelines If engine is equipped with a quick-discon-

nect fuel hose, you MUST disconnect the
Vessel manufacturer, and/or installer of an EPA 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 amount of fuel may be
– 33 CFR 183 released when the fuel connector is dison-
• American Boat & Yacht Council (ABYC) nected.
– Standard H-24
– Standard H-25. Store portable fuel tanks in well-ventilated
areas, away from heat sources and open
flames. Close the vent screw of the fuel
tank cap, if equipped, to prevent escape of
fuel or fuel vapors which could acciden-
tally ignite. Do not allow disconnected fuel
hoses to leak fuel.
NOTICE Do not use portable fuel tanks for

outboards larger than 115 HP. Inadequate fuel
flow to high horsepower outboards can result
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
130
FUEL SYSTEM
FUEL SYSTEM REQUIREMENTS
Fuel Requirements When using alcohol-extended fuels, be aware of

the following:
WARNING • The boat’s fuel system may have different
requirements regarding the use of alcohol fuels.
Gasoline is extremely flammable and Refer to the boat’s owner guide.
highly explosive under certain conditions. • Alcohol attracts and holds moisture that can
Improper handling of fuel could result in cause corrosion of metallic parts in the fuel sys-
property damage, serious injury or death. tem.
• Alcohol blended fuel can cause engine perfor-
Always turn off the outboard before fuel- mance problems.
ing. • All parts of the fuel system should be inspected
Never permit anyone other than an adult 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 tank all the way to the
top or fuel may overflow when it expands 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 tanks from the boat
and varnish deposits which can damage the out-
before fueling.
board.
Always wipe off any fuel spillage.
Additives
Do not smoke, allow open flames or
sparks, or use electrical devices such as IMPORTANT: The only fuel additives approved
cellular phones in the vicinity of a fuel leak for use in Evinrude outboards are 2+4 ® fuel condi-
or while fueling. tioner and Evinrude/Johnson Fuel System
7
Cleaner. Use of other fuel additives can result
Minimum Octane in poor performance or engine damage.
Evinrude/Johnson outboards are certified to oper- Evinrude/Johnson 2+4 Fuel Conditioner will
ate on unleaded automotive gasoline with an help prevent gum and varnish deposits from form-
octane rating equal to or higher than: ing in fuel system components and will remove
• 87 (R+M)/2 AKI, or moisture from the fuel system. It can be used con-
• 90 RON tinuously and should be used during any period
Use unleaded gasoline that contains methyl ter- when the outboard is not being operated on a reg-
tiary butyl ether (MTBE) ONLY if the MTBE con- ular basis. Its use will reduce spark plug fouling,
tent does not exceed 15% by volume. fuel system icing, and fuel system component
deterioration.
Use alcohol-extended fuels ONLY if the alcohol
content does not exceed: Evinrude/Johnson Fuel System Cleaner will
• 10% ethanol by volume help keep fuel injectors in optimal operating condi-
• 5% methanol with 5% cosolvents by volume tion.
131
FUEL SYSTEM
COMPONENTS
COMPONENTS Vacuum from the fuel lift pump pulls fuel from the
fuel tank. Once fuel reaches the pump, internal
The fuel system includes the following compo- pump pressure forces the fuel from the pump
nents: through the fuel filter and into the vapor separator.
• Fuel Lift Pump
• Fuel Filter Fuel Filter
• Vapor Separator The fuel filter protects the vapor separator and the
• Fuel Circulation Pump high-pressure components of the fuel system from
• Fuel Supply Manifolds contaminants. Refer to INSPECTION AND MAIN-
• Fuel Injectors TENANCE SCHEDULE on p. 16 for service fre-
• Fuel Return Manifolds quency.
Fuel Lift Pump 1

The fuel lift pump is a mechanical, pressure-pulse
pump. The diaphragm of the pump is driven by a
pulse hose that connects to the cylinder/crank-
case assembly.
Fuel lift pump pulse hose location:
• 2-Cylinder Models: Number 2 cylinder
• 3-Cylinder Models: Number 3 cylinder
1. Filter 002145
Vapor Separator
1
The vapor separator:
• Serves as a water-cooled fuel reservoir to accu-
mulate incoming fuel from the fuel lift pump and
2
from the fuel return manifold.
• Contains a float controlling the venting of fuel
vapors.
• Contains a fuel pressure regulator for the high
2-Cylinder models 006558 pressure fuel system.
1. Fuel lift pump
2. Pulse hose fitting
3-Cylinder models 002314

1. Fuel lift pump
2. Pulse hose fitting
132
FUEL SYSTEM
COMPONENTS
The vapor separator is serviced as an assembly

and includes the fuel circulation pump.
1. Vent hose connection to intake 002180
Vapor Separator Assembly 006555 The vapor separator vent is opened and closed by
1. Circulation pump
a float valve. The float valve moves with the fuel
level in the fuel chamber. Hot fuel causes an
Fuel Reservoir increase in vapor pressure. This results in a lower
The vapor separator accumulates fuel in an inter- fuel level in the vapor separator. The float valve
nal fuel reservoir and supplies fuel to the electric drops and the vent opens. This allows fuel vapor
circulation pump. It is water-cooled to enhance to flow to the intake manifold through the vent
vapor separating capabilities. hose.
Cooling As the vapor pressure in the vapor separator
Water is used to cool the fuel as it flows through decreases, the fuel level begins to increase. An 7
the vapor separator. The cooling passage of the increase in the fuel level raises the float valve and
separator self-drains when the outboard is stored the vent closes.
vertically. Refer to HOSE ROUTING AND WATER
FLOW DIAGRAMS on p. 174. Pressure Regulator
The fuel pressure regulator helps maintain consis-
Venting tent fuel pressure in the fuel system.
The fuel vapor vent regulates fuel vapor pressure
in the reservoir. Fuel returning from the injectors enters the fuel
chamber of the vapor separator through a pres-
sure regulator. The pressure regulator maintains
1 approximately 20 to 30 psi (138 to 207 kPa) of fuel
pressure in the high pressure side of the fuel sys-
tem.
1. Vent 005007
133
FUEL SYSTEM
COMPONENTS
Fuel Circulation Pump Fuel Manifolds

The fuel circulation pump is an electric high pres- The fuel supply and return manifolds route fuel
sure fuel pump. through the high pressure side of the fuel system.
Fuel Supply Fuel Supply Manifold

The pump is mounted to the vapor separator and The fuel supply manifold supplies pressurized fuel
draws fuel from the fuel chamber. It pumps pres- to the inlet port of each fuel injector.
surized fuel through a fuel supply manifold con-
nected to the fuel injectors. Fuel Return Manifold
The fuel return manifold provides a route for fuel
Electrical Circuit passing through the fuel injectors to flow back to
The circulation pump is controlled by the EMM the fuel chamber of the vapor separator.
and operates on the 55 V circuit. The outboard
must be cranking or running (CPS input to EMM)
for the circulation pump to be activated. The EMM
controls pump operation by rapidly connecting
and disconnecting the pump’s internal coil to 1 2
ground.
1. Fuel supply 006560

1 2. Fuel return
Fuel Injectors
Fuel injectors are fuel metering, electric solenoids
(55 V) bolted directly to the cylinder head. The
1. Fuel pump electrical connector 006557 EMM controls the activation of each injector by
rapidly connecting and disconnecting the injec-
tor’s internal coil to ground.
Fuel Flow Compensation

The flow rate of each injector is measured as part
of the manufacturing process. This information is
recorded and assigned to the injector by serial
number.
134
FUEL SYSTEM
COMPONENTS
The EMM is programmed to compensate for vari- Injector Fuel Supply

ations in fuel flow. Each injector and its location on Fuel is supplied to the injectors by the fuel circula-
the outboard is identified by the EMM. DO NOT tion pump and the fuel supply manifold.
install an injector without updating the compensa-
tion software. Each injector has internal fuel passages. These
passages are designed to:
Each service injector includes its fuel flow infor- • Provide fuel to the injector's injection chamber
mation on a 3.5 in. floppy disk. This software • Route fuel through the injector housing to cool
allows the EMM to be reprogrammed for this injec- the injector coil and armature
tor’s unique fuel flow characteristics.
NOTICE Fuel injectors MUST NOT be moved

from one cylinder to another. EMM program-
ming is associated with the cylinder location
of each injector. Installing an injector on the
wrong cylinder can result in powerhead fail-
ure.
006619
135
FUEL SYSTEM
FUEL SYSTEM PRIMING
FUEL SYSTEM PRIMING Priming the Fuel System

Vent Line Clamp WARNING
Federal Regulations require that all outboards Fuel vapors are highly flammable. Perform
with a fuel vapor separator must be shipped with a the following procedure in a well venti-
vent line clamp installed. This clamp must be lated area. Extinguish all smoking materi-
removed before priming the fuel system or starting als and make certain no ignition sources
the outboard for the first time. are present.
REMOTE MODELS
Insert the fuel supply hose from the fuel tank into a
suitable container. Squeeze the fuel primer bulb or
activate the boat-mounted electric fuel primer until
fuel flows from the fuel hose.
Once fuel flow is observed, connect fuel supply

hose from fuel tank to hose fitting on outboard.
Secure hose with Oetiker clamp.
002552
TILLER MODELS
Connect the fuel hose connector to the quick con-
IMPORTANT: Failure to remove the clamp may nect fitting on the outboard.
cause fuel starvation and poor running qualities. ALL MODELS
Use the primer to fill the vapor separator.
The high-pressure fuel circuits and injectors will
prime as the outboard is cranked with the starter.
Observe all fuel lines, both in the boat and on the

outboard. Repair any fuel leaks.
WARNING
Failure to check for fuel leaks could allow
a leak to go undetected, resulting in fire or
explosion and may cause personal injury
or property damage.
136
FUEL SYSTEM
FUEL SYSTEM TESTS
FUEL SYSTEM TESTS Shut OFF outboard. Monitor pressure gauge.

Pressure should not drop below 15 psi (103 kPa).
WARNING IMPORTANT: If outboard does not run, prime

fuel system and crank outboard; check circulation
Use caution when working on any pres-
pump operation; check fuel system pressure.
surized fuel system. Wear safety glasses
and work in a well ventilated area. Extin- Results:
guish all smoking materials and make cer- Normal pressure:
tain no open flames or ignition sources
• Observe pressure reading after outboard is shut
exist. Before starting any fuel system ser-
OFF
vice, carefully relieve fuel system pres-
• Refer to Lift Pump Pressure Test on p. 139
sure. Failure to properly relieve fuel
system pressure can result in spraying Pressure drops after outboard is shut OFF:
fuel and/or excessive fuel spillage during • Check for leaking fuel injector.
servicing. Fuel is flammable 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 restricted filter or fuel return fitting of
Relieve fuel system pressure. Refer to Relieving vapor separator, damaged pressure regulator in
Fuel System Pressure on p. 142. vapor separator, or restricted fuel return mani-
fold.
WARNING
Protect against hazardous fuel spray. Low pressure: 7
Before starting any fuel system service, • Check fuel supply to fuel lift pump. Refer to Lift
carefully relieve fuel system pressure. Pump Vacuum Test on p. 140. 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 psi (0 to 415 kPa) Fuel Pressure Gauge, • Lift pump not supplying enough fuel to vapor
P/N 5007100 or equivalent, to the upper fuel pres-
separator. Refer to Lift Pump Pressure Test
sure test fitting.
on p. 139.
• If the above tests are good and vapor separator
remains full of fuel, check for damaged circula-
tion pump. Replace vapor separator assembly.
1 2 No pressure:
• Check electrical circuit and ground connections
for circulation pump.
• If voltage is present and pump does not run,
repair connection or replace vapor separator
assembly.
Relieve fuel system pressure before removing fuel

1. Test fitting 006655
2. Fuel pressure gauge pressure gauge. Refer to Relieving Fuel System
Pressure on p. 142.
START outboard and check pressure. System
pressure should be 20 to 35 psi (138 to 241 kPa).
137
FUEL SYSTEM
FUEL SYSTEM TESTS
Pressure Regulator Test Fuel Injector Pressure Test

Refer to Vapor Separator Service on p. 144 to This test requires Injector Test Fitting kit,
remove vapor separator. P/N 5005844.
Make sure filter is not clogged. Clean or replace Disconnect the battery cables at the battery.
as needed.
Loosen oil tank assembly to provide access to fuel
Apply oil to valve and connect pressure pump and manifolds. Refer to Oil Tank Assembly on p. 169.
hose to the fuel return fitting of vapor separator.
Relieve fuel system pressure. Refer to Relieving
Apply pressure to check regulator operation. The Fuel System Pressure on p. 142.
pressure should open check valve at approxi-
mately 15 psi (103 kPa). WARNING
Protect against hazardous fuel spray.
Before starting any fuel system service,
carefully relieve fuel system pressure.
IMPORTANT: Perform test with injector

mounted to cylinder head and fittings 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 injector to 30 psi
(207 kPa). Pressure must hold for at least five
minutes.
1
2 2
3 1
1. Filter 000249r
2. Fuel return fitting
3. Pressure regulator
Vapor Separator Vent Check 1. Outlet fitting 002379

Monitor the vapor separator vent hose. No fuel or 2. Inlet fitting
a trace of fuel is acceptable. Excessive fuel dis-

charge indicates a vapor separator vent malfunc- Refer to FUEL DELIVERY TESTS on p. 84 for
tion. Monitor vent for presence of fuel during additional test procedures.
testing. Temporarily install clear tubing for moni-
toring. Replace vapor separator if the venting of
fuel is continuous.
138
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 appropriate adapter
coil resistance. leads to measure the fuel pump circuit and coil
resistance.
Fuel Injector Coil Resistance
2 to 3 @ 72°F (22°C) Fuel Pump Resistance
3  @ 77°F (25°C)
006620
006633
Use a digital multimeter with appropriate adapter
leads to measure resistance of the complete injec- Lift Pump Pressure Test 7
tor circuit, including injector and associated wiring.
Install a 0 to 15 psi (0 to 103 kPa) Fuel Pressure
Measure resistance between pin 1 (white/red) of Gauge, P/N 5006397 or equivalent, to the lower
injector connector (connected) and the appropri- fuel pressure test fitting.
ate pin location of EMM J1-B connector (discon-
nected). Refer to engine wiring diagram for
1
specific EMM J1-B connector pin location for the
injector circuit being tested (blue, purple or green).
1. Fuel pressure gauge 006634

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

outboard and run at idle speed. Hold gauge level
006621
with inlet fitting and monitor gauge for pressure
Resistance should be the same as, or slightly reading.
higher than, the injector alone. Pressure should stabilize at a reading greater
than 3 psi (27 kPa).
139
FUEL SYSTEM
FUEL SYSTEM TESTS
Results: NOTICE Do not use fuel primer bulb, manual

Normal pressure: fuel primer, or electric fuel pump primer to
• Perform the Lift Pump Vacuum Test on p. 140. restart outboard. A positive pressure in the
Make sure no air leaks or restrictions exist in fuel supply could damage some vacuum
the fuel supply hose or boat fuel system. gauges.
Low pressure:
• Check pulse hoses and fittings for restrictions.
• Perform the Lift Pump Vacuum Test on p. 140.
Make sure no air leaks or restrictions exist in
the fuel supply hose or boat fuel system.
• Check fuel flow through fuel lift pump. Use fuel
primer bulb to force fuel through pump.
No pressure:
• Check pulse hoses and fittings restrictions.
• Check fuel flow through fuel lift pump. Use fuel
primer or primer bulb to force fuel through
000243
pump.
• Momentarily prime or squeeze primer bulb to START outboard and run at FULL THROTTLE for
check gauge operation. at least two minutes. Monitor clear vinyl hose for
• Check pulse hose and fittings for restrictions. the presence of air. Air bubbles indicate a faulty
hose, connection, or fuel tank pick-up. Repair, if
Lift Pump Vacuum Test necessary, before proceeding.
Confirm fuel supply to the fuel lift pump.
There should be no air or vapor bubbles visible in
Temporarily install a vacuum gauge, T-fitting, and the clear hose. The maximum inlet fuel vacuum
8 in. (20.3 cm) of clear vinyl hose between the fuel should not exceed 4 in. Hg. (13.5 kPa) at the inlet
supply hose and fuel lift pump (inlet). Secure con- to the fuel lift pump under any operating condi-
nections with tie straps to prevent fuel or air leaks. tions (IDLE to WOT).
A higher vacuum indicates an excessive restric-

tion in the fuel supply. Repair as needed. Refer to
FUEL SYSTEM REQUIREMENTS on p. 130 for
fuel supply component requirements.
140
FUEL SYSTEM
FUEL SYSTEM TESTS
Lift Pump Diaphragm Test Anti-Siphon Valve Test

Perform this test only if a damaged pump is sus- Remove anti-siphon valve from fuel tank. Install
pected. This test does not confirm the perfor- adapter fittings and a 36 in. (91.4 cm) length of
mance of internal fuel pump check valves. clear hose to the inlet side (tank end) of valve.
Remove the pulse hose from the crankcase fitting.
Apply 15 psi (103 kPa) to the pulse hose of the 3

pump. Replace lift pump if pump fails to hold pres-
sure.
20 in. (500 mm)

2
1
1. Anti-siphon valve DR2277

2. Adapter fitting
3. Clear hose
1. Pulse fitting 002334a
Fill clear hose with water to a height of 20 in. (500
mm). Water must NOT flow through valve. An 7
occasional drip is acceptable. Replace valve if
water drips continuously.
Increase height of water to 25 in. (630 mm). Water

should flow through valve as water level reaches
25 in. (630 mm). Replace the anti-siphon valve if
test results are different.
141
FUEL SYSTEM
FUEL COMPONENT SERVICING
FUEL COMPONENT Wrap a shop towel completely around the pres-

sure test valve while connecting fitting from Fuel
SERVICING Pressure Gauge, P/N 5007100, to top test fitting
of fuel pump/vapor separator assembly.
WARNING
Gasoline is extremely flammable and
highly explosive under certain conditions.
Use caution when working on any part of
the fuel system. 1
Refer to Relieving Fuel System Pressure.
Always disconnect the battery cables at
1. Shop towel 005011
the battery before servicing the fuel sys-
tem unless instructed to do otherwise. Insert venting hose of gauge into a suitable con-
Always work in a well ventilated area and tainer.
wipe off any fuel spillage.
Slowly open gauge’s venting valve.
DO NOT smoke and make certain no open
flames or ignition sources exist. Clean up any spilled fuel with shop towels.
After servicing the fuel system check for
leaks. Failure to check for fuel leakage 1
could allow a leak to go undetected,
resulting in fire or explosion. 2
Relieving Fuel System Pressure

IMPORTANT: Minimize fuel system pressure
before disassembly. Temporarily restrict the fuel 3
supply hose from fuel tank with hose pincer.
Remove propeller and disconnect circulation fuel
1. Test fitting 005012
pump electrical connector. If outboard runs, start 2. Venting valve
and run at IDLE for 5 seconds and STOP out- 3. Venting hose
board. If outboard does NOT run, crank for 10
seconds.
142
FUEL SYSTEM
Fuel Filter Service Fuel Lift Pump Service

Removal The fuel lift pump is serviceable as a complete
assembly or can be repaired with a fuel pump
repair kit. Refer to parts catalog for service parts.
Remove filter carefully to prevent spilling contents.
Removal
Inspect contents for any presence of water. If Disconnect the battery cables at the battery.
water is present, identify the source and correct
the problem. Take additional fuel samples and Disconnect the fuel hoses from the fuel pump
drain fuel tank(s) if necessary. housing.
Disconnect the fuel lift pump pulse hose at the

crankcase fitting.
2
1
1. Fuel filter 002192

2. Arrow
7
Installation 1. Crankcase fitting 006558
Install filter in fuel supply hoses. Note arrow indi-

Loosen the fuel lift pump mounting screws.
cating direction of fuel flow on filter. Secure filter
Remove the fuel lift pump as an assembly.
with appropriate clamps.
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.
1. Screws 002194
Fuel pump repair kit, P/N 438616, is available for

internal service of fuel pump. Refer to instructions
included with kit.
143
FUEL SYSTEM
Installation Remove vapor separator/fuel pump from the

Place fuel pump in position on crankcase. Apply mounting stud and slide vapor separator housing
Nut Lock to mounting screws. Tighten screws to a from the grooves of the isolator mounts.
torque of 24 to 36 in. lbs. (2.8 to 4.0 N·m).
Installation
Connect the fuel lift pump pulse hose to the crank- Slide the vapor separator bracket notches into
case. Secure with tie strap. grooves of the isolator mounts. Install forward iso-
lator of vapor separator on mounting stud and
Connect the fuel hoses to the fuel filter. Secure secure with retainer clip.
with Oetiker clamps.

pressure on bulb and check for fuel leaks.
Connect battery cables. 2

1
Vapor Separator Service

Removal
1. Notches 007859
Relieve fuel system pressure. Refer to Relieving 2. Isolator mounts
Fuel System Pressure on p. 142.
Install all hoses and manifolds in original locations
Disconnect circulation pump electrical connector. and secure with appropriate clamps. Route hoses
Remove clamp and fuel supply manifold from top and secure with tie straps as shown.
of circulation pump. Remove clamp and vapor
vent hose from separator cover.
Remove clamps and vapor separator cooling

water hoses.
Remove clamps and fuel return manifold and fuel

supply hose from bottom of vapor separator.
Remove the vapor separator housing retainer clip.
007860

1 pressure on bulb and observe for fuel leaks.
Connect battery cables.

1. Retainer clip 005013
144
FUEL SYSTEM
Fuel Manifold Service Installation

Check condition of sealing O-rings on fuel mani-
Removal fold fittings. Lubricate O-rings with outboard lubri-
Disconnect the battery cables at the battery. cant and insert fuel manifold fittings into injector.
Both fittings must be fully seated into the injector
fuel ports.
Install retainer in the outer groove of the manifold
Remove oil tank assembly. Refer to Oil Tank
fittings. Install and tighten screw to a torque of 24
Assembly on p. 169.
to 36 in. lbs. (2.7 to 4 N·m).
Remove clamps and disconnect the fuel manifolds
as follows:
• Fuel supply manifold to circulation pump.
1
• Fuel return manifold to vapor separator.
1 2
1. Retainer 005342
2. Manifold fitting groove
2 7
Install the fuel manifolds to the fuel pump assem-
bly and secure with clamps:
1. Fuel supply manifold 006555
• Fuel supply manifold to circulation pump.
• Fuel return manifold to vapor separator.
Remove fuel manifold retainer screws and remove
Install oil tank assembly. Refer to Oil Tank
retainers from fuel injectors.
Assembly on p. 169.
1. Screw 006559
Disconnect fuel manifold fittings from fuel injector

ports, then remove the manifold assemblies.
145
FUEL SYSTEM
Fuel Injector Service Remove injector screws.

Mark fuel injectors to show cylinder locations.
NOTICE Fuel injectors must be installed in

the correct cylinder locations. Use Evinrude
Diagnostics Software to make sure that EMM 1
programming matches injector positioning.
The Injector Coefficients screen displays
injector serial numbers for each cylinder.
1. Injector screws 006561
Remove fuel injector and insulator.
Crush Ring Replacement
NOTICE Injector crush rings must be

replaced if injector is installed in a different
head or cylinder location.
Use Slide Hammer assembly, P/N 391008, with

Slide Hammer Adaptor kit, P/N 390898, to remove
Injector Coefficients Screen 008079
injector from mounting cup.
Thread adaptor and stud into face of injector. Hold

Use caution when handling fuel injectors. Prevent
mounting cup securely. Use slide hammer to sep-
dirt and debris from entering fuel inlet and outlet
arate injector from mount housing.
ports of injectors or fuel manifolds. Cover the
injector nozzle port in cylinder head to prevent
contamination of combustion chamber.
Removal

Remove fuel manifolds. Refer to Fuel Manifold

Service on p. 145.
Remove the ignition coil assemblies. 002345
Disconnect the fuel injector electrical connector. Remove adaptor from injector. Remove crush ring
and O-rings from injector. Inspect and clean injec-
146
FUEL SYSTEM
tor filter. Install new crush ring and O-rings. Lubri- Installation
cate O-rings with STP † Oil Treatment.
NOTICE All injectors must be installed in the
correct cylinder by serial number. Improper
injector installation can result in powerhead
failure.
Installation of a replacement injector requires that

1 coefficient data for the new injector is uploaded to
the EMM.
Coefficient data for some replacement injectors is

supplied on a computer disk shipped with the
injector. If a disk is not included with the injector,
1. Adaptor 002196 coefficient data can be downloaded from the
Evinrude/Johnson dealer website. Refer to the
instructions provided with the injector kit.
Upload Coefficient Files to EMM

2
Use the Evinrude Diagnostics software Settings
screen to upload the coefficient file to the EMM.
1 Select the Injectors tab.
Select the cylinder tab for injector being replaced.
7
Select the Replace Injector button.
1. Crush ring 002317

2. O-rings
Install injector into mount housing. Press on injec-

tor face until injector seats in mount housing.
1. “Replace Injector” button 008079
002318
147
FUEL SYSTEM
Use the drop down menu to navigate to the saved Install Injector
coefficient file location. The following items and their mating surfaces
must be cleaned prior to reassembly:
The coefficient file name must match the serial
• Injector
number of the injector.
• Cylinder head
Select the correct file for the injector. • Adapter
• Screws
Select the Replace Injector button. • Threaded areas.
1 CAUTION
All injector components must be clean to
2 ensure correct torque tightening specifi-
cations. To prevent fuel leakage, carefully
3 follow these installation instructions.
Place injector and insulator in the proper cylinder

location.
1. Navigation menu 008335 IMPORTANT: Be careful not to pinch any wiring

2. Injector coefficient file
3. “Replace Injector” button
or hoses during assembly.
Lubricate mounting screw threads and under the

After the upload is complete, the program will head of the screw with a light coat of Triple-Guard
return to the Cylinder tab. grease. Install washers (one per screw) on injec-
Make sure the serial number displayed on the tor retaining screws. Install screws and washers
screen matches the serial number printed on the through mounting flange of injector and into cylin-
serial number label of the replacement injector. der head.
002316
1. Serial number 008079
148
FUEL SYSTEM
Tighten screws in stages, starting with the lower Intake Manifold Service
screw.
• First torque is 5 ft. lbs. (7 N·m). Removal
• Second torque is 10 ft. lbs. (14 N·m). Disconnect vapor separator vent hose, main bear-
• Final torque is 24 to 26 ft. lbs. (33 to 35 N·m). ing vent hose, air temperature sensor, crankshaft
position sensor, and throttle position sensor.
Use Ball Socket Remover Tool, P/N 342226, to
remove throttle link arm.
Remove throttle body screws and throttle body

assembly.
1 2
Tighten Screws in Stages 006562
Reconnect fuel injector electrical connectors.
Install the ignition coil assemblies. Tighten coil

screws to a torque of 60 to 84 in. lbs (7 to 9.5
N·m).
Install fuel manifolds. Refer to Fuel Manifold Ser-

1. Link arm
2. Throttle body screws
002499 7
vice on p. 145.
Remove gasket from throttle body.
Remove screws and reed plate assembly from the

crankcase.
1. Screws 002503
149
FUEL SYSTEM
Disassembly Inspection
All reed plate assembly and reed valve assem- Inspect the leaf plate assemblies for damage or
blies must be cleaned prior to reassembly. DO contamination:
NOT use strong carburetor cleaner or the hot • Leaf plates must not be distorted.
soaking tank method for cleaning. • Leaf valve must not be cracked or chipped.
• Leaf plate stops must not be distorted or loose.
Remove the reed valve retainer screws and
remove the assembly. • Leaf plate assemblies must be clean.
Inspect the intake manifold. All gasket surfaces
must be cleaned, smooth, and free of nicks. Use a
machinist’s straight-edge and a feeler gauge to
check flatness in all directions. Surface must be
flat, ± 0.004 in. (0.10 mm).
002496
Use caution to prevent damaging reed valve

assemblies.
1. Straight-edge 002324
Assembly
Remove old adhesive from reed valve retaining
screws.
Install gasket on reed plate assembly. DO NOT

use sealer on the gasket.
002504
NOTICE DO NOT disassemble reed valve

assemblies. Damaged reed plates are not ser-
viceable and are replaced as an assembly.
002333
150
FUEL SYSTEM
Prime screw threads with Locquic Primer and let Tighten the center screws first and expand out-
dry. Apply Nut Lock to threads. Position reed valve ward. Tighten in stages to a final torque of 60 to
on reed plate and install screws. Tighten screws 120 in. lbs. (7 to 13.5 N·m).
to a torque of 25 to 35 in. lbs. (2.8 to 4.0 N·m).
002501
002326
Install vapor separator vent hose and main bear-
Installation ing vent hose. Secure with tie straps.
Place reed plate assembly on cylinder/crankcase.
Install air temperature sensor, crankshaft position
Apply Nut Lock to two reed plate screws. Install sensor, and throttle position sensor electrical con-
and tighten screws to a torque of 60 to 120 in. lbs. nectors.
(7 to 13.5 N·m).
Connect throttle linkage. 7
IMPORTANT: DO NOT lubricate throttle link-
ages.
002505
Place gasket on throttle body. Install throttle body

on reed plate and install new screws. 1. Throttle linkage 002500
IMPORTANT: If old screws must be re-used,

Refer to TPS Calibration on p. 114.
make sure all previous thread locking material is
removed and apply Nut Lock to threads.
151
FUEL SYSTEM
NOTES
NOTES
Bulletins
Instruction Sheets
Other
152
OILING SYSTEM
OILING SYSTEM
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
OIL SUPPLY DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
OIL RECIRCULATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
OILING SYSTEM CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
OIL SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
RECOMMENDED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
OIL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
OIL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
ELECTRICAL CIRCUIT (55 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
LOW OIL WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
NO OIL WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
CYLINDER AND CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
OIL RECIRCULATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
OIL CONTROL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
OIL INJECTION RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
BREAK-IN OILING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
OIL SUPPLY PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
OILING SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
OIL INJECTION PUMP VOLTAGE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
OIL INJECTION PUMP RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
OIL INJECTION PUMP FUNCTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
OIL INJECTION FITTINGS FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8
LOW OIL SENDING UNIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
OIL COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
OIL DISTRIBUTION HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
OIL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
OIL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
153
OILING SYSTEM
SERVICE CHART
SERVICE CHART
40 – 65 HP
30 to 42 in lbs.
(3.5 - 5 N·m) F
F
30 to 42 in lbs.
30 tp 42 in lbs. (3.5 to 5 N·m)
(3.5 - 5 N·m)
C Adhesive 847
E Red Ultra Lock
F Blue Nut Lock
008058
X See Service Manual instructions
154
OILING SYSTEM
75 – 90 HP
30 to 42 in lbs.
(3.5 to 5 N·m)
F
F 30 to 42 in lbs.
(3.5 to 5 N·m)
30 to 42 in lbs.
(3.5 to 5 N·m)
C Adhesive 847
E Red Ultra Lock
F Blue Nut Lock
008059
X See Service Manual instructions
155
OILING SYSTEM
OIL SUPPLY DIAGRAMS
OIL SUPPLY DIAGRAMS

40 – 65 HP
3 1
1 6
008060
1. Oil tank 4. Oil distribution manifold

2. Oil pick-up/filter 5. Crankcase oil inlet (port)
3. Oil injection pump 6. Cylinder oil inlet (starboard)
156
OILING SYSTEM
75 – 90 HP
5
3
5 1
5
2
4
8
1 6
008061
1. Oil tank 4. Oil distribution manifold

2. Oil pick-up/filter 5. Crankcase oil inlet (port)
3. Oil injection pump 6. Cylinder oil inlet (starboard)
157
OILING SYSTEM
OIL RECIRCULATION DIAGRAMS
OIL RECIRCULATION DIAGRAMS

40 – 65 HP
Starboard view Port view
002483a
75 – 90 HP
Starboard view Port view

002223
158
OILING SYSTEM
OILING SYSTEM CIRCUIT DIAGRAM
OILING SYSTEM CIRCUIT DIAGRAM
5 3 4
BA
10 11
8 7
16 9
BA
5 26 18 10
10 1
27 19 11
11 2
28 20 12
12 3
29 13
13 4
30 21
5 J1-A
31 22
23
14
14
15
15 6 19
32 7
33 24 16
16
17 8
34 25 17 9
20 8 1
14 2
21 15 9
22 3
16 10
6 543 21 23 17 11
4
5
J1-B
24 18 12 6
6 25
26 19 13 7
6 5 4 3 2 1
9
1
10
2
11
3
12
13
14
4
5
6
J2 8
15
7
16
8
2
3
008050
1. Stator
2. Stator output (55 V)
3. Alternator grounds (BLACK)
4. Oil Injector ground (BLACK)
5. Alternator output, WHITE / RED wires (55 V)
6. Capacitor (55 V)
7. Main harness ground (BLACK)
8. 55 V to injection pump (WHITE / RED)
9. EMM injector control (BLUE)
10. Oil injection pump
11. Low oil switch
12. Low oil switch to EMM (TAN/BLACK)
13. Low oil signal to SystemCheck gauge (TAN/BLACK)
14. No oil signal to SystemCheck gauge (TAN/YELLOW)
159
OILING SYSTEM
OIL SYSTEM REQUIREMENTS
OIL SYSTEM COMPONENTS

REQUIREMENTS The oiling system includes the following compo-
nents:
Recommended Lubricants • Oil tank
Evinrude/Johnson XD100, XD50, or XD30 out- • Oil injection pump and manifold assembly
board oils are recommended for use in Evinrude • Oil level switch
E-TEC outboards. If these oils are not available, • Electrical circuit
you must use a TC-W3 certified oil. • LOW OIL and NO OIL warning systems
• Cylinder and crankcase
Evinrude/Johnson XD100 outboard oil is highly
• Oil recirculation system.
recommended for all conditions and applications.
Engine Lubricant Below 32°F (0°C) Oil Tank Assembly

If the outboard will be operated in temperatures The oil tank is mounted on the powerhead under
below freezing (32°F, 0°C), use Evinrude/Johnson the engine cover. Oil level must be monitored.
XD100.
3-CYLINDER MODELS
IMPORTANT: For new outboards, test low oil Oil Tank Components:
warning before filling oil tank. • Tank, 2.4 quart. (2.3 liter) capacity
• Oil pickup and filter assembly
Turn key switch to ON. The engine monitor warn-
• Oil injection pump and manifold assembly
ing display should show “LOW OIL.”
• LOW OIL switch
Add enough oil to raise level to at least one-quar- • Oil distribution hoses
ter capacity.
The “LOW OIL” warning should not display.
NOTICE Failure to follow these recommen-

dations could void the outboard warranty if a
lubrication-related failure occurs.
008062
160
OILING SYSTEM
COMPONENTS
2-CYLINDER MODELS The oil manifold distributes the oil supplied by the
Oil Tank Components: pump.
• Tank, 2 quart. (1.87 liter) capacity
• Oil pickup and filter assembly 2
• Oil injection pump and manifold assembly
• LOW OIL switch
• Oil distribution hoses
008063
3
Oil Injection Pump
1. Oil injector pump 008064
The oil injection pump is an electric (55 V) actua- 2. Oil distribution manifold
tor style pump. It draws oil from the oil tank and 3. Pickup tube and filter
supplies pressurized oil to the oil manifold. The
EMM supplies 55 V and controls activation of the Electrical Circuit (55 V)
pump. The oil injector is powered by the 55 V electrical 8
circuit. The EMM controls pump operation by rap-
idly connecting and disconnecting the pump’s
internal coil to ground.
The EMM monitors the oil injection pump electri-

cal circuit. If circuit voltage is beyond the specified
range, or the circuit is open, the EMM:
Activates S.A.F.E.
Stores a service code 34
Engine Monitor NO OIL display: ON
161
OILING SYSTEM
COMPONENTS
LOW OIL Warning Cylinder and Crankcase

A switch in the oil tank assembly monitors the oil The oil distribution manifold provides crankcase
level in the oil tank. lubrication through oil distribution hoses and
pressed-in fittings on the crankcase and cylinder
If the oil level falls below one-quarter capacity, the block.
EMM signals:
Engine Monitor LOW OIL display: ON 3-CYLINDER MODELS
Approximate oil reserve at Low Oil activation:

• 0.45 qt. (0.43 l).
NO OIL Warning 1
When the oil level falls below one-quarter, the
EMM begins counting oil pump pulse cycles.
When it reaches:
• 40 – 65 HP: 4800 pulses
• 75 – 90 HP: 6000 pulses
the EMM: 1. Crankcase oil fittings 006758
Activates S.A.F.E.
1
Engine Monitor NO OIL display: ON
To recover from S.A.F.E. mode:

• Oil level must be above one-quarter
• The warning resets after three oil pump pulse
cycles when the outboard has been stopped
and restarted.
If outboard has been run for more than 3 hours 1. Cylinder block oil fittings 006759
with NO OIL faults (codes 34 & 117), the EMM
Activates SHUTDOWN
EMM LED 4: FLASHING
Engine Monitor NO OIL display: FLASHING
162
OILING SYSTEM
COMPONENTS
2-CYLINDER MODELS Crankcase / Main Bearing Recirculation

The movement of oil through the main bearings is
controlled by internal passages, external fittings
and hoses, and check valves.
Lower to upper main bearing oil flow:

1 • Lower main bearing cavity to internal crankcase
passage to external fitting, external hoses with
in-line check valve to external fitting at upper
main bearing, and into upper main bearing
through internal crankcase passage.
• Internal crankcase passage to external fitting in
crankcase cover at upper main bearing, hose
1. Crankcase oil fittings 006614
routed to reed plate fitting. This circuit vents the
upper main bearing cavity to promote oil flow.
1 1
1. Cylinder block oil fittings 006615
Oil Recirculation System

1. Upper main bearing vent 002399 8
External hoses and fittings, internal cylin- Refer to the OIL RECIRCULATION DIAGRAMS
der/crankcase passages, and intake manifold pas- on p. 158.
sages are used to recirculate any accumulation of
oil from various locations in the powerhead. The
movement of oil is controlled by check valves.
Cylinder Recirculation
Internal powerhead oil drain passages connect
the intake port areas of the cylinders to circulate
residual oil in the block.
External fittings and in-line check valves on each

side of the cylinder block control the movement of
oil from the lower cylinder port to the upper cylin-
der port.
163
OILING SYSTEM
OIL CONTROL SETTINGS
OIL CONTROL SETTINGS CAUTION

Oil Injection Rate Running an Evinrude E-TEC outboard on
EMM programming controls the rate of oil injection other grades of oil while set to the XD100
based on engine RPM. This rate can be adjusted oil ratio will result in increased engine
for the type of oil being used, and also for power- wear and shortened outboard life.
head break-in. Use Evinrude Diagnostics software
to access these features. Powerhead oil programming labels are provided
to identify EMM oil programming. Install the cor-
The Set Oil Type option controls the injection rate
rect label to alert user to specific oil requirements.
for the oil being used and typical operating condi-
tions.
1 2
The TC-W3 oil type setting is the standard setting
for all outboards. Set TC-W3 for:
• Operation with all TC-W3 outboard oils includ-
ing XD30, XD50, or XD100.
• Applications requiring maximum lubrication.
• Extreme applications (commercial or harsh con-
ditions, racing or other high performance opera-
tion).
• Use this setting with XD100 outboard oil in
extreme applications 1. Evinrude/Johnson XD30 outboard lubricant (TC-W3) 002507
YELLOW label
The XD100 setting provides an option to run the 2. Evinrude/Johnson XD100 outboard lubricant (Premium)
BLUE label (Installed)
outboard at a reduced oil injection rate. This set-
ting REQUIRES the use of Evinrude XD100 out-
An XD100 Outboard Oil Decal, P/N 352369, is
board lubricant and is not recommended for all
available to label boats equipped with outboards
applications.
that have been programmed for the reduced oil
IMPORTANT: The XD100 setting is not avail- injection ratio.
able on all models.
Use the XD100 setting for:

• Conventional use (runabouts, cruisers)
• Moderate applications
XD100 Outboard Oil Decal 004522
1. Oil control setting 008084
164
OILING SYSTEM
OIL CONTROL SETTINGS
Install decals in a highly visible location, such as Oil Supply Priming

one of the following:
• Dashboard/deck of boat, next to key switch WARNING
• Deck of boat, next to the remote oil fill
• Deck of boat, next to oil tank assembly Always use caution while working around
• Oil tank cover machinery with moving parts. The follow-
• Cover of oil tank compartment ing set-up procedures require running
• Attach to oil tank or oil fill cap. tests that are performed with the out-
board’s motor cover removed.
IMPORTANT: Make sure the engine label and
boat decals match EMM programming. Start the outboard. Use the oil priming function in
the software to make sure the system is com-
Break-In Oiling pletely primed.
IMPORTANT: DO NOT add oil in the fuel tank Use the Prime Oil System button of the Dynamic
on Evinrude E-TEC models. Test screen to prime the oil pump.
The EMM automatically supplies extra oil to the
engine as follows:
• 40 – 90 HP: First two hours above 2000 RPM
Follow these steps for outboard set-up:
• Use Evinrude Diagnostics software to make 1
sure the break-in program has been started on
a new outboard.
• Use the diagnostics software to start break-in
oiling after a powerhead rebuild.
8
1 Dynamic Test Screen
1. Prime Oil System button
008083
1. Break-in oil setting 008084
NOTICE The operator must monitor the oil

tank level to confirm oil consumption. This
may require several hours of operation above
idle.
165
OILING SYSTEM
OILING SYSTEM TESTS
Observe oil flow through all oil distribution hoses.

Air must be purged during the priming procedure.
OILING SYSTEM TESTS
IMPORTANT: Always perform visual inspections
to identify oiling system leaks. Make sure the oil
tank is filled and oil supply is not contaminated.
1 Oil Injection Pump Voltage Tests

IMPORTANT: Do NOT perform static tests using
Diagnostic Power Supply Tool, P/N 587005, with
internal 9 volt batteries only. This will produce
1. Oil distribution hoses 007997 The EMM controls the pump by providing ground
through pin 23 (blue wire) of the J1-B connector
Small bubbles are acceptable. Large bubbles and pin B (blue wire) of the oil pump connector.
must be eliminated through continued priming. Acceptable Oil Injection Pump
Test Readings
1 Key switch ON approximately 12 VDC
Control signal approximately 5 Hz
Engine running approximately 55 VDC
Use a digital multimeter calibrated to a scale that

3 2
reads 12 V (DC) to measure voltage between the
1. Oil distribution hose 004398
2. Small bubbles oil pump electrical connector and engine ground.
3. Large bubbles
Connect negative meter lead to ground.
Repair any fuel or oil leaks.
Use an appropriate test probe to connect positive
The oiling system on these models can also be meter lead to pin B (blue wire) of oil injection
primed using the Self-Winterizing feature if diag- pump electrical connector.
nostics software is not available. Refer to STOR-
AGE on p. 45.
1
1. Oil injection pump electrical connector 008065
Turn the key switch to the ON position. Observe

voltage at pin B.
• Voltage at pin B should be approximately 12 V.
166
OILING SYSTEM
OILING SYSTEM TESTS
Use the Oil Injector test of Evinrude Diagnostic Set digital multimeter to a scale that reads 55 V
software Static Test screen to activate the oil (DC).
pump.
Start the engine. Observe voltage at pin A.
• Voltage at pin A should be approximately 55 V.
• If voltage at pin A is within range, refer to Oil
Injection Pump Resistance Test on p. 167.
• No voltage reading at pin A, refer to System
Voltage Test on p. 80.
1
Oil Injection Pump Resistance
Test
Disconnect the electrical connector from the oil

injection pump.
Static Tests Screen 008082A
1. Oil injector test button
Use a digital multimeter to measure the resistance
between the pins of the oil injection pump connec-
IMPORTANT: This test is operating the pump
tor. Calibrate the meter to the LOW OHMS scale.
with 12 V battery power on the system voltage
(55 V) circuit. The oil injection pump will not pump Oil Injection Pump Circuit Resistance
oil when operating on 12 V. 22 
Observe voltage at pin B.
• Voltage at pin B should drop as the oil pump
cycles.
Check the control signal while the Oil Injector test 8

is running. Set the digital multimeter to the Hertz 1
(Hz) scale.
• Meter should read approximately 5 Hz.
Results:
• If voltage and control signal readings at pin B
are within range, the EMM and wiring are not at
fault. 1. Oil injection pump connector 008420
• If voltage at pin B is not within range, check volt-
age at pin A (white/red wire) of oil pump electri- Results:
cal connector. • An infinite reading () indicates an open circuit
of the injection pump winding. Replace faulty
Connect positive meter lead to pin A (white/red pump.
wire) of oil injection pump electrical connector.
Observe voltage at pin A.
• Voltage at pin A should be approximately 12 V.
167
OILING SYSTEM
OILING SYSTEM TESTS
Oil Injection Pump Function Test Oil Injection Fittings Flow Test
Remove oil distribution hose from fitting at oil dis- Make sure the oil injection fittings of the cylinder
tribution manifold. Do not lose the brass hose sup- and crankcase assembly allow fluid to move.
port.
Remove oil distribution hose from oil distribution
manifold.
Use a Syringe, P/N 346936, filled with isopropyl

alcohol to force fluid through hose and fitting.
1
1
1. Retainer mechanism 008067
Temporarily install a length of oil hose.
1. Syringe 008069
LOW OIL Sending Unit Test

Remove oil from the oil tank.
Turn the key switch ON. The dash mounted

Engine Monitor system should show a LOW OIL
warning.
Once the warning has been confirmed, refill the oil

008068 tank and start the outboard. The LOW OIL warn-
ing should stop after the oil pump cycles 3 times.
Start the outboard and observe oil flow:
• Oil flows from hose, compare to oil flow at other
distribution fittings
• If one or more fittings fail to flow oil, replace the
oil injection pump assembly.
Reinstall hose into manifold.
IMPORTANT: Make sure hose support is in

hose and hose is fully inserted into manifold.
Refer to Oil Distribution Hoses on p. 169.
168
OILING SYSTEM
OIL COMPONENT SERVICING
OIL COMPONENT Installation

Cut Replacement Oil Hose, P/N 778708, to the
SERVICING correct length. Insert hose support in manifold end
of hose.
WARNING IMPORTANT: DO NOT insert distribution hoses
To prevent accidental starting while ser- into manifold without a hose support.
vicing, twist and remove spark plug leads.
Be sure the hose is fully inserted into manifold.
Insertion depth is 5/8 in. (16 mm). Visually inspect
Oil Distribution Hoses for hose supports.
The oil distribution hoses to each cylinder MUST
be the same length. DO NOT alter the length of
Oil Tank Assembly
any hoses. Removal
Oil Distribution Hose Length: Disconnect the battery cables at the battery.
• 20 in. (508 mm) Remove engine covers and air silencer.
Removal Remove oil tank retaining screws.
Release the hose by depressing the outer ring of
the hose retaining mechanism. 3-CYLINDER MODELS
1
8
1
1. Retainer mechanism 008067 1. Screw 008071
Once hose is removed from the manifold, make

sure hose support is in the end of the hose.
1. Screws 008072
1
1. Hose support 008070
169
OILING SYSTEM
2-CYLINDER MODELS
1. Low oil switch connector 008076

1. Screw 008073
IMPORTANT: Note oil distribution hose rout-
ings before proceeding with disassembly.
Remove oil distribution hoses from the manifold.
Installation
Position oil tank assembly on powerhead. Clean
1 mounting screws and apply Nut Lock to threads.
Install screws and tighten to a torque of 30 to 42
in. lbs. (3.5 to 5 N·m).
Install protective sleeves and route oil distribution
hoses from the oil distribution manifold to the
1. Screws 008074
crankcase oil delivery fittings. Refer to OIL SUP-
PLY DIAGRAMS on p. 156. Secure oil hoses to
ALL MODELS
crankcase fittings with tie straps.
Disconnect the electrical connector to the oil injec-
tion pump and manifold assembly.
1. Tie strap 006573
1. Oil pump connector 008075 Run outboard and check for leaks. Use Evinrude
Diagnostics software to activate “Oil Prime.”
Disconnect the electrical connector to the low oil Check oil flow through oil distribution hoses.
switch. Check oil system operation and routing of oil sys-
tem hoses.
Repair any oil leaks and kinked or misrouted

hoses. Install air silencer and engine covers.
170
OILING SYSTEM
Oil Injection Pump Installation

Apply a drop of outboard lubricant to a new oil
Removal pump o-ring. Install o-ring on oil pump flange.
Remove oil distribution hoses from oil manifold.
Refer to Oil Distribution Hoses on p. 169.
Remove oil from oil tank.

Remove oil tank. Refer to Oil Tank Assembly on
p. 169. Remove retaining screw(s) from oil pump
assembly. Twist and pull up on oil pump to remove
from tank. DO NOT pull up on oil manifold. 1
1. O-ring 008064
1
2-CYLINDER MODELS
Install oil pump and manifold so that bend of oil
pick up assembly is positioned to follow the con-
tour of the oil tank as shown.
2-Cylinder Models 008180

1. Screw
1
8

1. Screws
008182
171
OILING SYSTEM
3-CYLINDER MODELS
Install oil pump and manifold straight into oil tank.
IMPORTANT: Be sure oil pick up assembly is

positioned in front of oil tank baffle to prevent
interference with the LOW OIL switch.
1. Oil pick up assembly 008183

2. Oil tank baffle
ALL MODELS
Install oil pump retainer screw(s). Tighten
securely.
IMPORTANT: Turn self-tapping screws counter

clock-wise to start the threads and clockwise to
tighten. Failure to follow this procedure can dam-
age the threads of the oil tank.
172
COOLING SYSTEM
COOLING SYSTEM
TABLE OF CONTENTS
HOSE ROUTING AND WATER FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
WATER PUMP AND INTAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
EXHAUST HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
WATER SUPPLY TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
ADAPTER/INNER EXHAUST HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
BLOCK VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
WATER PRESSURE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
CYLINDER BLOCK / CYLINDER HEAD COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
EMM AND VAPOR SEPARATOR COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
ENGINE TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
SOFTWARE METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
PYROMETER METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
TEMPERATURE SENDER SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
THERMOSTAT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
PRESSURE RELIEF VALVE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
173
COOLING SYSTEM
HOSE ROUTING AND WATER FLOW DIAGRAMS

2-CYLINDER MODELS
8
6 5
9
10
3 60, 65 HP
1. Water intake screens
2. Water pump
3. Exhaust housing
4. Cylinder block
5. Pressure relief valve
6. Thermostat
7. Water supply to EMM
8. Water supply, EMM to vapor
2 separator
9. Overboard indicator, outgoing
water from vapor separator
10. Exhaust Water Valve
1
Outgoing water (warm/hot)
Incoming water (cool) 004971
174
COOLING SYSTEM
3-CYLINDER MODELS
8
Incoming water (cool)
10 4 1. Water intake screens

2. Water pump
3. Water tube
4. Adapter housing
5. Cylinder block
9
6. Pressure relief valve
7. Thermostat
9. Water supply, EMM to vapor separator
10. Overboard indicator, outgoing water
from vapor separator.
001818
175
COOLING SYSTEM
COMPONENTS
COMPONENTS IMPORTANT: The water pump housing on 2-

cylinder models includes a small hole to the rear
Water Pump and Intakes of the water outlet. This hole provides cooling
water for the tip of the exhaust passage. Be sure
External water intakes mounted in the gearcase
to use the correct parts when replacing the water
housing collect water and must supply the inlet
pump.
side of the water pump with an unrestricted and
unaerated water supply. Water is drawn into the
water pump through a hole in the lower plate of
the water pump assembly. All cooling water to the
powerhead is provided by the water pump.
• A nylon wedge (impeller key) is used to engage
the impeller bushing and driveshaft. 1
• The nylon impeller housing with liner must seal
against a separate water pump plate.
• The bottom plate MUST seal to gearcase.
• The pump operates as a positive displacement
pump at LOW speeds (below 1500 RPM) and
as a centrifugal pump at HIGHER speeds. 1. Hole 004970
Refer to WATER PUMP SERVICE on p. 298, or Exhaust Housing

WATER PUMP SERVICE on p. 320 for servicing.
2-CYLINDER MODELS
The water pump outlet connects with passages
located in the outboard’s midsection. A grommet
seals the water pump housing to the exhaust
2 housing.
3
Water supplied to the exhaust housing provides all
cooling water to the cylinder block.
Water Supply Tube

3-CYLINDER MODELS
The water pump outlet connects with the water
supply tube located in the outboard’s midsection.
Grommets seal the water tube to the water pump
4 housing and the adaptor housing. The water tube
fastens to the base of the adapter housing with a
retainer plate and screws.
Water supplied to the water tube provides all cool-

ing water to the adapter housing and cylinder
1 block.
1. Water inlet 001216

2. Water outlet 001217
3. Seal
4. Plate
176
COOLING SYSTEM
COMPONENTS
Adapter/Inner Exhaust Housing Pressure Relief Valve

3-CYLINDER MODELS A pressure relief valve is used to control water
• Adapts the cylinder/crankcase assembly (pow- flow and operating temperature at higher speeds
erhead) to the exhaust housing and the water (above approximately 1800 RPM). The pressure
tube. relief valve opens as water pressure increases.
• Provides water passages which route incoming Spring tension sets the opening pressure.
and outgoing cooling water.
Overheating: A restricted or faulty valve typically
• Provides exhaust passages which connect to
results in HIGH SPEED overheating.
the gearcase.
Overcooling: Debris may prevent the valve from
closing completely.
5 Pressure relief valve components 002437
Thermostat
The thermostat controls water flow and operating
temperature at lower speeds (below 1800 RPM).
2
Overheating: A restricted or faulty thermostat typ-
ically results in LOW SPEED overheating. 9
Overcooling: Debris may prevent the thermostat
from closing completely.
1. Megaphone 002436
2. Exhaust housing 4 3 2 1
3. Water tube
4. Adapter housing
5. Inner exhaust housing
1. Cover and O-ring 002439

2. Spring and thermostat
3. Cylinder head
4. Cylinder head seal
177
COOLING SYSTEM
COMPONENTS
Block Venting Water Pressure Connection

A fitting and hose connected to the top of the A fitting and hose for an accessory water pressure
exhaust cover allows the constant movement of gauge can be connected at the top of the cylinder
water and/or air from the block. Circulated water block next to the pressure valve housing.
flows through the EMM and vapor separator
before exiting through the overboard indicator.
1. Fitting 002461

1. Fitting

1. Fitting
178
COOLING SYSTEM
OPERATION
OPERATION At higher speeds, water pressure opens the

pressure relief valve at approximately 1800 RPM.
All models use a two-stage cooling system Water flows through the valve to the cylinder head
design. The cooling system is dependent on water and bypasses the thermostat. All water flows
pump pressure and controlled by thermostat and through the cylinder head to the outlet passage of
pressure valve operation. the block and then exits through the exhaust
housing.
NOTICE Restricted or inadequate water flow
through the outboard reduces cooling system EMM and Vapor Separator
performance and may lead to severe power- Cooling
head damage.
Cooling water is routed from the top of the cylinder
block to the inlet fitting of the EMM water cavity.
Cylinder Block / Cylinder Head Cooling of the EMM helps to stabilize the temper-
Cooling atures of internal components.
The flow of water through the cylinder block and
cylinder head is controlled by a thermostat and a IMPORTANT: Improper EMM cooling will acti-
pressure relief valve. The pressure valve is vate service codes 25 and 29 and the Engine
located in the top of the block next to the exhaust Monitor warning system. Refer to the EMM Ser-
cover. vice Code Chart at the back of this manual for
specific service code information.
1 2
Cooling water from the EMM is routed to the water
inlet fitting of the vapor separator water cavity.
Cooling the vapor separator fuel chamber mini-
mizes fuel vaporization.
Cooling water from the vapor separator is routed
to the overboard indicator.
9
1. Thermostat 002441
2. Pressure valve assembly
The thermostat and pressure valve control the

flow of water entering the vertical water passages
of the cylinder head. 1
At low speed, the pressure valve is against the
seat and the thermostat is closed. Warm water
from the cylinder block gradually migrates to the
thermostat pocket at the top of the cylinder head.
The thermostat opens when the water tempera- 1. Overboard indicator 004969
ture reaches approximately 143°F (62°C).
When the thermostat opens, water flows down

through the cylinder head to a passage in the cyl-
inder block. Water flows through the block to the
exhaust housing and then out of the outboard.
179
COOLING SYSTEM
ENGINE TEMPERATURE CHECK
ENGINE TEMPERATURE Software Method

Use Evinrude Diagnostics software to read tem-
CHECK perature displays.
IMPORTANT: The engine temperatures listed

below are based on 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
minutes. Remember, running outboards at high
speeds in test tanks may disrupt water flow to
gearcase water intakes. Make sure the outboard
has adequate water flow.
CAUTION
When servicing the propeller, always shift Monitor Screen 008080
the outboard to NEUTRAL, turn the key
switch OFF, and twist and remove all Typical temperature sensor readings at IDLE
spark plug leads so the engine cannot be speed should be 155°F ± 5°F (68.3°C ± 3°C).
started accidentally.
Typical temperature sensor readings at WOT
speed should be 160°F ± 40°F (71°C ± 22°C).
Reduce speed to IDLE for five minutes. Check
IDLE operating temperature. Operating temperature must not exceed 212°F
(100°C).
Increase speed to 5000 RPM and check tempera-
ture. Pyrometer Method
If engine temperatures are not within range, trou- Use a Temperature Gun, P/N 772018, or a digital
bleshoot cooling system. pyrometer to measure the outboard’s operating
temperatures.
If engine temperature tests within range, but the
engine monitor display indicates a “WATER Measure temperature of the thermostat housing at
TEMP” warning, refer to WATER TEMP/ HOT Cir- the top of cylinder head.
cuit Test on p. 108.
Typical pyrometer readings at IDLE speed should
be 145°F ± 10°F (63°C ± 6°C).
Typical pyrometer readings at WOT speed should

be 150°F ± 40°F (66°C ± 22°C).
180
COOLING SYSTEM
ENGINE TEMPERATURE CHECK
IMPORTANT: If you get low or inaccurate read- Check thermostat for cracks, heat damage, or
ings with a digital pyrometer, coat the probe loca- signs of corrosion. Check for proper operation.
tion with Thermal Joint Compound, P/N 322170. Thermostat opens at 143°F (62°C).
Refer to THERMOSTAT SERVICING on p. 182.
1 Pressure Relief Valve Inspection

The pressure relief valve should be closed at
IDLE speed. Water should not flow past the
plunger and seal.
Start the outboard and check IDLE operating tem-

perature.
If IDLE temperature is too low, check pressure

relief valve plunger and seal for damage or debris
Thermostat housing 008345
that could prevent the valve from closing com-
pletely.
IMPORTANT: Digital pyrometer or temperature
gun measurements may be slightly lower than If IDLE temperature is still below operating range,
software temperature readings. replace pressure relief valve assembly and
plunger seal.
Idle Operating Temperature
To test pressure relief valve operation, monitor
Troubleshooting (Below Range) temperature at the thermostat housing with Tem-
If engine IDLE temperature is below operating perature Gun, P/N 772018, or digital pyrometer.
range, 155°F ± 5°F (68.3°C ± 3°C), check thermo-
stat and pressure relief valve operation. Confirm normal IDLE operating temperature.
Thermostat Inspection Slowly increase engine speed from IDLE, up

Check position of thermostat seal and how ther- through 2500 RPM.
mostat seals against cylinder head. Seal must be Engine temperature should decrease from normal
properly fitted to flange of thermostat. IDLE temperatures as pressure relief valve opens. 9
Valve should open between 1800-2200 RPM.
If temperature decreases at a lower RPM, replace

pressure relief valve assembly.
1 Refer to PRESSURE RELIEF VALVE SERVIC-

ING on p. 183.
1. Thermostat seal 006401
181
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.
008346 008347
Clean sensor threads, sensor, and sensor cavity. Remove spring, thermostat, and gasket.
Installation
Fill bottom of sensor cavity with 0.7 cc of Thermal
Joint Compound, P/N 322170. Sensor cavity
should be filled to 1 inch (25 mm) below the top
edge of the cavity.
Install sensor. 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
002444
(25 mm)
Remove the cylinder head if cylinder head ther-
mostat seal requires replacement. Place new seal
in the cylinder head with side marked “TO CYL
3 2
1. Temperature sensor 007049

2. Sensor cavity
3. Thermal joint compound
Wait 10 minutes for trapped air to bleed from cav-

ity. Thermal compound may seep past threads.
Retighten sensor.
182
COOLING SYSTEM
PRESSURE RELIEF VALVE SERVICING
HEAD” facing thermostat. Refer to Cylinder Head

PRESSURE RELIEF
VALVE SERVICING
The pressure relief valve assembly should be ser-
viced at the same time as the thermostat.
1 Disassembly
Remove screws and cover from pressure valve
assembly.
1. Cylinder head seal 002445
Inspection
Inspect all parts for cracks, heat damage, or signs
of corrosion. Replace damaged parts. Clean
debris from housing and parts.
002443
Remove the pressure relief valve assembly.
000756
9
Assembly
Assembly is the reverse of disassembly. Pay
close attention when performing the following
additional tasks.
Coat threads of thermostat cover with Gasket

002459
Sealing Compound and install new O-ring. Install
and tighten cover to a torque of 120 to 144 in. lbs.
(13.5 to 16 N·m).
183
COOLING SYSTEM
PRESSURE RELIEF VALVE SERVICING
Inspection
Inspect all parts for cracks, heat damage, or signs
of corrosion. Replace damaged parts. Clean
debris from housing and parts.
Pressure Relief Valve Assembly Components 002442
Assembly
Assembly is the reverse of disassembly. Pay
close attention when performing the following
additional tasks.
Install a new plunger seal squarely over ridge in

housing.
Apply a light coat of Triple-Guard grease to a new

cover o-ring and place in groove in housing.
1. Plunger seal 002458

2. Cover o-ring
Install valve assembly into housing.
Tighten cover screws to a torque of 60 to 84 in.

lbs. (7 to 9.5 N·m).
184
POWERHEAD
POWERHEAD
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
COMPRESSION TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
POWERHEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
POWERHEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
SYSTEMS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
THROTTLE LINKAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
SHIFT LINKAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
CYLINDER BLOCK CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
POWERHEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
POWERHEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
CRANKSHAFT AND CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
SHIFT LINKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
THROTTLE LINKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
FINAL POWERHEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
UPPER MOUNT SERVICING (3-CYLINDER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
POWERHEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
POWERHEAD MOUNTING – 2-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
POWERHEAD MOUNTING – 3-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
FINAL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 10
POWERHEAD VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
2-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
185
POWERHEAD
SERVICE CHART
SERVICE CHART
2-CYLINDER MODELS
F
60-84 In. lbs.
(7-9.5 N·m)
J B
A 120-144 In. lbs.
(13.5-16 N·m)
H
168-192 In. lbs.
(19-21.5 N·m)
15-30 Ft. lbs.

(20-41 N·m)
IMPORTANT See Spark Plug
Indexing Procedure
M Q
Apply to water passages Apply to crankcase
mating flange
H
26-30 Ft. lbs.
(35-41 N·m)
F
60-84 In. lbs.
(7-9.5 N·m)
B
F
60-84 In. lbs.
(7-9.5 N·m)
B
18-20 ft. lbs
(24.5-27 N·m)
A Triple-Guard Grease F Blue Nut Lock M RTV Sealant

B Gasket Sealing Compound G Needle Bearing Grease P Permatex No. 2
D Moly Lube H Outboard Lubricant Q Gel Seal II
002283 E Red Ultra Lock J Thermal Grease Y Extreme Pressure Grease
186
POWERHEAD
SERVICE CHART
2-CYLINDER MODELS
H
G
H
30-32 Ft. lbs.
(41-43 N·m)
Must have
alignment tool H
H
B
A
H
D 10
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
H Outboard Lubricant
P Permatex No. 2
Q Gel Seal II
002284 Y Extreme Pressure Grease
187
POWERHEAD
SERVICE CHART
3-CYLINDER MODELS
F
60-84 In. lbs.
(7-9.5 N·m)
J B
A 120-144 In. lbs.
(13.5-16 N·m)
H
168-192 In. lbs.
(19-21.5 N·m)
15-30 Ft. lbs.

(20-41 N·m)
IMPORTANT See Spark Plug
Indexing Procedure
Q
M Apply to crankcase
mating flange
Apply to water passages
F
60-84 In. lbs.
(7-9.5 N·m)
B
H 60-84 In. lbs.
26-30 Ft. lbs. (7-9.5 N·m)
(35-41 N·m)
B Gasket Sealing Compound F
60-84 In. lbs.
D Moly Lube (7-9.5 N·m)
E Red Ultra Lock
F Blue Nut Lock
J Thermal Grease
B
M RTV Sealant
P Permatex No. 2
Q Gel Seal II
Y Extreme Pressure Grease 002281
188
POWERHEAD
SERVICE CHART
3-CYLINDER MODELS
H
G
H
30-32 Ft. lbs.
(41-43 N·m)
Must have
alignment tool
H D Moly Lube
B E Red Ultra Lock
F Blue Nut Lock
A
P Permatex No. 2
H
Q Gel Seal II
D
Y Extreme Pressure Grease
10
D
15-20 Ft. lbs.
(20-27 N·m) D
110-130 Ft. lbs.

(149-176 N·m)
002282
189
POWERHEAD
COMPRESSION TESTING
COMPRESSION TESTING POWERHEAD REMOVAL

Start and run outboard until it achieves operating 2-Cylinder Models
temperature, then shut OFF.
WARNING
Disconnect crankshaft position sensor (CPS) con-
nector. Remove all spark plugs. Protect against hazardous fuel spray.
Advance throttle linkage to WOT. carefully relieve fuel system pressure.
Install compression tester’s hose attachment into Refer to Relieving Fuel System Pressure
spark plug hole (14 mm threads). on p. 142.
While cranking outboard with starter, note maxi-
mum pressure reading on gauge. Repeat proce-
dure for each cylinder.
Remove lower motor covers. Refer to Lower
If engine shows a variation greater than 15 psi Cover Removal on p. 50.
(100 kPa) between cylinders, check for:
• damaged cylinder head Disconnect power trim connectors and exhaust
• damaged pistons water valve electrical connector (60, 65).
• broken or stuck piston rings
• scored cylinder walls
Return throttle to idle position and reconnect CPS
connector. Replace spark plugs. Refer to Spark
Plug Indexing on p. 42. 1
1. Connectors 008429
Disconnect cooling water hoses from exhaust

housing.
1. Overboard indicator hose 004298

2. Drain hose
190
POWERHEAD
POWERHEAD REMOVAL
Remove pin and washer from shift rod lever to ALL MODELS
release the lower shift rod. Install Lifting Fixture, P/N 396748, on flywheel and
seat the three screws completely.
NOTICE Be sure to use only the 1 1/8 in.

(short) screws, P/N 398067, included with the
tool to avoid damage to electronic compo-
1 nents under the flywheel.
1
1. Shift rod screw 002171 2
ROPE START MODELS
Remove throttle cable and tiller shift rod.
1 1. Lifting fixture 002098

2. 1 1/8 in. screws
2
Fasten appropriate chain hook to eye of tool and
3 support weight of powerhead with hoist.
4
Loosen the screws holding the exhaust water
valve to the exhaust housing.
Move water valve aside and remove the eight

1. Cable anchor 006526m exhaust housing to powerhead screws.
2. Anchor screw
3. Cable retainer
4. Shift rod retainer
Remove the recoil starter housing and starter

ratchet. Refer to RECOIL STARTER REMOVAL 10
on p. 363.
1
1 1
1. Powerhead screws 004292
Use a suitable tool to carefully separate the pow-

1
erhead from exhaust housing.
IMPORTANT: Do not damage the powerhead or

1. Starter housing screws (3) 002515 exhaust housing mating surfaces.
191
POWERHEAD
POWERHEAD REMOVAL
3-Cylinder Models Remove six retaining screws and exhaust relief

muffler.
WARNING
Refer to Relieving Fuel System Pressure
on p. 142.
Remove lower motor covers. Refer to Lower

Cover Removal on p. 50. 002159
Disconnect power trim connectors. Install Lifting Fixture, P/N 396748, on flywheel and
seat the three screws completely.
NOTICE Be sure to use only the 1 1/8 in.

(short) screws, P/N 398067, included with the
tool to avoid damage to electronic compo-
nents under the flywheel.
1
002152 2
Remove pin and washer from shift rod lever to
release the lower shift rod.
1. Lifting fixture 002098

2. 1 1/8 in. screws
1
Fasten appropriate chain hook to eye of tool and
support weight of powerhead with hoist.
1. Shift rod pin 002013
192
POWERHEAD
POWERHEAD DISASSEMBLY
Remove the small powerhead screw at rear.

POWERHEAD
DISASSEMBLY
Systems Removal
1
To simplify reassembly and wiring installation, lay
out the various screws and clamps in the order of
their proper location.
Remove the electric starter. Refer to Starter

Removal on p. 115.
Remove the oil tank. Refer to Oil Tank Assembly

1. Rear small powerhead screw 002160
on p. 169.
Remove remaining four small powerhead screws, Remove fuel pump assemblies, fuel manifolds,
six large powerhead screws, and the upper mount and filter. Refer to FUEL COMPONENT SERVIC-
screws. ING on p. 142.
3 Remove EMM, then electrical harness assembly.

Label connectors for reassembly locations. Refer
1 to EMM SERVICING on p. 70.
Remove flywheel and stator. Refer to FLYWHEEL

1 AND STATOR SERVICING on p. 110.
Remove ignition coils and fuel injectors. Refer to

IGNITION COIL SERVICING on p. 112 and Fuel
2 Injector Service on p. 146.
1. Small powerhead screws 002153 IMPORTANT: Mark injectors for cylinder loca-
2. Large powerhead screws
3. Upper mount screws tion before removal. All injectors must be installed
in their original location. Improper injector installa-
Use a suitable tool to carefully separate the pow- tion can result in powerhead failure.
erhead from exhaust housing.
Remove all oil distribution and recirculation hoses.
10
Remove throttle linkage. Refer to Throttle Link-
age Removal on p. 194.
Remove shift linkage. Refer to Shift Linkage

Removal on p. 194.
Remove the throttle body and reed plate assem-

blies. Refer to Intake Manifold Service on p. 149.
Remove pressure valve assembly. Refer to

002161 PRESSURE RELIEF VALVE SERVICING on
p. 183.
IMPORTANT: Do not damage the powerhead or
exhaust housing mating surfaces.
193
POWERHEAD
Throttle Linkage Removal Shift Linkage Removal

Remove throttle cam and throttle lever. Remove shoulder screw from shift arm and retain-
ing screw from shift rod lever.
Remove the cotter pin and washer holding the

1 2 shift shaft (2-cylinder models).

1. Throttle lever screw
2. Throttle return lever
1. Shift lever screw 002250
1 2
1

1. Throttle cam screw 2
1. Shift rod lever screw 002246
2. Cotter pin
Slide entire shift linkage assembly from crank-

case.
Remove the ball, guide, and spring of the shift

detent assembly from the crankcase.
1. Shift detent assembly 002135
194
POWERHEAD
Crankcase Disassembly IMPORTANT: Do not use a tapered punch or

any other tool that could jam in or damage the
Remove screws and carefully pry off exhaust side
taper bore when removing the pin.
water cover.
Remove crankcase flange screws.
002234
002137
Loosen in stages and remove the main bearing

nuts and washers.
002124
WARNING
Wear safety glasses to avoid injury. 002138
Use a 1/8 in. diameter pin punch to push crank- Separate crankcase and cylinder block. It may be 10
case taper pin toward the front side of the engine. necessary to tap on crankshaft with a rawhide or
rubber mallet to loosen.
002232
002252
195
POWERHEAD
Cylinder Head Removal Use Torquing Socket, P/N 331638, to loosen in

stages the rod cap retaining screws. DO NOT
Remove thermostat cover and thermostat assem-
remove the screws.
bly. Refer to THERMOSTAT SERVICING on
p. 182.
Loosen in stages and remove cylinder head

screws. Remove the cylinder head. Discard ther-
mostat seal and O-rings.
1
1
002123
Use one hand to support the piston, and remove

the rod cap screws with your other hand. Remove
each piston and rod assembly.
1. Cylinder head screws 007850
Connecting Rods and Pistons

Use a permanent marker to identify each connect-
ing rod cap, connecting rod, and piston by cylinder
number. Number 1 is closest to the top.
002141
NOTICE Reattach each rod cap to its rod as

soon as the piston is removed. Each cap is
unique and can only be installed on its mated
rod. Do not allow rod to contact inside surface
of cylinder or crankshaft.
002140
IMPORTANT: Identify all internal components

so that if reused, they can be reinstalled in their
original positions.
Repeat steps for each remaining piston and con-

necting rod.
196
POWERHEAD
Use an appropriate ring expander to remove all necting rod. If necessary, use Wrist Pin Pressing
piston rings from pistons. Discard the rings. Tool, P/N 326356, to remove the wrist pin bearing.
WARNING
Wear safety glasses to avoid injury.
002047
Be careful not to lose any of the 28 needle bear-

ings or the two wrist pin washers. Do not mix bear-
ings with those from another cylinder. If any of the
002054 bearings are worn or lost, replace all 28 bearings
during reassembly.
Remove wrist pin retaining rings. Discard retaining
rings. Crankshaft Removal
Carefully lift crankshaft straight up and remove
from crankcase.
002046 10
The wrist pin fit is loose on both sides. Push the
002263
wrist pin through to free the piston from the con-
Remove upper seal from crankshaft. Discard the
seal. A new upper seal must be installed on
assembly.
197
POWERHEAD
Remove the upper main bearing. Use a punch to remove the housing seal. Discard
seal.
1
1. Upper oil seal 002034

2. Upper main bearing
1. Punch 002053
Remove the lower bearing seal housing. Inspect housing and replace if necessary.
Remove the O-ring from crankshaft sleeve and

inspect it. Replace the O-ring if it is not in good
condition.
002042
Remove the housing O-ring. Discard O-ring.
002040
002044
198
POWERHEAD
Inspect the crankshaft sleeve and replace if nec- Use a bearing separator to support the bearing,
essary. To remove the sleeve, use Slide Hammer, and press off the crankshaft.
P/N 432128, and Large Puller Jaws, P/N 432129.
002052
002041
Remove the lower main bearing only if it needs to Remove center main bearings and split sleeves
be replaced. Use external retaining ring pliers to for inspection. DO not mix parts. Note location of
remove the lower bearing retaining ring. bearings for reassembly.
002039 24381
IMPORTANT: If the lower main bearing is

removed from the crankshaft, it must be dis- 10
carded. DO NOT reuse it.
199
POWERHEAD
CYLINDER BLOCK CLEANING
CYLINDER BLOCK sealant from the cylinder block, crankcase, cylin-

der head, and water cover.
CLEANING WARNING
IMPORTANT: Before inspecting or assembling To avoid personal injury, wear eye protec-
powerhead, all internal components must be com- tion and rubber gloves when using Gel
pletely clean and free of contaminants. Be careful Seal and Gasket Remover.
to avoid damaging any machined surfaces.
Remove any carbon accumulation from exhaust

port areas.
Remove any carbon accumulation from cylinder
head combustion chambers.
If cylinder walls are glazed from extended use,

use a rigid, medium grit cylinder hone to resurface
walls. Use slow RPM for best oil retention and ring
sealing. When finished, a cross hatch pattern of
22 to 32° should be visible in the cylinder wall. 002068
The pattern should be uniform in both directions.
Carefully remove any carbon accumulation from
IMPORTANT: To avoid piston or cylinder block the tops and ring grooves of the piston using
damage, restore the chamfer to all port edges Engine Tuner. A ring groove cleaning tool can be
using a ball hone or other suitable tool. made by breaking an old ring and grinding an
angle on its end. Do not damage ring grooves
while cleaning.
Thoroughly wash entire cylinder block and crank-

2 case with warm, soapy water to remove all traces
of contaminants.
1
Air dry cylinder block and crankcase. Blow all
holes and passageways with compressed air.
WARNING
1. Crosshatch pattern in cylinder wall 002067

To avoid personal injury, wear eye protec-
2. Chamfered port edge tion and set compressed air pressure at
less than 25 psi (172 kPa).
Use Gel Seal and Gasket Remover to remove all
traces of gaskets, adhesives, and Gel-Seal II™ Cover the cylinder walls with a liberal amount of
outboard lubricant to prevent corrosion.
200
POWERHEAD
POWERHEAD INSPECTION
POWERHEAD Crankshaft
Measure the diameter of each crankpin and main
INSPECTION bearing journal. The lower main bearing journal
For dimensions, refer to SERVICE SPECIFICA- would only be measured if the bearing was
TIONS on p. 10. removed for another reason.
IMPORTANT: Before any inspection process

can begin, all internal components must be com-
pletely clean and free of contaminants.
Visually inspect all parts. Check for unusual wear

patterns, scuffing, or deterioration of aluminum
parts, heat-related discoloration of bearings and
bearing surfaces, and broken components.
Cylinder Head
Check for cylinder head warpage using a piece of
002142
bar stock or machinist’s straightedge and a feeler
gauge set.
Cylinder Bore
Cylinder head warpage must not exceed 0.006 in. Use a Cylinder Bore Gauge to inspect each cylin-
(0.15 mm) per inch of measurement. Replace der bore for an out-of-round, oversize, or tapered
head if warpage exceeds this dimension. condition. Be sure the gauge is perfectly square in
the bore when measuring.
10
24423
007283
Check fuel deflector pins for damage.
Measure each cylinder in at least two areas. Each
area should be measured twice. The difference
between the two measurements in each area is
the cylinder out-of-round dimension.
• The cylinder must not be out-of-round by more
than 0.004 in. (0.10 mm).
201
POWERHEAD
POWERHEAD INSPECTION
The dimensional difference between the two IMPORTANT: Ring end gap increases approxi-
areas is cylinder taper. mately 0.003 in. (0.076 mm) for each 0.001 in.
• The cylinder taper must not exceed 0.002 in. (0.025 mm) increase in cylinder bore diameter.
(0.05 mm). DO NOT exceed cylinder oversize dimension.
Use a machinist’s straightedge to check for proper

ring clearance. Position piston rings on piston.
1 Push rings into groove and hold straightedge
against the side of the piston. Rings must be even
or just below the surface of piston. Rings must
move freely in piston ring groove.
1. Measurement areas DR3482
The difference between the measurements and

standard bore is cylinder oversize. For dimen-
sions, refer to SERVICE SPECIFICATIONS on
p. 10.
• The cylinder must not be oversized by more
31796
than 0.003 in. (0.08 mm).
Pistons Bearings
Visually inspect pistons for signs of abnormal Inspect center main bearings and split sleeves for
wear, scuffing, cracks, or burning. excess wear, nicks, or scratches. Replace if nec-
essary.
Piston Rings
Inspect crankshaft rod bearings for excess wear,
For new ring sets, place each ring separately in its nicks, or scratches. Replace if necessary.
respective bore. Use a piston to square the ring in
the cylinder. Use a feeler gauge to measure the
ring end gap.
24381
002143
Ring end gap should be:

• 0.011 to 0.023 in. (0.28 to 0.58 mm)
202
POWERHEAD
POWERHEAD ASSEMBLY
POWERHEAD If the installer sticks on the sleeve after installa-

tion, thread Slide Hammer, P/N 391008, into
ASSEMBLY installer and pull it off.
IMPORTANT: Inspect sleeve after installation.

IMPORTANT: Proceed slowly. Make no forced Sleeve must not be used if surface is damaged.
assemblies unless a pressing operation is called
for. All internal components must be perfectly Use retaining ring pliers to install bearing retaining
clean and lightly coated with outboard lubricant. ring with sharp edge facing away from bearing.
IMPORTANT: Use new wrist pin retaining rings, Lubricate a new driveshaft O-ring and lightly lubri-
gaskets, seals, and O-rings during assembly. cate crankshaft splines with Moly Lube. Install
O-ring in sleeve.
Crankshaft Assembly
Oil the end of the crankshaft. Use Crankshaft
Bearing/Sleeve Installer, P/N 338647, and place a
1
new lower main bearing onto crankshaft with let-
tered side facing the tool. Install bearing until it
seats on the crankshaft.
2
1. Bearing retaining ring 002031

2. O-ring
Lubricate the center main bearings and split

sleeves with outboard lubricant and install them in
their original positions. The split sleeve ring
grooves must face toward driveshaft (lower) end
002029 of crankshaft when installed.
Oil the end of the crankshaft. Use Crankshaft
Bearing/Sleeve Installer, P/N 338647, to drive a 1
new sleeve onto the crankshaft until the installer 10
contacts the lower main bearing.
1. Groove toward driveshaft end 002032
Lightly coat the outside edge of a new lower hous-

ing seal with Gasket Sealing Compound. Press
against outer case of the seal to install seal in the
002030
203
POWERHEAD
POWERHEAD ASSEMBLY
lower housing with extended lip facing down. Lubricate upper main bearing with outboard lubri-
Lubricate seal lip with Triple-Guard grease. cant and install on crankshaft.
1. Seal lip 002036 1. Upper main bearing 002033
Pack lip of upper oil seal with Moly Lube. Place

seal on crankshaft with lip down and enclosed
face up. Do not apply sealer to outside edge of the
seal.
002037
Install a new O-ring on the lower housing. Before

installing crankshaft into cylinder block, apply a
thin coat of Gasket Sealing Compound to outer
edge of O-ring. 1. Upper oil seal 002034
Place lower seal housing on crankshaft.
1. Lower seal housing 002038

2. O-ring
204
POWERHEAD
POWERHEAD ASSEMBLY
Pistons and Connecting Rods Apply Needle Bearing Grease to the wrist pin
bearings. Install the bearings in the small end of
NOTICE It is very important that the pistons the connecting rod. Align bearings with Wrist Pin
in this engine are installed in the correct loca- Bearing Tool, P/N 336660.
tion and direction. Engine damage will occur if
installed incorrectly. 2
New pistons are stamped “EXH.” This marking

should be turned toward the exhaust side of the
block. The splash bowl on the dome of the piston 1
will be located toward the top and starboard side
of the block.
1. 28 needle bearings 24903

1 2. Wrist pin bearing tool
3
Place the two wrist pin thrust washers on the tool
2 with flat side of the washers facing out.
1
1. Exhaust side of block 002049
2. Stamped markings
3. Splash bowl
NOTICE It is also very important that the

connecting rods are installed with the align- 1. Wrist pin thrust washers DR3480
24902
ment dots and the diagonal oil hole facing up,
toward the flywheel. Oil the wrist pin bore and wrist pin. Place connect-
ing rod, with bearings, washers, and tool, into the
piston with the alignment dots facing the top of the
1 piston. 10
Install wrist pin through piston and connecting rod,
pushing bearing tool out through the piston.
1. Oil hole 002055

2. Raised dots
002057
205
POWERHEAD
POWERHEAD ASSEMBLY
Use Wrist Pin Cone, P/N 318600, and Driver, IMPORTANT: Be sure gap of ring fits squarely
P/N 318599, to install new wrist pin retaining rings around dowel pin.
in each wrist pin hole. Gap of retaining ring faces
up, away from notch in piston.
002048
NOTICE Before continuing, make sure that

all Gel-Seal II has been removed from the cyl-
002058 inder block and crankcase mating flanges. If
traces of hardened Gel-Seal II are left, main
bearings could be misaligned. Refer to CYLIN-
DER BLOCK CLEANING on p. 200.
1
Coat pistons, rings, cylinder walls, and an appro-
priate ring compressor with outboard lubricant.
Center connecting rod in piston and locate piston

2
rings on dowel pins. Place appropriate ring com-
pressor on piston.
Slide piston and rod assembly into the correct cyl-

1. Gap of retaining ring 002050 inder, as marked during disassembly. Guide con-
2. Notch in piston necting rod through cylinder block to avoid
scratching cylinder wall.
Installing Pistons
When all pistons and connecting rods are assem-
bled, install piston ring sets. Be sure rings are
installed in the cylinder used to test ring end gap.
Refer to POWERHEAD INSPECTION on p. 201. 1
1. Ring compressor 002059
Repeat steps for each piston.
206
POWERHEAD
POWERHEAD ASSEMBLY
Cylinder Head Installation Apply a 1/16 in. (2 mm) bead of RTV Adhesive
around each water passage on the block and cyl-
Install a new thermostat seal in cylinder head with
inder head as shown.
side marked “TO CYL HEAD” facing toward ther-
mostat.
Refer to THERMOSTAT SERVICING on p. 182

before installing cylinder head.
2
Lightly lubricate new cylinder head O-rings with
Triple-Guard grease and install in cylinder head. 1
1. RTV sealant 002272

2. Thermostat seal
002061
Install cylinder head with the thermostat toward
the top. Place ignition coil brackets as shown
Apply soapy water to water dam and insert into below.
block.
Apply outboard lubricant to screw threads and
install the cylinder head screws. DO NOT use any
sealant or locking compound on threads.
10
1. Water dam 002062
207
POWERHEAD
POWERHEAD ASSEMBLY
Following sequence stamped on cylinder head, Crankshaft and Connecting

tighten all screws in stages to a torque of 168 to
192 in. lbs. (19 to 21.7 N·m).
Rod Installation
Apply Gasket Sealing Compound to lower oil seal
1 groove in cylinder block. DO NOT put any sealer
in upper seal groove.
Check that main bearing alignment dowel pins are

2 seated in the block.
2 1
1

1. Cylinder head screws
2. Ignition coil bracket 3
1. Gasket Sealing Compound 002262

2. Dowel pins
3. No sealer here
2
Push all pistons to the top of cylinders. Remove
numbered connecting rod caps.
1
Gently lower crankshaft into place.
• Align tab on lower bearing seal housing with
hole in crankcase.
1. Cylinder head screws • Align upper oil seal in groove.
2. Ignition coil bracket
• Locate each main bearing on its dowel pin. A
mark placed on the bearing race opposite the
dowel pin hole will help in the alignment pro-
cess.
2 1
1. Lower seal housing 002070

2. Upper oil seal
3. Alignment marks
208
POWERHEAD
POWERHEAD ASSEMBLY
Lubricate each crankpin and bearing assembly IMPORTANT: Be sure alignment dot on rod cap
with outboard lubricant. Slowly pull connecting rod matches dot on rod and that both dots face fly-
up to crankshaft and install bearing halves. wheel.
1. Alignment dots 53628
002115
NOTICE Tightening rod cap screws without
Lubricate rod cap screw threads and under screw Alignment Fixture, P/N 396749, or using an
head mating surface with outboard lubricant. Align incorrect procedure could cause permanent
dot on rod cap with dot on the connecting rod. damage to the connecting rod and crankshaft.
Install rod cap screws finger tight (NO MORE than To maintain accurate torque values, keep
6 in. lbs. (1 N·m) maximum). torque wrench extension length to a minimum.
Install Rod Cap Alignment Fixture, P/N 396749,

before tightening rod cap screws. Align the flat
marked “SET” on the rod engagement stop with
the arrow on the frame. Position stop at the center
setting (one line showing). Rotate adjustment
knob 180° to lock in position.
002116
10
1. Center position, one line showing 002484
209
POWERHEAD
POWERHEAD ASSEMBLY
Secure restraining jaw “C” and forcing jaw “D” to • Tighten the forcing screw to a torque of 14 to 16
frame. in. lbs. (1.6 to 1.8 N·m).
2
4
Restraining Jaw “C” 21591

1. Contact area of jaw 002071
2. Forcing screw
3. Adjustment stop
4. Groove line
IMPORTANT: Make sure that frame is squarely

in position and that rod and cap are aligned.
Loosen both rod cap screws one-quarter turn.
Use Torquing Socket, P/N 331638, to tighten rod

cap screws in three stages:
Forcing Jaw “D” 21594 • Apply first torque of 40 to 60 in. lbs. (5 to 7 N·m)
to both rod cap screws.
Apply a light coat of outboard lubricant to the cor- • Tighten screws to a torque of 14 to 16 ft. lbs. (19
ners of the connecting rod and rod cap. Place to 21.7 N·m).
frame on connecting rod using the following pro- • Apply final torque of 30 to 32 ft. lbs. (41 to 43
cedure. N·m).
• Place frame onto the connecting rod so the con-
tact area of the jaw is centered on the side of
the rod.
• Tighten forcing screw until jaws contact con-
necting rod.
• Slide frame down until adjustment stop contacts
the rod cap. The groove lines on the jaws must
be centered on the rod/crankpin diameter.
002072
IMPORTANT: If a new screw is used, it must be

installed as above. Then, it must be removed, re-
lubricated, and installed again.
Loosen forcing screw and remove the frame.
210
POWERHEAD
POWERHEAD ASSEMBLY
Test at least three corners of the rod and cap joint IMPORTANT: Gel-Seal II has a shelf life of at
with a pick. Joint must be smooth with no step. least one year when stored at room temperature.
Test the Gel-Seal II or replace it if the age of the
tube cannot be determined. Using old Gel-Seal II
could cause crankcase air leaks.
IMPORTANT: The use of Locquic Primer is NOT

recommended. If primer is used, crankcase
halves must be assembled and tightened within
ten minutes after the Gel-Seal II has been applied.
Lower the crankcase into place. Make sure that

upper oil seal and lower seal housing are seated
in grooves.
002117
Apply outboard lubricant to the main bearing
studs. Install nuts and washers finger tight, no
Crankcase Assembly more than 60 in. lbs. (7 N·m).
Make sure crankshaft is still seated on dowel pins
before assembling crankcase.
Thoroughly clean and degrease the mating
flanges of the crankcase and cylinder block with a
non-petroleum based solvent, such as isopropyl
alcohol or acetone, and let air dry.
IMPORTANT: DO NOT allow solvent to get on

internal components. Clean only the mating
flanges.
Apply Gasket Sealing Compound to lower oil seal

002271
groove in crankcase. DO NOT put any sealer in
upper seal groove.
When the crankcase is seated, install and firmly
Use a small brush with a tapping motion to apply a seat the crankcase taper pin.
thin, even coat of Gel-Seal II sealant to the crank-
case mating flange. The sealer must not come 10
within 1/4 in. (6.4 mm) of bearings.
002260
Tighten main bearing nuts in stages to a final

TYPICAL 003874 torque of:
• 26 to 30 ft. lbs. (35 to 41 N·m).
211
POWERHEAD
POWERHEAD ASSEMBLY
Start in the center and work outward in a spiral Note: 3-Cylinder models include a double-ended
pattern. stud and use a lock washer under the J-clamp.
002254 2-Cylinder models 002242r

1. J-clamp
Apply Nut Lock to crankcase flange screws. Install

screws and tighten to a torque of 60 to 84 in. lbs.
(7 to 9.5 N·m).

1. Double-ended stud
2. J-clamp
002259
Shift Linkage Installation
Test that the crankshaft spins freely without bind- Place the spring, guide, and ball of the shift detent
ing. assembly into the crankcase. Lubricate with Tri-
ple-Guard grease.
IMPORTANT: After powerhead has been
assembled, allow at least two hours for Gel-Seal II
to cure before running outboard.
1
Apply Gasket Sealing Compound to both sides of
a new water cover gasket. Place gasket and cover
on cylinder block.
Apply Nut Lock to cover screws. Position J-
clamps as shown. Tighten all screws to a torque of
60 to 84 in. lbs. (7 to 9.5 N·m).
1. Shift detent assembly 002135
212
POWERHEAD
POWERHEAD ASSEMBLY
Lubricate shift linkage bosses at the base of the Throttle Linkage Installation
crankcase with Triple-Guard grease. Insert bush-
Apply Nut Lock to threads of throttle lever screw.
ings into bosses.
Insert spring into cavity of throttle return lever.
Apply Triple-Guard grease to the shaft and detent
of the shift lever assembly. Guide shaft through Install lever, screw, and washer on crankcase and
bushings in crankcase. hook spring on rib as shown. Tighten screw to a
torque of 120 to 144 in. lbs. (13.5 to 16 N·m).
Install cotter pin and washer on the shaft (2-cylin-
der models).
1
Install shift rod lever and tighten retaining screw to
1 4

1. Throttle lever spring
2 3
1. Shift lever and shaft 002246

2. Bushing
3. Cotter pin and washer
4. Shift rod lever screw
Apply Triple-Guard grease to shoulder of shift arm 1

screw and Nut Lock to threads. Install arm, screw,
and washer and tighten screw to a torque of 120
to 144 in. lbs. (13.5 to 16 N·m).
1
1. Throttle lever spring
10
Apply Nut Lock to threads of throttle cam screw.
Install cam, screw, and washer on cylinder block
1. Shift lever screw 002250
213
POWERHEAD
POWERHEAD ASSEMBLY
and tighten screw to a torque of 120 to 144 in. lbs. Final Powerhead Assembly
(13.5 to 16 N·m).
Install the reed plate and throttle body assemblies.
Refer to Intake Manifold Service on p. 149.
Install oil recirculating hoses and check valves.

1 2
Refer to OIL RECIRCULATION DIAGRAMS on
p. 158, or POWERHEAD VIEWS on p. 221.
Install thermostat assembly. Refer to THERMO-

STAT SERVICING on p. 182.
Install pressure valve assembly. Refer to PRES-

SURE RELIEF VALVE SERVICING on p. 183.
2-Cylinder models 002245 Install shift linkage. Refer to Shift Linkage Instal-
1. Throttle lever screw lation on p. 212.
2. Throttle return lever
Install throttle linkage. Refer to Throttle Linkage
Install fuel injectors and ignition coils. Refer to

1 2 Fuel Injector Installation on p. 147 and IGNITION
COIL SERVICING on p. 112.
IMPORTANT: All injectors must be installed in

their original location. Improper injector installation
can result in powerhead failure.
Install stator and flywheel. Refer to FLYWHEEL
AND STATOR SERVICING on p. 110.
2. Throttle return lever Install electrical harness, then install EMM. Refer
to EMM SERVICING on p. 70.
IMPORTANT: Do not lubricate throttle levers or
shoulder screws. Install fuel pump assemblies, fuel manifolds, and
filter. Refer to FUEL COMPONENT SERVICING
on p. 142.
Install the oil tank and oil injection hoses. Refer to

Oil Tank Assembly on p. 169.
Install the electric starter. Refer to Starter Starter

WARNING
To prevent fire and explosion hazard,
make sure all electrical and ignition wiring
is routed and clamped in original posi-
tions.
214
POWERHEAD
UPPER MOUNT SERVICING (3-CYLINDER)
UPPER MOUNT Inspect mounts and replace if necessary.
IMPORTANT: The motor mount, washer, and

SERVICING (3-Cylinder) screw are serviced as an assembly. Do not disas-
Removal semble.
Remove mount retainer screw.
39820
Installation
002069
Place mount assemblies in position, with flats fac-
Insert suitable punch in taper of mount retainer. ing away from each other.
Tap side of punch to loosen mount retainer.
Apply Moly Lube to all sides of retainer and install
between mounts.
002130
002133 10
Dislodge mount assemblies and remove.
Install the retainer screw and tighten to a torque of
15 to 20 ft. lbs. (20 to 27 N·m).
002132
002134
215
POWERHEAD
POWERHEAD INSTALLATION
POWERHEAD Loosely install all powerhead screws before tight-

ening:
INSTALLATION
Powerhead Mounting – 2-Cylinder
Models
Apply Permatex No. 2 to both sides of a new base
gasket around the exhaust port only. Install gasket
on exhaust housing. To ensure proper sealing,
mating surfaces must be clean and dry.
1
1 1. Powerhead screws 004292

3
Tighten the eight powerhead screws to a torque of
18 to 20 ft. lbs. (24 to 27 N·m) in the sequence
2 shown.
1. Exhaust port 004972

2. Clean surface
3. Moly Lube
Coat the driveshaft splines with Moly Lube. Do not

apply lubricant to end of driveshaft.
Permatex #2
Use Lifting Fixture, P/N 396748, and hoist to
slowly lower powerhead onto exhaust housing. If
necessary, rotate flywheel in a clockwise direction
to align crankshaft and driveshaft splines.
Large screw torque sequence, 1 – 10 002175
IMPORTANT: Retighten powerhead mounting

screws after outboard has been run at full operat-
ing temperature and allowed to cool.
002269
Apply Triple-Guard grease to the threads, and

Gasket Sealing Compound to the shank of the
powerhead screws.
216
POWERHEAD
Place the shift rod in the shift rod lever. Install the Connect cooling water hoses to exhaust housing.
retaining pin and washer. Tighten pin to a torque
of 60 to 84 in. lbs. (7 to 9.5 N·m).
1 2
1. Overboard indicator hose 004298

2. Drain hose
1. Shift rod screw 002171

Connect the power trim connectors and exhaust
Check shift linkage adjustment. Refer to Shift water valve connector (60, 65). Secure cables in
Linkage Adjustment on p. 220. clamps.
IMPORTANT: Make sure the gearcase shifts ROPE START MODELS

completely into both forward and reverse and that Install throttle cable and tiller shift rod.
propeller shaft spins freely in neutral.
Apply Nut Lock to threads of exhaust water valve
screws and tighten to a torque of 60 to 84 in. lbs. 1
(7 to 9.5 N.m). 2
3
4
1
1. Cable anchor 006526m

2.
3.
Anchor screw
Cable retainer 10
4. Shift rod retainer
Refer to Throttle Cable Adjustment on p. 276, or

1. Exhaust water valve 004293 Throttle Cable Adjustment on p. 287.
217
POWERHEAD
Install recoil starter ratchet and housing on out- Use Lifting Fixture, P/N 396748, and hoist to
board. Refer to RECOIL STARTER INSTALLA- slowly lower powerhead onto exhaust housing.
TION on p. 369. Guide into position over alignment pin at rear of
exhaust housing. If necessary, rotate flywheel in a
clockwise direction to align crankshaft and drive-
shaft splines.
1
1
1
1
1. Starter housing screws (3) 002515
Install the lower engine covers. Refer to LOWER

1. Alignment pin 002162
COVER SERVICE on p. 50.
Powerhead Mounting – 3-Cylinder Apply Triple-Guard grease to the threads, and

Gasket Sealing Compound to the shank of the
Models powerhead screws.
Apply Permatex No. 2 to both sides of a new base
gasket around the exhaust port only. Install gasket Apply Triple-Guard grease to upper mount screw
on adapter. To ensure proper sealing, mating sur- threads.
faces must be clean and dry. Loosely install all powerhead screws and upper
mount screws before tightening.
• Tighten the six large powerhead screws to a
1 torque of 18 to 20 ft. lbs. (24 to 27 N·m) in the
sequence shown.
• Tighten the five small powerhead screws to a
torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
1. Apply Permatex No. 2 here 002164
Coat the driveshaft splines with Moly Lube. Do not

apply lubricant to end of driveshaft.
218
POWERHEAD
• Tighten the upper mount screws to a torque of Apply Gasket Sealing Compound to exhaust relief
110 to 130 ft. lbs. (149 to 176 N·m). Make sure muffler gasket and retaining screws. Install muffler
that screw heads are tight against steering arm. and tighten screws to a torque of 60 to 84 in. lbs.
(7 to 9.5 N·m).
3
1
1. Large powerhead screws 002153
2. Small powerhead screws
3. Upper mount screws
002163
Place the shift rod in the shift rod lever. Install the
retaining pin and washer. Tighten pin to a torque
1 of 60 to 84 in. lbs. (7 to 9.5 N·m).
1. Rear small powerhead screw 002160 1
Check shift linkage adjustment. Refer to Shift 10

Linkage Installation on p. 212.
IMPORTANT: Make sure the gearcase shifts

solidly into both forward and reverse and that pro-
peller shaft spins freely in neutral.
Large screw torque sequence, 1–8 002167

Small screw torque sequence, A–E
IMPORTANT: Retighten powerhead mounting

screws after outboard has been run at full operat-
ing temperature and allowed to cool.
219
POWERHEAD
Connect the power trim connectors. • Tighten adjustment screws to 60 to 84 in. lbs. (7
to 9.5 N·m).
5
4
3
1
002152 2
Install the lower engine covers. Refer to LOWER 1. Adjustment screws 002125
COVER SERVICE on p. 50. 2. Shift detent assembly
3. Shift lever pin
4. Trunnion pocket
Shift Linkage Adjustment 5. 7 inch dimension
Adjust shift linkage as follows:
• Loosen adjustment screws on shift lever. Final Adjustments
• Be sure that ball is centered in detent assembly.
• Adjust shift lever so that the screw hole in shift NOTICE After installing a new or rebuilt
rod lever lines up with the hole in the gearcase powerhead, perform the following procedures
shift rod when gearcase is in neutral. before returning outboard to service:
• When correctly adjusted, the shift lever will be
• Adjust timing pointer.
parallel with the vertical line of the outboard,
and the distance between the shift lever pin and
• Index all spark plugs. Refer to Spark Plug
Indexing on p. 42.
the center of the shift cable trunnion pocket
should be approximately 7 in. (17.8 cm). • Use Evinrude Diagnostics software to start pow-
erhead break-in oiling. Refer to Powerhead
IMPORTANT: The shift rod height is the most Break-In on p. 67.
critical of these adjustments and should not be • Use Evinrude Diagnostics software to set TPS
moved during this procedure. Refer to SHIFT calibration. Refer to TPS Calibration on p. 114.
ROD ADJUSTMENT on p. 300, or SHIFT ROD • Use Evinrude Diagnostics software to make
ADJUSTMENT on p. 323. sure engine management software version and
revision are current. Update as required.
• Prime fuel system.
• Prime oiling system. Refer to Oil Supply Prim-
ing on p. 165.
• Use Evinrude Diagnostics software to check
engine timing. Refer to TIMING ADJUST-
MENTS on p. 113.
• Run outboard and check for water, fuel, or oil
leaks.
• Make sure engine reaches correct operating
temperature and does not overheat.
220
POWERHEAD
POWERHEAD VIEWS
POWERHEAD VIEWS
2-Cylinder Port – Hose Routings
006490
2-Cylinder Starboard – Hose Routings
10
006491
221
POWERHEAD
POWERHEAD VIEWS
2-Cylinder Port Dressed Powerhead
008428
2-Cylinder Starboard Dressed Powerhead
008159
222
POWERHEAD
POWERHEAD VIEWS
2-Cylinder Port Rope Start Models
008370
2-Cylinder Starboard Rope Start Models
10
008185
223
POWERHEAD
POWERHEAD VIEWS
2-Cylinder Front
008160
224
POWERHEAD
POWERHEAD VIEWS
2-Cylinder Rear
10
008161
225
POWERHEAD
POWERHEAD VIEWS
2-Cylinder Top
008162
226
POWERHEAD
POWERHEAD VIEWS
2-Cylinder Top, Rope Start Models
10
008186
227
POWERHEAD
POWERHEAD VIEWS
3-Cylinder Port – Hose Routings
006760
3-Cylinder Starboard – Hose Routings
006761
228
POWERHEAD
POWERHEAD VIEWS
3-Cylinder Port Dressed Powerhead
008163
3-Cylinder Starboard Dressed Powerhead
10
008164
229
POWERHEAD
POWERHEAD VIEWS
3-Cylinder Front
008166
230
POWERHEAD
POWERHEAD VIEWS
3-Cylinder Rear
10
008167
231
POWERHEAD
POWERHEAD VIEWS
3-Cylinder Top
008165
232
MIDSECTION
MIDSECTION
TABLE OF CONTENTS
SERVICE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
TILT TUBE, 75 – 90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
EXHAUST HOUSING, 40 – 65 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
EXHAUST HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
EXHAUST WATER VALVE (60–65 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
EXHAUST RELIEF MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
EXHAUST HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
EXHAUST HOUSING, 75 – 90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
EXHAUST HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
LOWER MOUNT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
EXHAUST HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
EXHAUST HOUSING DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
EXHAUST HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
STERN BRACKET, 40 – 60 HP POWER TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
STERN BRACKET DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
STERN BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
STERN BRACKET, 75 – 90 HP POWER TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
STERN BRACKET, 40 – 60 HP MANUAL TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
CLAMP SCREW SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
TILT ASSIST CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
STERN BRACKET, 90 HP MANUAL TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
TILLER HANDLE SERVICE – STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 11
THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
TILLER HANDLE SERVICE – LONG HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
CONTROL CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
233
MIDSECTION
SERVICE CHARTS
SERVICE CHARTS
EXHAUST HOUSING, 40 – 65 HP
F F
24-26 Ft. lbs.
C (32.5-35 N·m) 18-20 Ft. lbs.
(24.5-27 N·m) F
60-84 In. lbs.
(7-9.5 N·m)
B
18-20 ft. lbs
(24.5-27 N·m)
F
60-84 in. lbs
(7-9.5 N·m)
16-18 ft. lbs

(22-24.5 N·m)
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
P Permatex No. 2
004304 Q Gel Seal II
234
MIDSECTION
SERVICE CHARTS
E
60-84 In. lbs.
B (7-9.5 N·m)
60-84 In. lbs.
(7-9.5 N·m) B
60-84 In. lbs.
(7-9.5 N·m)
C
A
B
B
18-20 Ft. lbs.
(24.5-27 N·m)
B
60-84 In. lbs.
(7-9.5 N·m)
A 11
F
150-180 In. lbs. C
(17-20 N·m) A Triple-Guard Grease
C Adhesive 847
D Moly Lube
A
E Red Ultra Lock
F Blue Nut Lock
P Permatex Number 2
235
MIDSECTION
SERVICE CHARTS
STERN BRACKET, 40 – 60 HP POWER TILT
A
A
45-50 Ft. lbs.

(61-68 N·m)
10-16 In. lbs.

(1-2 N·m)
A F
144-168 In. lbs.
(16-19 N·m)
45-50 Ft. lbs.

(61-68 N·m)
IMPORTANT
Use Triple-Guard grease
on all pivot points
002220 B Gasket Sealing Compound
236
MIDSECTION
SERVICE CHARTS

40-50 In. lbs. 8-12 In. lbs.
(4.5-5.5 N·m) (0.9-1.4 N·m)
A 110-130 Ft. lbs.

(149-176 N·m)
A
10-16 In. lbs.
(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.
(61-68 N·m) 216-240 In. lbs.
(25-27 N·m)
IMPORTANT
on all pivot points
40-50 In. lbs.
(4.5-5.5 N·m)
216-240 In. lbs.

(25-27 N·m)
170-190 In. lbs. F

11
(19-22 N·m) 38-45 Ft. lbs.
(52-61 N·m)
40 Ft. lbs. (54 N·m)

Marine Sealant
120-144 In. lbs.
(13.5-16.5 N·m)
A B
130-150 Ft. lbs.
(176-204 N·m)
F Blue Nut Lock
004105a U Instant Bonding Adhesive
237
MIDSECTION
SERVICE CHARTS
STERN BRACKET, 40 – 65 HP MANUAL TILT
40-45 Ft. lbs.

144-168 In. lbs. (54-61 N·m)
(16-19 N·m) See Text
144-168 In. lbs.

(16-19 N·m)
40-45 Ft. lbs.

(54-61 N·m)
See Text
F
144-168 In. lbs.
(16-19 N·m)
IMPORTANT
Use Triple-Guard grease A Triple-Guard Grease
on all pivot points B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
P Permatex No. 2
238
MIDSECTION
SERVICE CHARTS
STERN BRACKET, 90 HP MANUAL TILT
IMPORTANT
on all pivot points
A
110-130 Ft. lbs.
(149-176 N·m)
F
18-20 Ft. lbs.
(24-27 N·m)
F
60-84 In. lbs.
(7-9.5 N·m)
A
60-84 In. lbs. 18-20 Ft. lbs.
(7-9.5 N·m) (24-27 N·m)
A
28-30 Ft. lbs.
(38-41 N·m)
18-20 Ft. lbs.

(24-27 N·m)
8-12 In. lbs.

F A F
60-84 In. lbs.
(0.9-1.4 N·m) 60-84 In. lbs.
(7-9.5 N·m)
(7-9.5 N·m)
40-50 Ft. lbs.

(61-68 N·m) F
60-84 In. lbs.
(7-9.5 N·m)
F
60-84 In. lbs.
(7-9.5 N·m) A
A
18-20 Ft. lbs.

(24-27 N·m)
A
F
18-20 Ft. lbs.

38-45 Ft. lbs.
(52-61 N·m) 11
(24-27 N·m)
A
B A Triple-Guard Grease
130-150 Ft. lbs.
40 Ft. lbs. (54 N·m) (176-204 N·m)
Marine Sealant C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
P Permatex No. 2
239
MIDSECTION
SERVICE CHARTS
TILLER HANDLE (LONG)

18-20 Ft. lbs.
(24.5-27 N·m)
24-36 In. lbs.

(2.7-4 N·m)
36-48 In. lbs.

(4-5.4 N·m)
A
18-20 Ft. lbs.
(24.5-27 N·m)
A
36-40 Ft. lbs.
(49-54 N·m) 18-20 Ft. lbs. 20-30 In. lbs.
(24.5-27 N·m) (2.3-3.4 N·m)
F
F A D
18-20 Ft. lbs.
(24.5-27 N·m)
Steering Friction Device To Remote

Optional on 2-Cylinder Models SystemCheck Harness
60-84 In. lbs.

(7-9.5 N·m) To Engine SystemCheck
Connector
To Engine Key To Remote
Switch Connector Key Switch
Switched 12V
For CANbus
Stop Switch
To Engine Trim
Connector
Tiller Key Switch Start Switch
18-20 Ft. lbs.
To Remote
(24.5-27 N·m) 18-20 Ft. lbs. Trim Gauge
(24.5-27 N·m) Trim Switch
D Moly Lube
006663
F Blue Nut Lock
240
MIDSECTION
TILT TUBE, 75 – 90 HP
TILT TUBE, 75 – 90 HP 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
WARNING
Support the outboard with a suitable hoist.
30747
Pull the locking tabs on the tilt limit cam loose from
the collar.
Thread the spacer from Tilt Tube Service Kit,
P/N 434523, onto the starboard end of the tilt
tube.
1. Locking tabs 30749
30746
Remove the cam and collar from the tilt tube.
Remove steering cable wiper nut from tilt tube.
Thread the adapter from Tilt Tube Service Kit,
P/N 434523, onto the port end of the tilt tube.
11
30748
30745
241
MIDSECTION
TILT TUBE, 75 – 90 HP
Thread Slide Hammer, P/N 432128, into the Install the starboard locknut.
adapter until at least 2 in. (51 mm) of thread are
engaged. 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 bracket,
remove tilt tube from the spacer.
Installation
Thread starboard end of tilt tube into the spacer.
30741
Thread the adapter onto port end of tilt tube.
Use a wood or leather mallet to tap the tilt tube Replace steering cable wiper nut on port end of tilt
into position. tube.
Apply one drop of instant bonding adhesive in

receiving channels of tilt limit switch collar and
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.
30750
1. Lock tab 30742
242
MIDSECTION
EXHAUST HOUSING,
40 – 65 HP
The exhaust housing contains no serviceable
internal parts. The exhaust water valve and the
exhaust relief muffler can both be serviced without
removing the exhaust housing.
1
Exhaust Housing Removal
Before removing the exhaust housing:
• Remove the gearcase. Refer to Gearcase 1. Lower side mount 17524
GEARCASE REMOVAL AND INSTALLATION
on p. 296. Remove the three upper mount to exhaust hous-
• Remove the powerhead. Refer to Powerhead ing screws. Be sure to support exhaust housing
POWERHEAD REMOVAL on p. 190. so it does not fall.
Remove the three lower mount cover screws.
COA2943
17527
Remove the exhaust housing.
Separate lower mount covers from swivel bracket.
Check condition of the lower front mount and two

lower side mounts.
11
1
Exhaust Housing 005069
1. Lower front mount 17526
243
MIDSECTION
Exhaust Water Valve (60–65 HP) Apply Nut Lock to screws, install and tighten 60 to
84 in. lbs. (7 to 9.5 N.m).
Disconnect water valve electrical connector.
Remove screws and bracket holding valve to

exhaust housing.
Remove tie straps and disconnect water valve 1

hoses (3) from exhaust housing.
1
1. Exhaust water valve screws 004293
2
3 Exhaust Relief Muffler
Remove exhaust relief muffler cover to inspect fil-
ter element. Clean or replace as needed.
1. Electrical connector 004293
2. Inlet hose
3. Outlet hose
Check that all water passages are clear. 1
1 1. Exhaust relief muffler cover 004301
1
Apply Gasket Sealing Compound to cover gasket
and install cover.
1. Fitting, water passage 004300 Apply Nut Lock to cover screws and tighten to a
torque of 60 to 84 in. lbs. (7 to 9.5 N.m).
Install hoses to fittings on exhaust housing.
Place water valve and bracket in position.
244
MIDSECTION
Exhaust Housing Installation Place lower thrust washer on the steering shaft
and place the lower front mount into position.
Bring the exhaust housing into position with the
stern bracket.
1. Thrust washer 17526

2. Lower front mount
Exhaust Housing 005069
Install lower side mount covers. Install and tighten
Apply Nut Lock to threads of the upper mount the screws in stages to a torque of 16 to 18 ft. lbs.
screws. Install the screws and place ground lead (22 to 24 N·m) following sequence shown.
under the center screw. Tighten screws to a
torque of 18 to 20 ft. lbs. (24 to 27 N·m).
2
1 3
Torque sequence 17528
1. Ground lead COA2943 Install gearcase. Refer to Gearcase GEARCASE

REMOVAL AND INSTALLATION on p. 296.
Install powerhead. Refer to Powerhead POWER-

HEAD INSTALLATION on p. 216.
11
245
MIDSECTION
EXHAUST HOUSING, Remove the exhaust housing.
75 – 90 HP
Exhaust Housing Removal
Before removing the exhaust housing:
• Remove the gearcase. Refer to GEARCASE
• Remove the powerhead. Refer to POWER-
HEAD REMOVAL on p. 190.
Remove and discard four lower mount screws.

001986
Lower Mount Service

Remove lower mount covers and inspect the
lower mounts.
If replacement is necessary, lubricate mount with
soapy water and carefully pry at both ends to
remove.
20” Models
“ 23036
001971
25” Models
“ 32590
246
MIDSECTION
If removed, coat the lower mounts with soapy Exhaust Housing Installation
water and press into the exhaust housing with the
Bring the exhaust housing into position with the
“OUTSIDE” mark facing outward.
stern bracket.
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).
001970
Install the mount covers. Apply Nut Lock to

screws, install washers and screws, and tighten to
a torque of 150 to 180 in. lbs. (17 to 20 N·m). 20” Models 23036
001972
25” Models 32590
Install gearcase. Refer to GEARCASE REMOVAL

AND INSTALLATION on p. 296.
Install powerhead. Refer to POWERHEAD

INSTALLATION on p. 216. 11
247
MIDSECTION
Exhaust Housing Disassembly

Remove the front and rear screws retaining the
adapter/inner exhaust housing to the exhaust
housing.
1 1
1 1
1. Lower inner exhaust housing screws 001974
Remove the water tube from the inner exhaust

housing. Discard water tube grommet.
1. Adapter retaining screws 001981
Lift the adapter/inner exhaust housing out of the

exhaust housing.
1. Water tube grommet 001984
Remove the seal from the bottom flange of the

inner exhaust housing.
001980 Remove the four screws securing the exhaust
megaphone to the adapter housing.
Remove the three upper screws and three lower
screws securing the inner exhaust housing to the
adapter housing. 1
1 1 2
1. Adapter to megaphone screws 001976

2. Exhaust megaphone
1. Upper inner exhaust housing screws 001975
248
MIDSECTION
Cleaning and Inspection Inspect the water tube for obstructions or kinks,
which may restrict water flow.
WARNING
Exhaust Housing Assembly
Wear safety glasses to avoid personal
Place a new gasket between the exhaust mega-
injury, and set compressed air to less than
phone and adapter housing. Apply Ultra Lock to
25 psi (172 kPa).
the threads of the screws and tighten to a torque
of 60 to 84 in. lbs. (7 to 9.5 N·m).
Clean all parts with parts cleaning solvent and dry
with compressed air. All nut and screw threads
coated with thread locking material must be thor- 1
oughly cleaned before assembly. When using a
thread locking product, be sure to prime the
threads with Locquic Primer. 2
Examine the upper and lower thrust mounts, and
replace if deteriorated or damaged.
1
Before checking the exhaust housing for distor-
tion, thoroughly clean the top and bottom mating
surfaces and remove all sealer and corrosion. 1. Adapter to megaphone screws 001976
2. Exhaust megaphone
Check the exhaust housing for distortion. Place
the housing on a surface plate. Use a dial indica- Place a new grommet on the water tube and coat
tor to check flatness by measuring the run-out on the outside edge with Adhesive 847.
the top edge of housing. The maximum allowable
run-out is 0.009 in. (0.228 mm). If you do not have
access to a dial indicator and surface plate, seek
the services of a machine shop. DO NOT attempt
to straighten a distorted housing; replace it. 1
IMPORTANT: A distorted exhaust housing will
cause the upper driveshaft splines to wear exces-
2
sively and will damage the crankshaft splines.

2. Flared end of water tube
11
DR2223
249
MIDSECTION
Install the water tube through the top of the inner Apply Adhesive 847 to the bottom flange of the
exhaust housing and align as shown: inner exhaust housing. Install a new seal. Apply
Triple-Guard grease to outer seal surface.
001982
1. Seal 001973
Place a new gasket between the inner exhaust 2. Bottom flange
housing and the adapter housing. Apply Ultra

Lock to the screws. Install the three lower screws Clean and degrease the adapter housing and
and three upper screws and tighten to a torque of outer exhaust housing mating surfaces with
60 to 84 in. lbs. (7 to 9.5 N·m). Cleaning Solvent. Apply Gel-Seal II sealant to the
adapter flange of the exhaust housing.
1 1
1. Lower inner exhaust housing screws 001974

001983
1 1 Place the adapter/inner exhaust housing into the

exhaust housing. Guide the water tube through
1. Upper inner exhaust housing screws 001975
250
MIDSECTION
the hole in the outer housing and the alignment

pin into the adapter housing.
STERN BRACKET,
40 – 60 HP Power Tilt
Stern Bracket Disassembly
Remove the bumpers from the upper mount
retaining screws. Remove the screws, upper
mount, and ground lead from the bracket.
1
1. Alignment pin 001980
Apply Gasket Sealing Compound to threads of the

four retaining screws and tighten to a torque of 60
to 84 in. lbs. (7 to 9.5 N·m).
17505
Pull the steering arm out of the swivel bracket.

1 1 Use an appropriate tool to pry the upper and lower
seals from the swivel bracket.
1. Adapter retaining screws 001981
COA2957
11
COA2958
251
MIDSECTION
To separate the swivel bracket from the stern Stern Bracket Assembly
bracket, remove one tilt tube nut.
Assemble the tie bar to the stern brackets. Place
the ground lead and starwasher between the port
stern bracket and tie bar.
17544
Remove the tie bar to separate the two stern 17540

brackets.
Lubricate the swivel bracket bushings with Triple-
Guard grease. Place the bushings in the swivel
bracket.
Position the swivel bracket between the stern

brackets. Place a thrust washer between each of
the stern brackets and the swivel bracket.
17541
Check the condition of the anode. Replace the

anode if it has been reduced to two-thirds its origi-
nal size.
17553
17551
17552
252
MIDSECTION
Install the tilt tube. Tighten the tilt tube nuts 40 to

45 ft. lbs. (54 to 61 N·m), then back off 1/8 to 1/4
STERN BRACKET,
turn. 75 – 90 HP Power Tilt
Apply Nut Lock to threads of the upper mount to
steering arm screws. Install the mount and tighten
the screws 24 to 26 ft. lbs. (32.5 to 35 N·m). Make Before servicing the stern bracket:
sure to place the ground lead under the starboard • Remove gearcase. Refer to GEARCASE
screw. REMOVAL AND INSTALLATION on p. 296.
• Remove powerhead. Refer to POWERHEAD
REMOVAL on p. 190.
• Remove exhaust housing. Refer to Exhaust
Housing Removal on p. 246.
• Remove power trim/tilt unit. Refer to TRIM AND
TILT REPLACEMENT on p. 352.
Remove and discard steering shaft locknut.
17506
Apply a liberal amount of Adhesive 847 to heads

of the upper mount screws.
30738
Remove the lower mount bracket and keeper.
17507
Place the bumpers on the upper mount screws.

11
Lower mount bracket – 20” Models 30736
17509
253
MIDSECTION
Remove the steering shaft and thrust washer. It Remove the anode.
may be necessary to tap the steering shaft out
using a wood dowel and mallet.
1. Anode 30762
30735 Remove the swivel bracket. Inspect and, if neces-

sary, replace the tilt tube bushings.
Pry out upper and lower steering shaft seals and
discard. Remove the upper and lower steering
shaft bushings.
1. Tilt tube bushing 30761
30765 / 30764
Remove the trim sender unit from the port stern
bracket and pull its wires through the braided
Remove the tilt tube. Refer to TILT TUBE, 75 – 90
tube.
HP on p. 241.
Remove the two tilt tube washers.
30760
30763
254
MIDSECTION
Remove the tilt limit switch and retainer from the Remove the two trim rod rollers from the swivel
swivel bracket. bracket.
1. Tilt limit switch 30758 1. Trim rod roller 30754

2. Retainer
Remove the tilt support and bushing from the

Disconnect the trail lock spring and remove it from swivel bracket and inspect the detent roller and
the swivel bracket. Remove trail arm retainer. spring.
1
2
1
1. Trail lock spring 30756

1. Tilt support bushing 30753
2. Trail arm retainer
Remove the trail lock arm and bushings from the

swivel bracket.
11
1
1. Trail lock bushing 30755
255
MIDSECTION
Stern Bracket Assembly Install the two trim rod rollers on the swivel
bracket. Tighten to a torque of 216 to 240 in. lbs.
IMPORTANT: Before proceeding, make sure all (25 to 27 N·m).
components have been thoroughly cleaned.
Replace any seals that have been removed.
Inspect all thrust washers and bushings for evi-
dence of deterioration.
Install the detent roller and spring and the tilt sup-
port with bushing in the swivel bracket. Tighten
bushing to a torque of 28 to 30 ft. lbs. (38 to 41 1
N·m).
1. Trim rod roller 30754
Install the trail lock and bushings in the swivel

bracket. Tighten to a torque of 216 to 240 in. lbs.
(25 to 27 N·m).
30752
1. Trail lock bushing 30755
Install the trail lock spring in the swivel bracket

1. Tilt support bushing 30753 and connect the spring to the trail lock.
2
1
1. Trail lock spring 30756

2. Trail arm retainer
256
MIDSECTION
Install the tilt limit switch and retainer on the swivel • Coat the bushings and seal lips with Triple-
bracket. Tighten screws to a torque of 40 to 50 in. Guard grease.
lbs. (4.5 to 5.5 N·m).
2 30765 / 30764
Coat tilt tube bushings with Triple-Guard grease

1. Tilt limit switch 30758
2. Retainer and, if removed, install them in the swivel bracket.
Route the trim sender wires through the braided

tube, and install the sender unit in the port stern
bracket.
30761
Place the swivel bracket between the stern brack-

ets and install the anode.
30760
Install the tilt tube and tilt limit cam. Refer to TILT
TUBE, 75 – 90 HP on p. 241.
Install the upper and lower steering shaft bushings
and new seals in the swivel bracket. Both seal lips Install the steering shaft and thrust washer.
face out.
• Coat the outside surfaces of seals with Gasket
Sealing Compound. 11
30735
257
MIDSECTION
Install the steering shaft keeper. Apply Locquic

Primer and Nut Lock to the splines of the steering
STERN BRACKET,
shaft and lower mount bracket. 40 – 60 HP Manual Tilt
Clamp Screw Service
Inspect clamp screw assemblies). Replace swivel
plate and retainer if bent or loose. To install a new
swivel plate, remove screw and old plate. Apply
Locquic Primer to the threads of the screw and
allow it to dry four to five minutes. Then apply
Ultra Lock to threads. Install a new swivel plate
with screw and tighten securely.

Remove bumpers from the upper mount retaining
screws.
30736
Install the lower mount bracket and a new locking 1

nut with its unstaked side facing the mount
bracket. Align the bracket with the steering arm
and tighten the nut to a torque of 130 to 150 ft. lbs.
(176 to 204 N·m).
1. Bumpers COA2949
Remove screws, upper mount, and ground lead

from the bracket.
30767 2
Fill the swivel bracket with Triple-Guard grease

through the grease fitting on the bracket’s port 3
side. Lubricate the tilt tube, swivel bracket, and
stern brackets through the two forward grease fit-
tings.
1. Screws COA2950
Install the exhaust housing. Refer to Exhaust 2. Upper mount
Housing Installation on p. 247. 3. Ground lead
258
MIDSECTION
Slide the pivot shaft and upper thrust washer out Loosen the steering friction screw while pushing
of the swivel bracket. outward on the steering friction pin. When the pin
is flush with the inside surface of the casting,
remove the steering friction thrust ring.
1. Upper thrust washer COA2956
Use an appropriate tool to pry the upper and lower

1. Steering friction screw COA2959
seals from the swivel bracket.
COA2957 1. Steering friction pin COA2988

2. Steering friction thrust ring
Tighten the steering friction screw until the steer-

ing friction pin can be removed. Then, remove the
steering friction screw.
Remove the two setscrews from the swivel

bracket.
11
COA2958
1. Setscrews COA2961
259
MIDSECTION
Drive the steering friction bushing up and out of Remove the two stern bracket flange screws and
the swivel bracket. separate the stern brackets from the swivel
bracket.
COA2974
1. Flange screws COA2992
Remove the thrust rod from the stern brackets.
Remove one tilt tube nut, and remove tilt tube Place the tilt/run lever in the RUN position.
from the stern brackets and swivel bracket. Loosen the bellcrank setscrew.
Remove the port and starboard stop link screws
and nuts from the stern brackets.
2
3
1. Bellcrank setscrew COA2976
1. Thrust rod COA2991R Remove the tilt/run lever, port stop link, and bush-
2. Tilt tube nut ing from the swivel bracket.
3. Stop link screw and nut
3
2
1. Tilt/run lever 002204

2. Port stop link
3. Bushing
260
MIDSECTION
Remove the starboard stop link retaining screw Stern Bracket Assembly
and nut from the swivel bracket.
Place the reverse lock springs in the swivel
bracket. Insert the reverse lock pins in the swivel
1 bracket and part way through the reverse lock
springs. Place the reverse lock assembly between
the springs. Push the pins through the springs and
the reverse lock assembly.
1. Starboard stop link screw 002205
Remove the cotter pins from both reverse lock

pins. Remove the reverse lock pins and springs. 2
1. Reverse lock springs COA2981

1 2. Reverse lock pins
Install the washers on the reverse lock pins. Install

the link spring on the port pin. Install the two cotter
pins in the reverse lock pins.
1. Cotter pin COA2979

2. Reverse lock pin
Remove the reverse lock assembly from the 1

swivel bracket.
1. Washers COA2982
11
COA2980
1. Link spring COA2979
261
MIDSECTION
Install the bushing, the port stop link, and the Place the swivel bracket between the stern brack-
tilt/run lever in the swivel bracket. The tilt/run lever ets.
should be in the RUN position.
Install the tilt tube through the following parts and
install the tilt tube nuts loosely:
3 • Starboard stern bracket
• Thrust washer
• Bushing
• Swivel bracket
1 • Bushing
2 • Thrust washer
• Port stern bracket
Apply Nut Lock to threads of the two flange
screws. Install the two screws through the star-
1. Tilt/run lever 002204
2. Port stop link
board stern bracket flange into the port stern
3. Bushing bracket flange. Tighten the screws to a torque of
144 to 168 in. lbs. (16 to 19 N·m).
Install the wave washer and the bellcrank on the
tilt/run shaft. Tighten the setscrew. Tighten the tilt tube nuts to a torque of 45 to 50 ft.
lbs. (61 to 68 N·m).
1 2
1 1
1. Bellcrank setscrew COA2976

1. Tilt tube nuts 002206
2. Flange screws
Install the starboard stop link on the swivel
bracket. Install and tighten the screw and the nut
Install the thrust rod in the stern brackets.
to a torque of 144 to 168 in. lbs. (16 to 19 N·m).
Install the larger shoulder screw through the port
stop link, wave washer, and port stern bracket.
1
1. Starboard stop link screw 002205
262
MIDSECTION
Install and tighten the nut to a torque of 144 to 168 Place the steering friction bushing in the swivel
in. lbs. (16 to 19 N·m). bracket with groove in line with the setscrews.
1 2
1. Port stop link screw COA2984 COA2986

2. Wave washer
Apply Triple-Guard grease to the steering friction

Install the smaller shoulder screw through the pin. Install the pin in the swivel bracket flush with
starboard stop link and stern bracket. Install and inside surface. The pin should point up.
tighten the nut to a torque of 144 to 168 in. lbs. (16
to 19 N·m).
Apply Ultra Lock to threads of large setscrews. 1
Install the screws in the swivel bracket so that one
thread remains outside the casting.
1. Steering friction pin COA2988

1
Install the steering friction thrust ring, bevel side
up, in the swivel bracket. Thread the steering fric-
tion screw in the swivel bracket. Turn the screw
until the steering friction pin makes contact with
1. Setscrews COA2961
top of the thrust ring. Do not tighten the screw.
11
1. Steering friction thrust ring COA2987
263
MIDSECTION
Install new upper and lower seals in the swivel Tilt Assist Cylinder
bracket with lips of seals facing away from the
The tilt assist cylinder can be replaced without dis-
bracket.
assembly of the stern brackets.
Slide the upper thrust washer on the pivot shaft.
Slide the pivot shaft through the swivel bracket. WARNING
Support the outboard with a suitable hoist.
Remove port stop link screw. Push port stop link

1 down to clear upper pivot pin access hole.
1. Upper thrust washer COA2956
Lubricate the swivel bracket through the four lubri-

cation fittings with Triple-Guard grease.
Apply Nut Lock to threads of the upper mount to 1. Stop link screw 006651
steering arm screws. Position the upper rubber
mount, the upper mount washers, and the retain- Remove both cotter pins and washers. Use appro-
ing washers on the steering arm with the word priate tool to remove upper pivot pin.
“UP” on the mount facing up. Be sure to place the
ground lead between the mount (starboard side)
and the steering arm. Install and tighten the mount 1 1
retaining screws to a torque of 24 to 26 ft. lbs.
(32.5 to 35 N·m). 2 2
3
5 1
3 4 4
2
5
3
1. Bushings 003939
2. Washers
4 3. Pivot pin
4. Cotter pins
The starboard stern bracket includes an access

1. Upper mount COA2950 hole for the lower tilt pin.
2. Upper mount washers
3. Retaining washers
4. Ground lead
5. Retaining screws
Place the mount screw bumpers on the upper

mount screws.
264
MIDSECTION
Remove set screw from starboard stern bracket

lower pivot pin access hole and use an appropri-
STERN BRACKET,
ate tool to remove lower pivot pin. 90 HP Manual Tilt
Loosen set screw and remove reverse lock
1 release collar.
1. Lower pivot pin access hole 004260
If lower pivot cannot be removed because of cor- 1

rosion or damage, stern brackets may need to be
disassembled.
1. Set screw 006697
2. Reverse lock release collar
Remove reverse lock springs from locking lever

and reverse lock spring screws.
003940
Assembly is the reverse of disassembly. Install 1 2

new cotter pins in upper pivot pin. Install a new
set screw in starboard stern bracket lower pivot 1. Reverse lock springs 006700
pin access hole and tighten securely. 2. Reverse lock spring screws
11
265
MIDSECTION
Remove cotter pins, pins and locking lever. Remove port reverse lock link.
1
1
1. Pins 006699 1. Port reverse lock link 006695

2. Locking lever
Loosen bellcrank set screw, remove bellcrank and

Remove starboard reverse lock link. handle link rod.
1
1
1. Starboard reverse lock link 006696 1. Bellcrank set screw 006694

2. Handle link rod
266
MIDSECTION
Remove retaining ring and bellcrank shaft spacer Remove port trail lock lever and trail lock shaft as
from reverse lock pivot shaft. an assembly.
1
1
1. Retaining ring 006693 1. Port trail lock lever and shaft 006704
Remove screw from trail lock lever. Remove trail Remove port and starboard trail lock shaft bush-
lock lever and reverse lock pivot shaft from swivel ings from swivel bracket.
bracket.
1
1
1. Trail lock shaft bushings 006687
1. Trail lock lever 006692
2. Reverse lock pivot shaft
11
267
MIDSECTION
Stern Bracket Assembly Apply blue Nut Lock to screw and assemble port
trail lock lever on trail lock shaft with screw,
Reverse Lock and Trail Lock Reference washer and nylon washer. Install in swivel bracket
from port side. DO NOT tighten screw at this time.
1. Port trail lock lever and shaft 006704
Refer to Reverse Lock and Trail Lock Refer-

ence on p. 268 for correct orientation of reverse
lock and trail lock components.
Assemble reverse lock pivot shaft, reverse lock

lever rod and bellcrank shaft spacer as shown.
1. Component reference view 2 006686
Place port and starboard trail lock shaft bushings

in the swivel bracket.
3 2
1
1. Reverse lock pivot shaft 006690
2. Reverse lock lever rod
3. Bellcrank shaft spacer
1. Trail lock shaft bushings (port side shown) 006687
268
MIDSECTION
Assemble starboard trail lock lever and trail lock Install remaining bellcrank shaft spacer on reverse
spring to reverse lock pivot shaft. lock pivot shaft, then install retaining ring.
3 1
1
2
1. Trail lock lever 006691 1. Retaining ring 006693

2. Trail lock spring
3. Reverse lock pivot shaft and rod
Install the handle link rod to reverse lock lever and
Install nylon washer on trail lock shaft and install bellcrank. Install bellcrank on reverse lock pivot
above components into swivel bracket. Install trail shaft. Tighten the setscrew.
lock washer, apply blue Nut Lock to screw and 1
install screw. Tighten both screws to a torque of
60 to 84 in. lbs. (7 to 9.5 N·m). 2
1. Handle link rod 006694

2 2. Reverse lock lever
3. Bellcrank setscrew
1. Reverse lock pivot shaft 006692 Install the port reverse lock link on the swivel
2. Trail lock lever bracket. Install washer screw. Apply blue Nut Lock
to screw threads and install washer and screw.
11
269
MIDSECTION
Tighten screw to a torque of 60 to 84 in. lbs. (7 to Install reverse lock release collar and tighten set
9.54 N·m). screw.
1. Port reverse lock link 006695 1. Reverse lock release collar 006697
2. Set screw
Place reverse lock lever rod through hole at top of

starboard reverse lock lever. Install the starboard Install locking lever, pins and new cotter pins.
reverse lock link on the swivel bracket. Apply blue 2
Nut Lock to screw threads and install washer and
screw. Tighten screw to a torque of 60 to 84 in.
lbs. (7 to 9.5 N·m).
1 1
1. Locking lever 006699

2. Pins
Install reverse lock springs on locking lever and

reverse lock spring screws.
1. Reverse lock lever rod 006696
2. Starboard reverse lock link
1 2
1. Reverse lock springs 006700

2. Reverse lock spring screws
270
MIDSECTION
TILLER HANDLE SERVICE – STANDARD
TILLER HANDLE Remove the electrical cover.
SERVICE – Standard
Removal 1
WARNING
To avoid accidental starting of engine
while servicing, twist and remove all spark
plug leads.
Use Ball Socket Remover tool, P/N 342226, to

unsnap the throttle cable clip from the throttle
lever. Disconnect the electrical harness coming from the
tiller handle.
1. Remover tool 005121
1. Electrical harness connector 002511

Remove the throttle cable anchor screw and
washer. Loosen throttle cable retainer screw. And, Remove throttle cable and wires from grommet in
remove the tie strap holding the tiller handle elec- lower engine cover.
trical harness.
Remove the screw attaching steering handle.
Remove handle.
1 4
2
3 11
1
1. Cable anchor screw and washer 002207

2. Cable retainer screw
3. Clip
4. Tie strap 1. Screw 31194
271
MIDSECTION
Disassembly Pull the throttle pin out of the cable.

Loosen throttle friction control so there is no
restriction on grip.
IMPORTANT: Do not back screw out com-

pletely. Nut is under spring tension.
1
24294
Remove stop switch cover screws and cover/stop

switch assembly.
1. Throttle friction control 001259
Use Twist-Grip Remover, P/N 390767, to depress

the grip detents. Tighten screw and remove the
grip by pulling grip.
1
24288
2
Remove the throttle control plate.
1
1. Twist-Grip Remover 002189
2. Screw
Remove the helix halves, rollers, and guides.
1. Throttle control plate 24287
1 2 3 2 1
1. Helix halves COA2674
2. Rollers
3. Guides
272
MIDSECTION
Remove the throttle cable retaining clip. Pry the outer handle. After removing, chip away remnants
cable trunnion out of the steering handle and of inner handle.
remove cable.
2 1
24284
1. Retaining clip 24286 Remove throttle cable seal from the inner handle.
2. Cable trunnion
IMPORTANT: DO NOT remove the inner handle

Inspection
except to replace it. Inspect the throttle cable for kinks and wear.
Replace if necessary.
Use a punch and mallet to drive out the steel pin
holding the inner handle into the steering handle. Inspect the steering handle components for wear,
cracks, or damage. Replace parts if necessary.
Assembly
Install the throttle cable seal in inner handle.
If removed, apply Loctite Depend 300 adhesive to

inner handle at areas shown.
0.5 in.
(12 mm)
24285
Remove the plastic inner handle from the metal

outer handle by driving the outer handle off with a
mallet and a punch. Inner handle is bonded to the
11
20849
273
MIDSECTION
Install the metal outer handle over the plastic inner Install the throttle control plate on outer handle.
handle and drive the outer handle into place.
1
1. Throttle control plate 24295
31202 Push the throttle cable pin through the end of the
throttle cable.
Secure tab of the inner handle into recess of the
outer handle with the steel pin.
24294
24285
Lubricate end of the pin, guides, rollers, helix
Install the handle end of the throttle cable. Snap grooves, and inner handle guide slot with Moly
the throttle cable trunnion into the recess in the Lube. Place the guides over the roller pin and into
handle. Install the retainer clip. the slots of the inner handle. Place the rollers on
the ends of the roller pin. Assemble the helix
halves on the handle and slide the grip over the
helix.
24293
1. Throttle cable trunnion 24282
2. Retainer clip 24286
274
MIDSECTION
Be sure the twist-grip's speed indicator line is Installation

positioned with the speed range symbol on the
Apply Triple-Guard grease to the two steering
handle. Snap the grip into place.
handle bushings. Place the bushings into the
steering bracket. Attach the steering handle to the
bracket. Tighten screw to a torque of 36 to 40 ft.
lbs. (49 to 54 N·m).
CAUTION
1 The steering handle nut must have a nylon
patch for locking. Replace the nut if it has
lost its locking feature. Tighten the nut so
the steering handle can be pivoted and
1. Indicator line 002190
maintained in any position.
Slide the protective sleeve over the stop switch
leads and throttle cable and install stop switch
cover.
1. Screw 31194
24291
Route throttle cable and electrical harness
through grommet in lower motor cover. Connect
harness to engine wiring harness.
1
11
24288
1. Electrical harness connector 002511
275
MIDSECTION
Install electrical cover. Secure electrical harness with tie strap.
4
1 1
2
1. Electrical cover 002509 1. Cable anchor 006526

2. Boss
3. Cable retainer
Throttle Cable Adjustment 4. Tie strap
Place throttle cable in position. Use Ball Socket

Installer tool, P/N 342225, to snap throttle cable
connector onto throttle lever.
1
1
1. Throttle lever stop 005114
1. Installer tool 005106

1
Place throttle cable in upper anchor pocket. Install
cable retainer on anchor block.
Hold twist grip in full SLOW position. Pull firmly on 1. Turn anchor four turns toward cable end. 006564
cable to remove backlash.
Adjust cable anchor so throttle cam is against idle IMPORTANT: Rotate twist grip. Make sure throt-
stop when anchor screw aligns with throttle body tle cam goes to full throttle without bending cable,
boss. Then, rotate anchor four turns toward the and still returns to IDLE stop.
end of the cable.
Install washer, cable anchor, and cable anchor
screw on throttle body boss. Tighten screw
securely.
276
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
TILLER HANDLE Remove the electrical cover.
SERVICE – Long Handle

Removal 1
WARNING
To avoid accidental starting of engine
while servicing, twist and remove all spark
plug leads.
Use Ball Socket Remover tool, P/N 342226, to

unsnap the throttle cable clip from the throttle
lever. Disconnect the electrical harness coming from the
.
tiller handle.
1. Remover tool 005121
Rope Start models 002511

Remove the throttle cable anchor screw and 1. Electrical harness connector
washer. Loosen throttle cable retainer screw. And,
remove the tie strap holding the tiller handle elec-
trical harness.
Remove retainer clip from shift cable.
1
4
1 11
2 3
Tiller Electric models 001999
1. Electrical harness connectors
Remove shift and throttle cables and wire harness

from grommet in lower engine cover.
1. Throttle cable anchor 006745
2. Shift cable retainer clip
3. Cable retainer
4. Tie strap
277
MIDSECTION
Remove locknuts from screws on top of steering Disassembly

arm.
Loosen throttle friction control so there is no
1 restriction on grip.
IMPORTANT: Do not back screw out com-

pletely. Nut is under spring tension.
1
1. Screw 006362
Remove the screws attaching tiller bracket to

steering arm. Remove tiller bracket and handle.
Remove seven screws and bottom cover of tiller

handle.
1
1
1. Screw 006361
1. Cover screw 006566
Remove stop switch cover screws, unplug stop

switch electrical connector and remove stop
switch assembly.
006713
278
MIDSECTION
Disconnect trim switch connector. Remove con- Remove the throttle friction control.
nector from trim switch wires. Refer to CONNEC-
TOR SERVICING on p. 116. 1
Use Twist-Grip Remover, P/N 390767, to depress

the grip detents. Tighten screw and remove the
grip by pulling grip.
1

2
Remove the throttle cable retaining clip. Pry the
cable trunnion out of the steering handle and
remove cable.
1. Twist-Grip Remover 006710 1
2. Screw
Remove the helix halves, rollers, and guides.
1. Retainer 006674
2. Throttle cable trunnion
1 2 3 2 1 The trim switch wiring can now be removed from

1. Helix halves COA2674 the inner handle.
2. Rollers
3. Guides Remove the screw and washer retaining the inner
handle tab.
Pull the throttle pin out of the cable.
11
006681
006712
279
MIDSECTION
Use an appropriate tool to carefully pry up on the Remove cotter pin from shift handle pin. Remove
inner handle retaining tab. shift cable.
1
1
1. Inner handle retainer tab 006679 1. Cotter pin 006708
Use a wooden dowel and a soft mallet to remove Remove shift handle screw and washer. Remove
the inner handle. shift handle, bushing and washer.
1
006678 1. Shift handle screw 006714
Remove shift cable retainer from shift cable trun- Remove shift handle detent ball, spring and guide.
nion.
1
1
1. Detent ball, spring and guide 006715

1. Shift cable retainer 006721
280
MIDSECTION
Remove the shift pin if necessary. Coat detent ball, spring and guide with Triple-
Guard grease and install into shift handle. Place
1 one washer on shift handle mounting boss.
1
1. Shift pin 006716
Inspection 1. Detent ball, spring and guide

2. Washer
006715
Inspect the throttle cable for kinks and wear.

Replace if necessary. Coat bushing and washer with Triple-Guard
Inspect the shift cable for kinks and wear. Replace grease. Apply Nut Lock to threads of screw.
if necessary.
1
Inspect the steering handle components for wear,
cracks, or damage. Replace parts if necessary. 2
Assembly 3
Apply Nut Lock to threads of shift pin and install
shift pin into shift handle. Tighten to a torque of 18
to 22 ft. lbs. (24.5 to 29 N·m).
1
1. Bushing 006717
2. Washer
3. Screw
Install shift handle on tiller handle and tighten

screw to a torque of 18 to 20 ft. lbs. (24.5 to 27
N·m).
1 11
1. Detent ball, spring and guide 006716
1. Shift handle screw 006714
281
MIDSECTION
Install shift cable on shift pin with a new cotter pin. Secure tab of the inner handle into the outer han-
dle. Tab must be flush with the back of the flange
1 and top of tab must be flush with top of flange.
1. Cotter pin 006720
Install shift cable retainer on shift cable trunnion. 1. Back of flange 006682
1 Apply Nut Lock on the screw threads, install the

washer and screw.
IMPORTANT: Turn self-tapping screw counter-

clock-wise until threads of screw engage threads
of screw boss. Failure to follow this procedure will
damage the screw boss threads. Once threads
are engaged, tighten screw so that there is no
space between tab, washer and screw. Top of tab
MUST be flush with top of flange.
1. Shift cable retainer 006721
Use a soft-faced mallet to install the inner handle.
006681
006680
282
MIDSECTION
Install the throttle control plate on outer handle. ing. If wire guide is forced into place, it WILL dam-
age trim switch wiring.
1
1 2
1. Throttle friction control 006671 3

1. Inner tiller handle 006684
Install trim switch wiring through inner steering 2. Wire guide
3. Trim switch wires
handle.
IMPORTANT: Trim switch wiring must NOT be Make sure trim switch wiring is NOT twisted
twisted through the throttle twist grip or inner tiller before proceeding.
handle / wire guide. 1
Insert wire guide into inner steering handle.
2
1 2

2. Wire guide
3
2. Wire guide
Wire guide should slide easily into place. If any

binding is felt, inspect trim switch wiring for twist- 11
283
MIDSECTION
Install the handle end of the throttle cable. Snap Place the guides over the roller pin and into the
the throttle cable trunnion into the recess in the slots of the inner handle. Place the rollers on the
handle. Install the retainer clip. ends of the roller pin.
1 1
1. Throttle cable trunnion 006683 1. Roller 006670

2. Retainer
Assemble the helix halves on the handle and slide

Push the throttle cable pin through the end of the the grip over the helix.
throttle cable.
1
006718
1. Pin 006712
Carefully pull trim switch wires through inner tiller

Lubricate end of the pin, guides, rollers, helix handle as twist grip assembly is installed.
halves, and inner handle guide slot with Moly
Lube. 1
1 2 3 2 1 1. Trim switch wiring 006677
1. Helix halves COA2674 Install trim switch connector. Refer to CONNEC-

2. Rollers
3. Guides TOR SERVICING on p. 116.
284
MIDSECTION
Be sure the twist-grip's speed indicator line is Installation

positioned with the speed range symbol on the
The steering arm can be positioned straight, or
handle. Snap the grip into place.
angled 15° port or starboard by moving the adjust-
1 ment plate.
1. Plate adjustment for tiller in CENTER position. 005083
1. Indicator line 006719

Place tiller bracket on steering arm from the bot-
Install stop switch assembly and connect to har- tom. Thread steering arm screws, with washers,
ness. into steering arm and tighten to a torque of 18 to
20 ft.lbs. (24.5 to 27 N·m).
1
006713
1. Screw 006361
Install bottom cover of tiller handle with seven

screws. Install locknuts on screws on top of steering arm.
Hold screws with wrench and tighten locknuts to a
1 torque of 18 to 20 ft.lbs. (24.5 to 27 N·m).
1
11
1. Cover screw 006566
1. Screw 006362
285
MIDSECTION
Route shift and throttle cables and electrical har- Control Cable Installation
ness through grommet in lower motor cover. Con-
nect harness to engine wiring harness. IMPORTANT: DO NOT complete final attach-
ment of cables to shift and throttle levers until all
cables, wires, and hoses have been routed and
grommet has been placed into the lower engine
cover.
1 Shift Cable Adjustment

Pull firmly on shift cable casing to remove back-
lash. With outboard and tiller handle shift lever in
NEUTRAL, place the cable trunnion into the lower
anchor pocket. Adjust the trunnion nut so the cas-
ing fits onto the shift lever pin.
Rope Start models 002511
1. Electrical harness connector
2
1 1
1. Shift lever pin 002100

2. Trunnion nut
Tiller Electric models 001999

1. Electrical harness connectors Secure shift cable to the shift lever pin. For proper
installation, review the following steps:
Use tie strap to secure harness to throttle body • Place washer on pin.
bracket. • Position retainer clip with straight section on the
bottom and angled section on the top.
• Use long nose pliers to insert straight section of
clip into linkage pin hole.
1 • Push the clip towards the hole while lifting on
the curved end with the pliers.
• Be sure retainer clip fully engages the pin.
• Lock the retainer by moving the angled section
behind the straight section.
1. Bracket 006314
1
Locked Retainer Clip DP0817a

1. Angled section behind straight section
286
MIDSECTION
Throttle Cable Adjustment Install washer, cable anchor, and cable anchor
Place throttle cable in position. Use Ball Socket screw on throttle body boss. Tighten screw
Installer tool, P/N 342225, to snap throttle cable securely.
connector onto throttle lever.
4
1
1 2
1. Cable anchor 006745

2. Boss
1. Installer tool 005106 3. Cable retainer
4. Tie strap
Place throttle cable in upper anchor pocket. Install
cable retainer on anchor block.
Hold twist grip in full SLOW position. Pull firmly on
cable to remove backlash.
Adjust cable anchor so throttle cam is against idle 1
stop when anchor screw aligns with throttle body
boss. Then, rotate anchor four turns toward the
end of the cable.
1. Throttle lever stop 005114
1. Turn anchor four turns toward cable end. 006564

11
IMPORTANT: Rotate twist grip. Make sure throt-
tle cam goes to full throttle without bending cable,
and still returns to IDLE stop.
287
MIDSECTION
NOTES
NOTES
Bulletins
Instruction Sheets
Other
288
GEARCASE
GEARCASE
TABLE OF CONTENTS
SERVICE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
GEARCASE TYPES, 75 – 90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
PROPELLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
GEARCASE LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
SHIFT ROD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
PRE-DISASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
PROPELLER SHAFT BEARING HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
PINION GEAR AND DRIVESHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
SHIFT HOUSING, GEAR AND PROPELLER SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
SHIFTER, BEARING AND SEAL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
DRIVESHAFT SHIMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
SHIFT HOUSING, GEAR, AND PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
SHIFT ROD HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
PINION GEAR AND DRIVESHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
FINAL ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
GEARCASE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
SHIFT ROD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
PRE-DISASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
PROPELLER SHAFT BEARING HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
PINION GEAR AND DRIVESHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
DRIVESHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
SHIFT HOUSING, GEAR AND PROPELLER SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
WATER INTAKE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
GEARCASE HOUSING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
SHIFTER, BEARING AND SEAL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
DRIVESHAFT SHIMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 12
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
WATER INTAKE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
SHIFT HOUSING, GEAR, AND PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
SHIFT ROD HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
PINION GEAR AND DRIVESHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
FINAL ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
289
GEARCASE
SERVICE CHARTS
SERVICE CHARTS
40 – 65 HP
B 60-84 In. lbs. A

(7-9.5 N·m)
96-120 In. lbs.
C (11-13.5 N·m)
B
C
A
D
B B
60-84 In. lbs.
A (7-9.5 N·m)
B
A
A
C
10-12 Ft. lbs.
(13.5-16 N·m) A
A 28-30 Ft. lbs.
(38-40 N·m)
X A 60-84 In. lbs.
18-20 Ft. lbs.
(24.5-27 N·m) (7-9.5 N·m) A
G 18-20 Ft. lbs.
(24.5-27 N·m)
F
48-80 In. lbs.
J (5.5-9 N·m)
40-45 Ft. lbs.
(54-60 N·m)
B
A 35-40 Ft. lbs.
(47-54 N·m)
60-84 In. lbs.

(7-9.5 N·m)
B B 120-140 In. lbs.

(13.5-16 N·m)
A G
B
B
108-132 In. lbs.

120-144 In. lbs. (12-15 N·m)
(13.5-16.5 N·m)
A B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
H Gearcase Lubricant
006482 X see Service Manual
290
GEARCASE
SERVICE CHARTS
“S”–TYPE GEARCASE
24-36 In. lbs.

C
(3-4 N·m)
B
B B
60-84 In. lbs.
(7-9.5 N·m) 120-144 In. lbs. A
(13.5-16.5 N·m)
D B
A B60-84 In. lbs.

(7-9.5 N·m)
C A B
B
F 18-20 Ft. Lbs.
(24-27 N·m)
A
A 26-28 Ft. lbs.
(35-38 N·m) A
C A 45-50 Ft. lbs.
(61-68 N·m)
B
X
A A 60-84 In. lbs.
18-20 Ft. lbs. 60-84 In. lbs. (7-9.5 N·m)
G (24-27 N·m) (7-9.5 N·m)
26-28 Ft. lbs.
(35-38 N·m)
14-18 In. lbs.
(1.5-2 N·m)
J
100-110 Ft. lbs.
(136-149 N·m)
B 60-84 In. lbs.
35-40 Ft. lbs. (7-9.5 N·m)
A (47-54 N·m)
E 18-20 Ft. lbs.

(24-27 N·m)
B G
A B
B
120-144 In. lbs.

108-132 In. lbs.
(13.5-16.5 N·m)
(12-15 N·m) A
B
Triple-Guard Grease
Gasket Sealing Compound
12
C Adhesive 847
D Moly Lube
A E Red Ultra Lock
F Blue Nut Lock
291
GEARCASE
SERVICE CHARTS
“O”–TYPE GEARCASE – STANDARD ROTATION
C B
24-36 In. lbs.
(3-4 N·m) B B
60-84 In. lbs.
(7-9.5 N·m) 120-144 In. lbs.
A
(13.5-16.5 N·m)
D B
A B
60-84 In. lbs.
(7-9.5 N·m)
C A
B B
F 18-20 Ft. Lbs.

(24-27 N·m)
A
A
26-28 Ft. lbs.
C (35-38 N·m) A
A 45-50 Ft. lbs.
(61-68 N·m)
X
A B
G 18-20 Ft. lbs.
60-84 In. lbs.
(24-27 N·m)
A (7-9.5 N·m)
60-84 In. lbs. 26-28 Ft. lbs.
(7-9.5 N·m) (35-38 N·m)
J 14-18 In. lbs.
100-110 Ft. lbs.
(1.5-2 N·m)
(136-149 N·m)
A
B 60-84 In. lbs.
35-40 Ft. lbs. (7-9.5 N·m)
(47-54 N·m)
B E 18-20 Ft. lbs.

(24-27 N·m) G
A B
B
E
15-20 In. lbs.
(1.7-2.3 N·m)
B
108-132 In. lbs.

70-80 Ft. lbs. (12-15 N·m)
(95-109 N·m)
C Adhesive 847
A D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
292
GEARCASE
GEARCASE TYPES, 75 – 90 HP
GEARCASE TYPES, 75 – 90 HP
Gearcase General Service Procedure
Outboard Model Type Comparison Comparison
(L) Models with Unique housing, shafts,
“S”
20 in. shaft gears, and bearings
Similar
(X) Models with Unique housing, shafts,
“O”
25 in. shaft gears, and bearings
PROPELLER SERVICE Propeller Selection

Inspection CAUTION
Carefully examine propeller and outboard for the Selection of the wrong propeller could
following: reduce engine service life, affect boat per-
• Damaged blades and signs of propeller cavita- formance, or cause serious damage to the
tion (burned paint, etc.) powerhead.
• Spun or overheated inner hub
• Worn or twisted splines and inadequate lubri- 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 correct propeller, under normal load condi-
• 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 operating range at full throttle.
spacer Refer to SERVICE SPECIFICATIONS on p. 10.
• Correct size and style Operating Range
• Check for bent or damaged propeller shaft and Peak HP
twisted splines.
H 100%
o 90%
Refer to Propeller Hardware Installation on r
p. 294. s 80%
e 70%
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 disconnect the battery 2000 3000 4000 5000 6000
positive (+) cable so the outboard cannot RPM
be started accidentally. 008329
NOTICE If the propeller blades have too

12
much pitch, the engine will operate below its
normal range at full throttle. Power will be lost,
and powerhead damage could occur. If the
propeller blades have too little pitch, the
engine will operate above its normal range and
damage from overspeeding could occur.
293
GEARCASE
PROPELLER SERVICE
When selecting a propeller, consider the following: Propeller Hardware Installation

• Use an accurate tachometer to determine the
engine’s full-throttle RPM. WARNING
• The outboard should be trimmed for top speed.
• Select a propeller that suits the customer’s To prevent accidental starting while servic-
application and allows the engine to run near ing, twist and remove all spark plug leads.
the midpoint of the full-throttle operating range
when the boat has a normal load. IMPORTANT: Depending on propeller style, dif-
• Occasionally, one propeller will not cover a wide
ferent thrust bushings, spacers, and cotter pin
range of boat applications — water skiing to
high speed performance boating. In such cases, keepers are used. See the Evinrude/Johnson
it might be necessary to have a propeller for Genuine Parts and Accessories Catalog for cor-
each situation. rect propeller hardware.
• Refer to the Evinrude/Johnson Genuine Parts
Apply Triple Guard grease to the entire propeller
and Accessories Catalog for propeller styles
and sizes. shaft before installing the propeller.
• Right-hand propellers are considered standard Install thrust bushing onto propeller shaft with
rotation propellers. When propelling a boat for- taper of bushing matching taper of shaft.
ward, the propeller rotates in a right-hand
(clockwise) direction as viewed from the rear. If installing a propeller with an interchangeable
• Left-hand propellers are considered counter- hub, assemble the propeller following instructions
rotation propellers. When propelling a boat 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 blade

and the anti-ventilation plate.
2 1
1. Right-hand rotation (clockwise) 000033
2. Left-hand rotation (counterclockwise)
WARNING
For dual-outboard installations, always 001992
check to be sure propellers are installed
on the correct engines before aggres- Install the propeller nut and tighten to a torque of:
sively operating the boat. • With Keeper – 70 to 80 ft. lbs. (95 to 109 N·m)
• Without Keeper – 120 to 144 in. lbs. (13.6 to
16.3 N·m)
294
GEARCASE
GEARCASE LEAK TEST
If cotter pin holes in the 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 plug and seal, thread
1 2 pressure test gauge fitting and 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 leakage, submerge

Aluminum or stainless steel
the gearcase in water to determine source of leak.
1 2 4 Large diameter hub
With keeper
70 to 80 ft. lbs If the gauge does not indicate leakage, 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 Gearcase Vacuum Tester, P/N 507982.
120 to 144 in. lbs Apply 3 to 5 in. of vacuum (76 to 127 mm) Hg.
with pump.
If vacuum gauge indicates leakage, apply oil

around suspected seal. If leak stops 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, gearcase must hold minimum of 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 002388
4. Keeper
IMPORTANT: After installation, make sure out- 12

board is in NEUTRAL and carefully spin propeller.
Propeller must turn freely and should not spin off
center. If propeller appears to wobble, check for
possible bent propeller shaft.
295
GEARCASE REMOVAL Remove the 5/16-18 x 1.25 in. screw and washer,
and remove 7/16-14 x 3.5 in. screw and washer.
AND INSTALLATION
Gearcase Removal
1
WARNING 2
vicing, twist and remove all spark plug
leads.
During service, the outboard may drop
unexpectedly. Avoid personal injury;
always support the outboard’s weight with 1. 5/16-18 x 1.25 in. screw 001995
2. 7/16-14 x 3.5 in. screw
a suitable hoist or the tilt support bracket
during service.
Remove the four 3/8-16 x 1.5 in. gearcase retain-
ing screws and washers.
1
1
1. Gearcase retaining screws 001994

Remove the gearcase assembly from the exhaust
Note where the index mark on the gearcase aligns housing, being careful not to bend the shift rod.
with the index number of the adjustable trim tab so
the trim tab can be installed in the same position.
Remove the trim tab retaining screw and trim tab
from the gearcase.
2
1. Trim tab 001996

2. Trim tab retaining screw
296
Gearcase Installation Slide the gearcase into place, making sure:

• Driveshaft engages the crankshaft.
WARNING • Inner exhaust housing installs correctly.
• Shift rod does not turn and is positioned prop-
erly in the shift rod lever below the crankcase.
always support the outboard’s weight with Apply Triple-Guard grease to threads of the gear-
a suitable hoist or the tilt support bracket case retaining screws. Tighten the screws to a
during service. torque of:
• 3/8 in. screws – 18 to 20 ft. lbs. (24 to 27 N·m)
NOTICE Before installing gearcase, shift rod • 7/16 in. screw – 28 to 30 ft. lbs. (38 to 40 N·m)
adjustment MUST be checked. Refer to SHIFT • 5/16 in. screw – 10 to 12 ft. lbs. (13.5 to 16 N·m)
Coat the driveshaft splines with Moly Lube. DO

NOT coat top surface of the driveshaft because
lubricant may prevent seating of the driveshaft in
the crankshaft.
1. 3/8 in. screws 001994
2
30385 1
Apply Adhesive 847 to the exhaust housing seal’s

outer surface. Place the seal in the gearcase
exhaust cavity. Apply Triple-Guard grease to the
seal’s inner surfaces.
1. 7/16 in. screw 001995
2. 5/16 in screw
1 Apply Triple-Guard grease to threads of the trim

tab screw. Install and align the trim tab with the
index marks noted prior to disassembly. Tighten 12
the trim tab screw to a torque of 35 to 40 ft. lbs.
1. Exhaust housing seal 008354
297
WATER PUMP SERVICE
(47 to 54 N·m). For adjustment, refer to Trim Tab

Adjustment on p. 31.
WATER PUMP SERVICE
1 Disassembly
Remove the four impeller housing screws.
1
1. Trim tab screw 001996
Place the shift rod in the shift rod lever. Install the
retaining pin and washer. Tighten pin to a torque 1. Impeller housing screws 001203
of 60 to 84 in. lbs. (7 to 9.5 N·m).

Slide the water pump off the driveshaft. Remove
the impeller key, impeller plate, and gasket. Dis-
card the gasket.
1
1
WARNING 1. Impeller plate 001214

2. Drive key
To prevent loss of operator control, check
for proper shifting operation and adjust, if Remove all the parts from the housing.
necessary.
Inspection
IMPORTANT: During break-in period of a reas- Check impeller for overheating, hub separation,
sembled gearcase, change the gearcase lubricant and other wear or damage.
between 10 to 20 hours of operation. Check liner and wear plate for scoring, distortion,
and impeller material transfer.
Inspect the housing for cracks or melting.
Make sure gasket surface is clean and smooth.
298
WATER PUMP SERVICE
Assembly Apply a thin bead of Adhesive 847 in the seal

groove, and install the special shaped O-ring seal.
Lightly coat the exterior rim of the impeller cup
with Gasket Sealing Compound. Install the cup in
the impeller housing. The cup locks in place in the
housing with a square index tab.
1
1. Impeller 001216
2. O-ring seal
Apply Gasket Sealing Compound to both sides of

1. Index tab 001215 a new impeller plate gasket. Install the gasket and
impeller plate.
IMPORTANT: Do not allow any sealer to get into
the air bleed groove in the impeller housing. If this Apply Triple-Guard grease to temporarily hold
groove is blocked by adhesive, the pump will lose drive key in place.
its prime and will not pump water.
3
1
1
1. Impeller plate gasket 001217

2. Impeller plate
1. Air bleed groove 006415 3. Drive key
Lightly coat the inside of the liner with Triple- The sharp edge of the key is the leading edge in
Guard grease. With a counterclockwise rotation, clockwise rotation.
install the impeller into the liner with the slot for the
impeller key facing out. Slide the water pump down the driveshaft. Align
impeller slot with the impeller key. Rotate the
driveshaft to engage the key with the impeller, and
12
299
SHIFT ROD ADJUSTMENT
slide water pump down over key. Be sure impeller

key does not fall out of position.
SHIFT ROD
ADJUSTMENT
Check the shift rod height from the shift rod hole to
2 the surface of the gearcase using Universal Shift
Rod Height Gauge, P/N 389997.
1. Sharp edge of drive key CO2995

2. Direction of driveshaft rotation
NOTICE Make sure the impeller engages the

impeller key. Serious powerhead damage will
result if impeller key is not in place.
Align the impeller housing with the gearcase.

Apply Gasket Sealing Compound to threads of the
four impeller housing screws. Install the screws COA6166
and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5
N·m). With the gearcase in NEUTRAL, rotate the shift
rod up or down as necessary for correct adjust-
Install the water tube grommet on the impeller ment. Once correct height is achieved, rotate rod
housing. one half turn or less to direct offset to the rear.
Apply a thin bead of Adhesive 847 to groove of Shift Rod Height:
the impeller housing grommet. Install the grommet • 21.38 in. (543 mm) ± One-Half Turn
on the impeller housing.
1. Housing screws 001203

2. Water tube grommet
3. Impeller housing grommet
NOTICE Before installing gearcase, shift rod

adjustment MUST be checked. Refer to SHIFT
300
GEARCASE DISASSEMBLY
GEARCASE • Hydrostatic Seal Grooves — Must be in good

condition to help prevent propeller ventilation.
DISASSEMBLY
Pre-Disassembly Inspection
1
WARNING
injury, and set compressed air pressure to
IMPORTANT: Clean and inspect all parts during

disassembly. Replace any damaged parts, seals,
1. Hydrostatic seal grooves 002217
O-rings, and gaskets.
Remove the propeller and mounting hardware. • Gearcase Anodes — If anodes have eroded to
two-thirds their original size, they must be
Drain and inspect oil as described in Gearcase replaced.
Lubricant on p. 39.
Remove gearcase. Refer to GEARCASE

Remove water pump. Refer to WATER PUMP 1

SERVICE on p. 298.
Before disassembling the gearcase, examine the
following:
• Gearcase Housing — Check for visible dam-
age to skeg, strut, anti-ventilation plate, bullet,
and mating surface. Check seal areas for visible 1. Gearcase anode 002014
signs of lubricant leakage.

• Propeller Shaft — Check for bent or damaged • Drive Shaft — Check splines for visible dam-
shaft. Check for twisted splines and damaged age, twisting and wear. Severe spline wear indi-
threads. cates the exhaust housing or gearcase has
• Shift Rod — Check for misadjusted, bent, or been distorted, possibly by impact damage.
binding rod. A misadjusted shift rod height can • Water Intake Screens — Check for damage
cause shift difficulty, loss of boat and outboard and blockage. If screens cannot be cleaned,
control, and gearcase damage. they must be replaced. Different screens are
available and should not be mixed. Refer to cor-
rect model parts manual for listing and descrip-
tion.
12
301
Propeller Shaft Bearing Housing Remove the two retaining rings using Retaining
Ring Pliers, P/N 331045.
Removal
Use a 5/16 in. thin wall socket to remove the four CAUTION
screws with O-rings holding the propeller shaft
bearing housing. Retaining rings are under extreme pres-
sure during removal and installation. To
prevent personal injury, wear safety
glasses and proceed with care to avoid
unsnapping the ring from the pliers. After
the retaining rings are removed far
enough from the gearcase to clear the
housing, release the tension on the pliers
while retaining ring is still around the pro-
peller shaft.
COA3571
Remove the propeller shaft bearing housing from 1

the gearcase using the following:
• Puller body, screw, and handle from Universal
Puller Set, P/N 378103.
• Two 5/16-18 x 8 in. screws, P/N 316982, from
Universal Puller Set, P/N 378103.
1. Retaining ring 9438
Remove the retainer plate from the gearcase.
1
9437
1. Retainer plate COA3513
302
Remove the larger thrust washer, thrust bearing, Remove the four driveshaft bearing housing
and reverse gear from the gearcase. Remove the screws.
smaller thrust washer located in front of the gear.
1
1
1 1
2
1. Driveshaft bearing housing screws COA3671
1. Larger thrust washer COA3514 Remove the driveshaft from the gearcase. The
2. Thrust bearing
3. Reverse gear bearing housing, shims, thrust bearing, and thrust
washer will come out with the driveshaft.
Pinion Gear and Driveshaft
Removal
1
Adjust the shift rod to move the clutch dog as far
forward as possible. This will help ease removal of
the pinion nut.
2
Use Driveshaft Holding Socket, P/N 334995, and 4
an 11/16 in. open-end wrench to loosen and
remove the pinion nut from the bottom of the 3
driveshaft. Pad handle of the wrench to prevent
damage to gearcase. 1. Bearing housing COA3558
2. Shims
3. Thrust bearing
4. Thrust washer
1
If driveshaft cannot be removed, refer to Locked
Driveshaft Removal on p. 304.
Remove the pinion gear from the gearcase.
12
1. Holding socket COA3573T
2. 11/16 Wrench
COA3159
303
Locked Driveshaft Removal Shift Housing, Gear and

The driveshaft to pinion taper is a locking taper. If Propeller Shaft Removal
necessary, use Puller, P/N 387206, and Backing
Plate, P/N 325867, to break the lock. Install the Push down on the shift rod. This will move the
tools as shown by clamping them around the detent lever downward to clear the inside of the
driveshaft with the tool’s setscrew aligned with the gearcase when the shaft assembly is pulled out.
impeller drive key slot. Tighten the setscrew into Unscrew the shift rod from the detent lever.
the slot. Alternately tighten the two vertical screws Remove screws, cover, and shift rod from the
against the backing plate inserted between the gearcase.
puller and the gearcase until the driveshaft pops Discard the cover gasket. Remove and discard
loose from the pinion. the shift rod O-ring from inside of cover.
3
COA3666
1. Drive shaft COA3664
2. Puller IMPORTANT: Make sure oil fill/drain plug is
3. Backing plate
removed from gearcase.
Remove propeller shaft assembly from gearcase.
COA3575
304
SHIFTER, BEARING AND SEAL SERVICE
SHIFTER, BEARING AND Water Intake Screen

Inspect the water intake screen for blockage and
SEAL SERVICE remove it by depressing the tabs on either side of
the screen and pushing upward.
Pinion Bearing Removal
Inspect the pinion bearing for damage without
removing it. If the bearing is removed for any rea-
son, it must be replaced.
If the pinion bearing must be replaced, remove the 1

bearing retaining screw from the gearcase. Dis-
card the O-ring from the screw.
1. Water intake screen 001997

1
Pinion Bearing Installation
Install the water intake screen. Drop it into the
water intake cavity and use a suitable tool to push
it down as far as it will go.
Assemble Pinion Bearing Remover and Installer,

1. Bearing retaining screw 001997
P/N 5005927, as shown:
Assemble Pinion Bearing Remover and Installer, 1
P/N 5005927, in the gearcase as follows:
2
1 3
4
2
5
3
6
4 7
1. 1/4-20 X 1/2 in. Hex head screw 824182
2.
3.
1 in. O.D. Flat washer
Spacer, P/N 326584
12
1. Flange Nut, P/N 326586 813305 4. Plate, P/N 391260
2. Plate, P/N 391260 5. Rod, P/N 326582
3. Rod, P/N 326582 6. Installer, P/N 326575
4. Remover, P/N 326580 7. 1/4-20 X 1 1/4 in. Hex head screw
Use a 1 in. wrench to hold the remover in place. IMPORTANT: Spacers are different sizes and
Use a 3/4 in. wrench to turn flange nut clockwise cannot be interchanged.
and draw the bearing up from the housing.
305
Place the bearing on the installer tool with the let- unwrapping it from around the clutch dog. Dis-
tered side of the bearing facing the top of the card the spring.
gearcase. Use Needle Bearing grease to hold the
bearing on the tool.
Insert the tool with the bearing into the gearcase.

Drive the bearing into the gearcase until the 1
washer on the tool contacts the spacer.
Place a new O-ring on the pinion bearing retaining

screw. Apply Gasket Sealing Compound to O-ring
and Nut Lock to screw threads. Install the screw
and tighten to a torque of 48 to 80 in. lbs. (5.5 to
9.0 N·m).
1. Clutch dog spring COA3560
Push the pin out of the clutch dog. Remove all

parts.
1. Bearing retaining screw 001997
Shift Housing Disassembly 1

WARNING 1. Pin COA3561
Wear safety glasses to avoid injury. Remove the gear, thrust bearing, and thrust
washer from the shift housing.
IMPORTANT: The shift housing and forward
gear bearing are serviced as an assembly. If
either are worn or damaged, replace the complete 1
assembly.
Insert a suitable tool under one end of the clutch
dog spring and remove it from its groove by 2 3
1. Gear COA3562
2. Thrust bearing
3. Thrust washer
306
Remove the shift lever pin from the housing. Shift Housing Assembly
Remove shift shaft, cradle and shift lever. Move
shifter detent as needed to help ease removal of IMPORTANT: Clean and inspect all parts before
parts. beginning assembly procedures. Replace any
damaged parts.
5 4 Lightly coat the detent ball and spring with Needle
Bearing grease. Insert the spring in the housing,
then the ball.
3
1
2
1. Shift lever pin DSC02449

2. Shift shaft DSC02489
3. Cradle
4. Shift lever
5. Shifter detent
WARNING
4518
injury. The detent ball and spring and
come out with great force.
Insert shifter detent at 90° angle into the housing
as shown, while depressing the ball and spring
Wrap the housing with a shop cloth to catch ball with a suitable tool. Once the shifter detent is past
and spring. Rotate the shifter detent 90° in either the ball, remove the tool and position detent to
direction, then pull the detent out of the housing. engage NEUTRAL position.
DSC02506
1. Shifter detent DSC02518

2. Ball and spring 12
Remove the detent ball and spring.
307
With shifter detent in NEUTRAL, install arms of Coat thrust bearing and thrust washer with Needle
shift lever into detent slots. Align the pivot holes Bearing grease. Place the bearing on the back of
and insert the retaining pin. Push shifter detent the gear. Set the washer on top of the thrust bear-
down. ing. Insert the gear, bearing, and washer into the
bearing housing.
NOTICE Bearing and washer must be

installed in the correct order.
1 3
2
1. Shifter detent DSC02449 1

2. Shift lever
3. Pin, shift lever
Rest the cradle on the shift shaft.

1. Thrust bearing DSC02297
2. Thrust washer
1 Align holes in the clutch dog with slot in the pro-

peller shaft. Install the clutch dog with grooved
2 end toward the forward end of the shaft.
NOTICE The clutch dog is not symmetrical.

If installed backward, it will not fully engage
and will immediately damage itself and the
1. Cradle 4512 gears.
2. Shift shaft
Place the shift lever arms into the recesses of the

shift cradle. Pull shifter detent back up to NEU-
TRAL position to hold the cradle and shaft in posi-
tion.
1
1. Grooved end COA3591
001219
308
Slide the propeller shaft onto the shift shaft, align Clean the bearing housing in solvent to remove
the hole in the shaft with the hole in the clutch sealer from the seal bore and the O-ring groove.
dog, install the pin and then, a new clutch dog
retaining spring. Place three coils over each end Lightly apply Gasket Sealing Compound to a new
of the pin, MAKING SURE NONE OF THE COILS O-ring. Install the O-ring in top groove of the bear-
OVERLAP OR ARE LOOSE. ing housing. Do not allow sealant in oil passage.
NOTICE Do not install the O-ring in the bear-

ing housing’s bottom groove. The bottom
groove is an oil passage. Gearcase damage
could result.
1 2
1. Retaining spring COA3592
Driveshaft Bearing Housing

Service 1. O-ring (top groove) 14156
2. Oil passage
The driveshaft bearing is not serviceable. Replace
the bearing housing assembly if the bearing is
Apply Adhesive 847 to casing of new seal before
worn or damaged. Also, inspect the driveshaft
installing.
bearing surface if the bearing is damaged.
Use Seal Installer, P/N 342665 to install seal in
Remove the driveshaft bearing housing seal using
bearing housing with the exposed lip facing away
Puller Bridge, P/N 432127, and Large Puller
from housing. Apply Triple-Guard grease to seal
Jaws, P/N 432129. Discard the seal.
lips.
12
DRC5720
14155
Remove and discard the O-ring from the bearing

housing.
309
Propeller Shaft Bearing Housing port the bridge, and tighten jaws securely behind
the bearing.
Service
Rear Seal Removal
Remove seals using Puller Bridge, P/N 432127,
and Large Puller Jaws, P/N 432129. Place the
plate on top of the housing to support the bridge,
and tighten jaws securely behind the inner seal.
21067
Inspect the bearing housing anode. Replace

anode if it is reduced to two-thirds of original size.
Tighten screws to a torque of 108 to 132 in. lbs.
(12 to 15 N·m).
21047
1
Bearing Removal
IMPORTANT: Inspect bearings in place. If a
bearing is removed for any reason, it must be dis-
carded.
Remove rear bearing using Puller Bridge,

P/N 432127, and Large Puller Jaws, P/N 432129. 1. Anode 001220
Place the puller plate on top of the housing to sup-
port the bridge, and tighten jaws securely behind Discard the bearing housing O-ring. Clean the
the bearing. housing and bearings in solvent and dry thor-
oughly. If bearings were not replaced, rotate the
needles to check for freedom of movement.
Inspect O-ring groove. Sand off any sharp edges

that might cut O-ring. Remove any nicks or burrs
on front of bearing housing.
21045
Remove front bearing using Puller Bridge,

P/N 432127, and Bearing Puller, P/N 432130. 1. O-ring groove DSC02291
310
Thoroughly clean the four bearing housing retain- Rear Seal Installation
ing screws in solvent. Discard the O-rings. Apply Gasket Sealing Compound to metal casings
of the seals before installing.
Bearing Installation
Oil, then install new bearings in bearing housing. Use Seal Installation Tool to install new seals back
to back in bearing housing.
Place the lettered end of the bearing case on the
bearing installer, then press the bearing into the Seal Installation Tool:
housing until the tool seats. When installed, the • P/N 326551
lettered end of the bearing should be visible.
Install inner seal with lip facing toward the bearing
Bearing Installation Tool: housing, then outer seal with lip facing away from
• P/N 326562 the bearing housing.
Forward Bearing COA3579

1. Bearing installation tool
1
2
1. Inner seal DR2061

2. Outer seal DR2062
Apply Triple-Guard grease to seal lips.
Rear Bearing COA3580

12
311
DRIVESHAFT SHIMMING
DRIVESHAFT SHIMMING Select correct collar and shim gauge bar:

• Collar: P/N 328363
• Shim gauge bar: P/N 328366
NOTICE If a new pinion gear is needed,
replace gear set before shimming. Slide the collar onto the driveshaft with large end
in contact with the bearing housing.
Pinion gear backlash is adjusted by using shims
between the driveshaft bearing housing and the Insert the assembled driveshaft into the tool base
thrust washer. When installing a new thrust bear- and tighten preload screw against the driveshaft
ing or washer, bearing housing, pinion, or drive- until groove on the spring-loaded plunger is flush
shaft, it is necessary to properly shim the with end of threads. Tighten locking ring on pre-
assembly to restore the correct clearance. load screw.
Use Driveshaft Shimming Tool, P/N 5005925. 1

3
Shim gauge bars are precision made and should
be handled carefully. The length of each bar is
stamped near the part number. This dimension is
0.020 in. (0.508 mm) shorter than the actual
shimmed length of the driveshaft.
IMPORTANT: Clean pinion and driveshaft

before assembly. Replace any damaged parts.
2
Assemble the driveshaft bearing housing, thrust
washer, thrust bearing, and pinion onto the drive- 1. Collar COA3566
shaft. Use Driveshaft Seal Protector, P/N 312403, 2. Tool base DSC00326
3. Groove
when installing or removing the bearing housing.
Lightly coat the threads of the pinion nut with out- Rotate the driveshaft several revolutions to seat
board lubricant and tighten to a torque of 40 to 45 bearings.
ft. lbs. (54 to 60 N·m).
Lay the tool base on its side. Place the shim
IMPORTANT: The original pinion nut may be gauge bar against guide pins of the tool base.
used for shimming, but must NOT be used in final
assembly.
1 2
3 4 1. Shim gauge bar 005416
1. Driveshaft bearing housing COA3565

Check squareness of the bearing housing mount-
2. Thrust washer ing surface by holding the shim gauge bar against
3. Thrust bearing the pinion while rotating just the bearing hous-
4. Pinion
ing. Use a feeler gauge to measure clearance
312
GEARCASE ASSEMBLY
between the gauge bar and the bearing housing

between each pair of screw holes. Replace the
GEARCASE ASSEMBLY
bearing housing and repeat check if variance is Shift Housing, Gear, and
greater than 0.004 in. (0.101 mm).
Propeller Shaft Installation
Check squareness of the pinion to the driveshaft. Push shifter detent into farthest downward posi-
Hold the shim gauge bar against the bearing tion. Tip the rear of the gearcase slightly down-
housing (between the screw holes) while rotating ward to assist in the installation of the shaft
just the driveshaft and pinion assembly. Mea- assembly.
sure clearance between the gauge bar and the
pinion at several locations. If variance is greater Be sure the thrust bearing and the thrust washer
than 0.002 in. (0.050 mm) replace the pinion or are in the proper position. Insert the shaft assem-
driveshaft, as necessary, and repeat check. bly fully into the gearcase while aligning shift
housing pin with hole in forward end of gearcase
Subtract the average clearance measurement housing.
from 0.020 in. (0.508 mm) to determine the cor-
rect shim thickness required. Select the fewest
number of shims to achieve the correct thickness.
Remove the driveshaft from the tool and add the
required shims between the bearing housing and
the thrust washer.
IMPORTANT: Use extreme care when removing

bearing housing to avoid damaging the seals. Use 1
Driveshaft Seal Protector, P/N 312403.
Check clearance again. The measurement

1. Pin 006648
between the gauge bar and pinion should be
0.020 in. (0.508 mm).
Shift Rod Housing Installation
Lubricate a new shift rod cover O-ring with Triple-
Guard grease. Install the O-ring into the shift rod
cover.
IMPORTANT: Make sure O-ring is fully seated

in groove.
1
005417
2
Remove the nut and pinion from the driveshaft. 12
Discard the nut.
1. O-ring 006649
2. Groove
313
GEARCASE ASSEMBLY
Apply Triple-Guard grease to the threaded end of Place the cover seal on the shift rod cover.
the shift rod and insert it through the cover. Turn
the shift rod while pushing it through the cover to
avoid damaging the O-ring.
1
1. Cover seal 002514
Pinion Gear and Driveshaft

COA3544
Installation
Apply Gasket Sealing Compound to both sides of Refer to DRIVESHAFT SHIMMING on p. 312
a new shift rod cover gasket. Place the gasket on before proceeding.
the gearcase. Thread the shift rod into the shifter
Install new seals in driveshaft bearing housing.
detent about four turns.
Refer to Driveshaft Bearing Housing Service on
p. 309.
Place the driveshaft thrust bearing, thrust washer,

and correct shim(s) on the driveshaft as shown.
1 3
1
2
1. Cover gasket COA3545
Move shift rod from side to side while pushing on

the propeller shaft to ensure proper alignment of
the bearing housing locator pin into the pin hole in 1. Thrust bearing COA3168
the gearcase. 2. Thrust washer
3. Shim(s)
Apply Gasket Sealing Compound to the threads of
the shift rod cover screws. Tighten the screws to a Lightly apply Gasket Sealing Compound to the
torque of 60 to 84 in. lbs. (7 to 9.5 N·m). gearcase area that contacts mounting flange of
314
GEARCASE ASSEMBLY
the driveshaft bearing housing. Do not coat inside Lightly coat the threads of a new pinion nut with
bearing housing bore surface of the gearcase. outboard lubricant. Use Pinion Nut Starting Tool,
P/N 320675, to install nut on the driveshaft. Turn
the driveshaft by hand to thread the nut on to
shaft.
6207
Adjust shift rod to move clutch dog as far forward

as possible. Be sure excess grease is removed 33220
from the pinion bearing.
Apply Gasket Sealing Compound to the threads of
IMPORTANT: The inside taper of the pinion the driveshaft bearing housing screws. Tighten
gear and the driveshaft taper MUST be com- screws in stages to a torque of 96 to 120 in. lbs.
pletely free of grease. Clean the tapers with (11 to 14 N·m).
Cleaning Solvent. Use a shop towel free of grease
and lint.
Place the pinion gear into the gearcase. Insert the

driveshaft into the gearcase and through the pin-
ion gear.
1
Using Driveshaft Seal Protector, P/N 312403, 1
slide the driveshaft bearing housing onto the
driveshaft and into position in the gearcase. Align
the embossed word “FRONT” toward the shift rod.
Do not install screws at this time.
12
1. Seal protector COA3130
315
GEARCASE ASSEMBLY
Use Driveshaft Holding Socket, P/N 334995, and assembly onto the propeller shaft until it engages
an 11/16 in. open-end wrench, to tighten the pin- the pinion gear.
ion nut to a torque of 40 to 45 ft. lbs. (54 to 60s
N·m). Pad handle of the wrench to prevent dam-
age to gearcase.
2
1
1
2 1. Thrust bearing DSC02295

2. Thrust washer
Slide the bearing housing retainer plate into posi-

tion over the propeller shaft.
1. Holding socket COA3573T

2. 11/16 Wrench
Propeller Shaft Bearing

Housing and Gear Installation
1
Place the small thrust washer in recess of the
reverse gear.
1 1. Retaining ring COA3513
Using Retaining Ring Pliers, P/N 331045, install

the two retaining rings.
CAUTION
Retaining rings are under extreme pres-
sure during installation. Wear safety
1. Small thrust washer COA3597 glasses and proceed with care to avoid
unsnapping the ring from the pliers.
Oil and install thrust bearing and larger thrust
washer on hub of reverse gear. Slide the gear
316
GEARCASE ASSEMBLY
Make sure the retaining rings are seated in the Install O-ring in groove in the bearing housing.
grooves in the gearcase. Lightly apply Gasket Sealing Compound to the
O-ring flange and aft support flange of the bearing
housing. Do not allow sealer to contact either for-
ward thrust surface or bearings in the housing.
1 Align the bearing housing on the guide pins with

the word “UP” toward the top. Place the housing
into gearcase and tap the housing with a soft face
mallet to seat the O-ring.
Apply Gasket Sealing Compound to the threads

and seals of the four propeller housing retaining
screws. Install two of the screws into the bearing
1. Retaining ring 9438 housing finger tight. Remove the guide pins and
install the remaining two screws. Tighten all four
Thread two Guide Pins, P/N 383175, into the screws to a torque of 120 to 140 in. lbs. (14 to 16
retainer plate to align holes in the plate with holes N·m).
in the propeller shaft bearing housing. Do not
thread guide pins more than two turns into the Final Assembly and Adjustment
retainer plate. To complete gearcase assembly, refer to:
• GEARCASE LEAK TEST on p. 295
• WATER PUMP SERVICE on p. 298
• SHIFT ROD ADJUSTMENT on p. 300
1 • GEARCASE REMOVAL AND INSTALLATION
on p. 296
• Gearcase Lubricant on p. 39
• Propeller Hardware Installation on p. 294
• Trim Tab Adjustment on p. 31.
During break-in period of a reassembled gear-
case, change the gearcase lubricant between 10
1. Guide pin COA3550 to 20 hours of operation.
12
317
GEARCASE REMOVAL Remove the 3/8-16 in. screw and washer, and
remove 7/16-14 x 3.5 in. screw and washer.
AND INSTALLATION
1
Gearcase Removal
WARNING
vicing, twist and remove all spark plug
leads.
During service, the outboard may drop 2
always support the outboard’s weight with O Type Gearcases 006869
a suitable hoist or the tilt support bracket 1. 3/8-16 x 3.5 in. screw
during service. 2. 7/16-14 x 3.5 in. screw

1
1
2
S Type Gearcases COA3139

1. 3/8-16 x 1.75 in. screw
2. 7/16-14 x 3.5 in. screw
Note where the index mark on the gearcase aligns Remove the four 3/8-16 x 1.75 in. gearcase retain-
with the index number of the adjustable trim tab so ing screws and washers.
the trim tab can be installed in the same position.
Remove the trim tab retaining screw and trim tab
from the gearcase.
3
1. Gearcase retaining screws 001990

1
Remove the gearcase assembly from the exhaust
housing, being careful not to bend the shift rod.
1. Index mark COA3663
2. Trim tab
3. Trim tab retaining screw
318
Gearcase Installation Slide the gearcase into place, making sure:

• Driveshaft engages the crankshaft.
WARNING • Water tube enters the water pump.
• Lower inner exhaust housing installs correctly.
• Shift rod does not turn and is positioned prop-
erly in the shift rod lever below the crankcase.
always support the outboard’s weight with
a suitable hoist or the tilt support bracket
IMPORTANT: New gearcase screws are treated
during service.
with a thread-locking material. Apply Triple-Guard
grease to threads to ensure that the correct
NOTICE Before installing gearcase, shift rod clamping force is achieved when tightening—If a
adjustment MUST be checked. Refer to SHIFT previously installed screw is re-used, use a wire
ROD ADJUSTMENT on p. 323. brush to remove any old thread-locking material or
corrosion and lubricate threads with Triple-Guard
Coat the driveshaft splines with Moly Lube. DO grease.
NOT coat top surface of the driveshaft because
lubricant may prevent seating of the driveshaft in Install screws and washers and tighten to a torque
the crankshaft. of:
30385
1
Apply Adhesive 847 to the lower exhaust housing 1. 3/8 in. screws 001990
seals’ inner surfaces. Place two new seals on the
housing. Apply Triple-Guard grease to the seals’
outer surfaces and place the housing on the gear-
case.
2
1
12
1. 3/8 in screw COA3139
2. 7/16 in. screw
1. Lower exhaust seals 32002
319
WATER PUMP SERVICE
Apply Triple-Guard grease to threads of the trim

tab screw. Install and align the trim tab with the
WATER PUMP SERVICE
index marks noted prior to disassembly. Tighten Disassembly
the trim tab screw to a torque of 35 to 40 ft. lbs.
(47 to 54 N·m). For adjustment, refer to Trim Tab Rotate the driveshaft counterclockwise to unlock
Adjustment on p. 31. the impeller key. Remove the four impeller hous-
ing screws.
1
1
1
1
2
1. Trim tab screw COA3663

2. Index mark 1. Screws 31998
Place the shift rod in the shift rod lever. Install the Slide the water pump off the driveshaft. Remove
retaining pin and washer. Tighten pin to a torque the impeller key, O-ring, impeller plate, and gas-
of 60 to 84 in. lbs. (7 to 9.5 N·m). ket. Discard the gasket.
2
1
1

1. O-ring DSC02328
2. Impeller plate
WARNING
Remove all the parts from the housing.
To prevent loss of operator control, check
for proper shifting operation and adjust, if Inspection
necessary. Check impeller for overheating, hub separation,
and other wear or damage.
IMPORTANT: During break-in period of a reas-
sembled gearcase, change the gearcase lubricant Check liner and wear plate for scoring, distortion,
between 10 to 20 hours of operation. and impeller material transfer.
Inspect the housing for cracks or melting.
Make sure gasket surface is clean and smooth.
320
WATER PUMP SERVICE
Assembly Install the water tube grommet with the inside

taper facing up.
Apply a drop of Adhesive 847 in the seal ring
groove at each of the four ribs.
1
IMPORTANT: Do not allow any sealer to get into
the air bleed groove in the impeller housing. If this
groove is blocked by adhesive, the pump will lose
its prime and will not pump water.
Apply Triple-Guard grease to screw threads and

3 install the impeller housing cover and tighten
screws to a torque of 24 to 36 in. lbs. (3 to 4 N·m).
2 Apply Adhesive 847 to flat side of the impeller

housing grommet. Install the grommet, flat side
1. Seal ring groove 2311 down.
2. Ribs DR1185
3. Air bleed groove
1
Install the O-ring in groove in the impeller housing.
2
1. Impeller housing cover 32001

2. Impeller housing grommet
1. O-ring 34814 Lightly coat the inside of the liner with Triple-
Guard grease. With a counterclockwise rotation,
Lightly coat the exterior rim of the impeller cup install the impeller into the liner with the slot for the
with Gasket Sealing Compound. Install the cup in impeller key facing out.
the impeller housing. The cup locks in place in the
housing with a square index tab. 12
Make sure vent hole in impeller cup is open.
321
WATER PUMP SERVICE
Apply a thin bead of Adhesive 847 in the seal slide water pump down over key. Be sure impeller
groove, and install the special shaped O-ring seal. key does not fall out of position.
1
1
1. Sharp edge of drive key CO2995

2. Direction of driveshaft rotation
1. O-ring 34815
Apply Gasket Sealing Compound to both sides of NOTICE Make sure the impeller engages the
a new impeller plate gasket. Install the gasket and impeller key. Serious powerhead damage will
impeller plate. result if impeller key is not in place.
Apply Triple-Guard grease to a new impeller O- Align the impeller housing with the gearcase.
ring. Slide the O-ring down the driveshaft and half Apply Gasket Sealing Compound to threads of the
way over installed impeller key to temporarily hold four impeller housing screws. Install the screws
key in place. and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5
N·m).
On 25 in. models, place water tube spacer and
grommet on the impeller housing cover.
3
2
1
2
4 1
1. Impeller plate gasket DSC02326

2. Impeller plate
3. O-ring
4. Drive key
25 in. Model Water Tube Spacer 32728

The sharp edge of the key is the leading edge in 1. Spacer
clockwise rotation. 2. Grommet
Slide the water pump down the driveshaft. Align NOTICE Before installing gearcase, shift rod
impeller slot with the impeller key. Rotate the
adjustment MUST be checked. Refer to SHIFT
driveshaft to engage the key with the impeller, and
322
SHIFT ROD ADJUSTMENT
SHIFT ROD With the gearcase in NEUTRAL, rotate the shift

rod up or down as necessary for correct adjust-
ADJUSTMENT ment. Once correct height is achieved, rotate rod
one half turn or less to direct offset forward.
Check the shift rod height from the shift rod hole to
the surface of the gearcase using Universal Shift IMPORTANT: The NEUTRAL detent is a two-
Rod Height Gauge, P/N 389997. step design. Make sure the NEUTRAL detent ball
is in the center step before checking shift rod
height.
Shift Rod Heights

Model Type Height
20 in. (L) “S” 21.25 in. ± One-Half Turn
25 in. (X) “O” 26.25 in. ± One-Half Turn
COA6166
12
323
GEARCASE • Hydrostatic Seal Grooves — Must be in good

condition to help prevent propeller ventilation.
DISASSEMBLY
Pre-Disassembly Inspection
WARNING 1
injury, and set compressed air pressure to
IMPORTANT: Clean and inspect all parts during

disassembly. Replace any 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 original size, they must be
Drain and inspect oil as described in Gearcase replaced.
Lubricant on p. 39.
Remove gearcase. Refer to GEARCASE

Remove water pump. Refer to WATER PUMP 1

SERVICE on p. 320.
Before disassembling the gearcase, examine the
following:
• Gearcase Housing — Check for visible dam-
age to skeg, strut, anti-ventilation plate, bullet,
and mating surface. Check seal areas for visible 1. Gearcase anode 14161
signs of lubricant leakage.

• Propeller Shaft — Check for bent or damaged • Drive Shaft — Check splines for visible dam-
shaft. Check for twisted splines and damaged age, twisting and wear. Severe spline wear indi-
threads. cates the exhaust housing or gearcase has
• Shift Rod — Check for misadjusted, bent, or been distorted, possibly by impact damage.
binding rod. A misadjusted shift rod height can • Water Intake Screens — Check for damage
cause shift difficulty, loss of boat and outboard and blockage. If screens cannot be cleaned,
control, and gearcase damage. they must be replaced. Different screens are
available and should not be mixed. Refer to cor-
rect model parts manual for listing and descrip-
tion.
324
Propeller Shaft Bearing Housing Assemble components and pull the bearing hous-
ing from the gearcase.
Removal
Remove the two screws, washers, and retainers
holding the propeller shaft bearing housing.
22775
Remove the thrust washer, thrust bearing, and

1. Retainer tab screws 001989 reverse gear from gearcase.
Remove wedge, screw, and washer (“O” Type). Pinion Gear and Driveshaft
Removal
Adjust the shift rod to move the clutch dog as far
forward as possible. This will help ease removal of
the pinion nut.
Use Driveshaft Holding Socket, P/N 311875, Pin-

ion Nut Holder, P/N 334455, and Wrench
Retainer, P/N 341438 to loosen and remove the
pinion nut from the bottom of the driveshaft. Pad
handle of holder to prevent damage to gearcase.
DSM02291 1
DSC02361
Remove the propeller shaft bearing housing from

the gearcase using the following:
• Puller body, screw, and handle from Universal
Puller Set, P/N 378103.
• Two 5/16-18 x 11 in. (279 mm) threaded rods,
two large 5/16 in. I.D. flat washers, and two 3
5/16-18 nuts (obtain locally).
2 12
1. Holding socket 42229
2. Pinion holder
3. Retainer
325
Remove the four driveshaft bearing housing Locked Driveshaft Removal

screws. The driveshaft to pinion taper is a locking taper. If
necessary, use Driveshaft Puller, P/N 390706, and
Backing Plate, P/N 325867, to break the lock.
Install the tools as shown by clamping them
around the driveshaft. Alternately tighten the two
vertical screws against the backing plate inserted
1 between the puller and the gearcase until the
1 driveshaft pops loose from the pinion.
1
Remove the driveshaft from the gearcase. The

2
bearing housing, shims, thrust bearing, and thrust
washer will come out with the driveshaft.
3
1
1. Drive shaft 41177
2. Puller
3. Backing plate
2
4 If upper driveshaft becomes separated from lower
driveshaft, use Lower Driveshaft Puller,
3 P/N 342681, to remove. Install puller into lower
driveshaft and turn 90° to position hook under pin
1. Bearing housing COA3558
2. Shims
in driveshaft. Thread Slide Hammer, P/N 391008,
3. Thrust bearing into puller and remove driveshaft.
4. Thrust washer
If driveshaft cannot be removed, refer to Locked

Driveshaft Removal on p. 326.
Remove the pinion gear from the gearcase.
46905
COA3159
326
Driveshaft Service “S” Type Gearcases

To separate the upper driveshaft (if needed) from Install the roll pin flush.
the lower driveshaft, remove the roll pin. Replace
the damaged component. 1
1. Roll pin DR4596
“O” Type Gearcases

29337 Install the roll pin to the specified dimension.
To assemble the driveshaft, install new driveshaft

retainer into the groove of the upper driveshaft.
0.125 in.
(3.2 mm)
1
1. Roll pin DR4610
29338
Install the upper driveshaft into the lower drive-

shaft, aligning the holes in the driveshaft retainer
and the lower driveshaft.
12
29330
327
GEARCASE HOUSING INSPECTION
Shift Housing, Gear and GEARCASE HOUSING

Propeller Shaft Removal
Push down on the shift rod. This will move the
INSPECTION
detent lever downward to clear the inside of the Thoroughly clean gearcase housing to remove all
gearcase when the shaft assembly is pulled out. dirt and debris prior to inspection. Inspect pinion
Unscrew the shift rod from the detent lever. bearing and forward thrust surface of gearcase
Remove screws, cover, and shift rod from the housing.
gearcase.
Use Gearcase Alignment Gauge Kit, P/N 5006349
Discard the cover gasket. Remove and discard to check the condition of gearcase housing prior
the shift rod O-ring from inside of cover. to reassembly. Refer to instructions provided with
kit. Use additional Gauging Head as follows:
• P/N 352879, for “S” Type gearcases.
Remove propeller shaft assembly from gearcase.
004315
IMPORTANT: DO NOT force gauging shaft into

alignment hole. Shaft MUST slide easily into hole
of gauging head. If shaft does not slide into hole,
gearcase housing is damaged and must be
replaced.
COA3149
Water Intake Screens

Remove and clean water intake screens. Replace
if damaged.
1
1
1. Gauging shaft 004347
1. Water intake screen 001991
328
SHIFTER, BEARING AND “O” Type Gearcases

Use a 7/8 in. wrench to hold the remover in place.
SEAL SERVICE Use a 3/4 in. wrench to turn flange nut clockwise.
Draw the bearing up from the housing.
Pinion Bearing Removal
Remove pinion bearing retaining screw. 1
2
2
3
1
3 1. Flange nut, P/N 326586 DR3419

2. Plate, P/N 391260
3. Rod, P/N 326582
1. Pinion bearing retaining screw DSC02370 4. Remover, P/N 326579
2. Water screen pocket DRC7416
3. Seal DSC02313
Pinion Bearing Installation
Assemble Pinion Bearing Remover/Installer, Assemble the following components of Pinion
P/N 5005927, in the gearcase as follows: Bearing Remover and Installer, P/N 5005927, as
shown:
“S” Type Gearcases
Use a mallet to drive the bearing from the hous- “S” Type Gearcases
ing.
1
1 2
3
2 4
3
5
5
6 12
7
6
1. 1/4-20 x 1/2 in. Hex Head Screw 824163 2. 1 in. O.D. Flat washer
2. 1 in. O.D. Flat Washer 3. Spacer, P/N 341437
3. Plate, P/N 391260 4. Plate, P/N 391260
4. Rod, P/N 326582 5. Rod, P/N 326582
5. Installer/Remover, P/N 326574 6. Installer/Remover, P/N 326574
6. 1/4-20 x 1 1/4 in. Hex Head Screw 7. 1/4-20 X 1 1/4 in. Hex head screw
329
“O” Type Gearcases Place a new O-ring on the pinion bearing retaining
screw. Apply Gasket Sealing Compound to O-
1 ring. Apply Nut Lock to screw threads. Install the
2 screw and tighten to a torque of 60 to 84 in. lbs. (7
3* to 9.5 N·m).
4
7
2. 1 in. O.D. Flat washer 1. O-ring DRC7416
3. Spacer, P/N 326584
4. Plate and Bearing P/N 391260
5. Rod P/N 326582 Shift Housing Disassembly
6. Installer/Remover, P/N 350958
7. 1/4-20 X 1 1/4 in. Hex head screw
WARNING
IMPORTANT: Spacers are different sizes and Wear safety glasses to avoid injury.
cannot be interchanged.
Apply Needle Bearing grease to the needle bear- IMPORTANT: The shift housing and bearing are
ings and insert them into the bearing case (“O” serviced as an assembly. If either are worn or
Type gearcases). damaged, replace the complete assembly.
Place the bearing on the installer tool with the let- Insert a suitable tool under one end of the clutch
tered side of the bearing facing the top of the dog spring and remove it from its groove by
gearcase. Use Needle Bearing grease to hold the unwrapping it from around the clutch dog. Dis-
bearing on the tool. card the spring.
IMPORTANT: The pinion bearing is tapered so

that, when installed correctly, its shape compen-
sates for stresses in the gearcase and allows full
bearing contact. Whenever a gearcase is disas- 1
sembled, the pinion bearing should be checked to
ensure that it has been installed with the lettering
facing up.
Insert the tool with the bearing into the gearcase.

Drive the bearing into the gearcase until the
washer on the tool contacts the spacer.
1. Clutch dog spring COA3560
Remove the tool.
330
Push the pin out of the clutch dog. Remove all shifter detent as needed to help ease removal of
parts. parts.
5 4
3
1
2
1 1. Shift lever pin DSC02449

2. Shift shaft DSC02489
1. Pin COA3561 3. Cradle
4. Shift lever
5. Shifter detent
Remove the gear, thrust bearing, and thrust
washer from the shift housing.
WARNING
1 injury. The detent ball and spring and
come out with great force.
2 3 Wrap the housing with a shop cloth to catch ball

and spring. Rotate the shifter detent 90° in either
direction, then pull the detent out of the housing.
2
1. Gear COA3562
2. Thrust bearing
3. Thrust washer 1
Remove the shift lever pin from the housing.
Remove shift shaft, cradle and shift lever. Move

2. Ball and spring
Remove the detent ball and spring. 12

Remove needle bearings from bearing housing for
cleaning and inspection (“O” Type).
331
Shift Housing Assembly Thoroughly grease 25 needle bearings with Nee-

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

Bearing grease. Insert the spring in the housing,
then the ball.
4520
With shifter detent in NEUTRAL, install arms of

shift lever into detent slots. Align the pivot holes
and insert the retaining pin. Push shifter detent
down.
4518
Insert shifter detent at 90° angle into the housing

as shown, while depressing the ball and spring
with a suitable tool. Once the shifter detent is past 1 3
the ball, remove the tool and position detent to
engage NEUTRAL position.
2

2. Shift lever
3. Pin, shift lever
Rest the cradle on the shift shaft.
DSC02506
TYPICAL 4512
1. Cradle
2. Shift shaft
332
Place the shift lever arms into the recesses of the Align holes in the clutch dog with slot in the pro-
shift cradle. Pull shifter detent back up to NEU- peller shaft. Install the clutch dog on the shaft with
TRAL position to hold the cradle and shaft in “PROP END” facing rear of the shaft.
place.
NOTICE The clutch dog is not symmetrical.
If installed backward, it will not fully engage
and will immediately damage itself and the
gears.
001219
Coat thrust bearing and thrust washer with Needle

Bearing grease. Place the bearing on the back of
the gear. Set the washer on top of the thrust bear- 1
ing. Insert the gear, bearing, and washer into the
1. “PROP END” COB7581
bearing housing.
Slide the propeller shaft onto the shift shaft, align
NOTICE Bearing and washer must be the hole in the shaft with the hole in the clutch
installed in the correct order. dog, install the pin and then, a new clutch dog
retaining spring. Place three coils over each end
2 of the pin, MAKING SURE NONE OF THE COILS
OVERLAP OR ARE LOOSE.

2. Thrust washer
1
1. Retaining spring COB3101
12
333
Driveshaft Bearing Housing NOTICE Do not install the O-ring in the bear-
Service ing housing’s bottom groove. The bottom
groove is an oil passage. Gearcase damage
The driveshaft bearing is not serviceable. Replace
could result.
the bearing housing assembly if the bearing is
worn or damaged. Also, inspect the driveshaft
bearing surface if the bearing is damaged.
1
Seal Removal
Remove the driveshaft bearing housing seals
using Puller Bridge, P/N 432127, and Large Puller 2
Jaws, P/N 432129. Discard the seals.
1. O-ring (top groove) 14156

2. Oil passage
Apply Gasket Sealing Compound to casings of

new seals before installing.
Use Seal Installation Tool, P/N 330268 to install

new seals back to back in bearing housing. Install
inner seal with lip facing toward bearing housing,
then the outer seal with lip facing away from bear-
ing housing. Apply Triple-Guard grease to seal
lips.
14155
Remove and discard the O-ring from the bearing

housing.
Clean the bearing housing in solvent to remove

sealer from the seal bore and the O-ring groove.
1
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.

334
Propeller Shaft Bearing Housing Inspect the bearing housing anode. Replace
anode if it is reduced to two-thirds of original size.
Service Tighten screws to a torque of 108 to 132 in. lbs.
Rear Seal Removal (12 to 15 N·m).
Remove seals using Puller Bridge, P/N 432127,
and Small Puller Jaws, P/N 432131. Place the
plate on top of the housing to support the bridge, 1
and tighten jaws securely behind the inner seal.
1. Anode 001220
Discard the bearing housing O-ring. Clean the

housing and bearings in solvent and dry thor-
13520 oughly. If bearings were not replaced, rotate the
needles to check for freedom of movement.
Bearing Removal
Inspect O-ring groove. Sand off any sharp edges
IMPORTANT: Inspect bearings in place. If a that might cut O-ring. Remove any nicks or burrs
bearing is removed for any reason, it must be dison front of bearing housing.
carded.
1
Remove either bearing using Puller Bridge,
P/N 432127, and Large Puller Jaws, P/N 432129.
port the bridge, and tighten jaws securely behind
the bearing.
1. O-ring groove DSC02291
12
13522
335
Bearing Installation Rear Seal Installation

Oil, then install new bearings in bearing housing. Apply Gasket Sealing Compound to metal casings
of the seals before installing.
Place the lettered end of the bearing case on the
bearing installer, then press the bearing into the Use Seal Installation Tool to install new seals back
housing until the tool seats. When installed, the to back in bearing housing.
lettered end of the bearing should be visible.
Seal installation tool:
Bearing installation tool: • P/N 326551 – “S” Type gearcases
• P/N 326562 – “S” Type gearcases • P/N 336311 – “O” Type gearcases
• P/N 339750 – “O” Type gearcases
Install inner seal with lip facing toward the bearing
housing, then outer seal with lip facing away from
the bearing housing.
1
Forward Bearing 29967


Apply Triple-Guard grease to seal lips.

Rear Bearing 44237
336
DRIVESHAFT SHIMMING
DRIVESHAFT SHIMMING Select correct collar and shim gauge bar:

• Collar: P/N 341440
• Shim gauge bar: P/N 328367
NOTICE If a new pinion gear is needed,
replace gear set before shimming. Slide the collar onto the driveshaft with large end
in contact with the bearing housing.
Pinion gear backlash is achieved by using shims
between the driveshaft bearing housing and the Insert the assembled driveshaft into the tool base
thrust washer. When installing a new thrust bear- and tighten preload screw against the driveshaft
ing or washer, bearing housing, pinion, or drive- until groove on the spring-loaded plunger is flush
shaft, it is necessary to properly shim the with end of threads. Tighten locking ring on pre-
assembly to restore factory clearance. load screw.
Use Driveshaft Shimming Tool, P/N 5005925 1

(replaces P/N 393185). 3
Shim gauge bars are precision made and should

be handled carefully. The length of each bar is
stamped near the part number. This dimension is
0.020 in. (0.508 mm) shorter than the actual
shimmed length of the driveshaft.
IMPORTANT: Clean pinion and driveshaft

before assembly. Replace any damaged parts. 2
Assemble the driveshaft bearing housing, thrust

1. Collar COA3566
washer, thrust bearing, and pinion onto the drive- 2. Tool base DSC00326
shaft. Use Driveshaft Seal Protector, P/N 318674, 3. Groove
when installing or removing the bearing housing.
Rotate the driveshaft several revolutions to seat
Lightly coat the threads of the pinion nut with out- bearings.
board lubricant and tighten to a torque of 100 to
110 ft. lbs. (136 to 149 N·m). Lay the tool base on its side. Position the shim
gauge bar against guide pins of the tool base.
1 2
3 4
12
1. Driveshaft bearing housing COA3565
2. Thrust washer 1. Shim gauge bar COA3567
3. Thrust bearing
4. Pinion
Check squareness of the bearing housing mount-
IMPORTANT: The original pinion nut may be ing surface by holding the shim gauge bar against
used for shimming, but must NOT be used in final the pinion while rotating just the bearing hous-
assembly. ing. Use a feeler gauge to measure clearance
337
GEARCASE ASSEMBLY
between the gauge bar and the bearing housing

between each pair of screw holes. Replace the
GEARCASE ASSEMBLY
bearing housing and repeat check if variance is Water Intake Screens
greater than 0.004 in. (0.101 mm).
Install water intake screens. Tighten screws to a
Check squareness of the pinion to the driveshaft. torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
Hold the shim gauge bar against the bearing
housing (between the screw holes) while rotating
just the driveshaft and pinion assembly. Mea-
sure clearance between the gauge bar and the
pinion at several locations. If variance is greater 1
than 0.002 in. (0.050 mm) replace the pinion or
driveshaft, as necessary, and repeat check.
Subtract the average clearance measurement

from 0.020 in. (0.508 mm) to determine the cor-
rect shim thickness required. Select the fewest 1. Water intake screen 001991
number of shims to achieve the correct thickness.
Remove the driveshaft from the tool and add the Shift Housing, Gear, and
required shims between the bearing housing and Propeller Shaft Installation
the thrust washer.
Push shifter detent into farthest downward posi-
IMPORTANT: Use extreme care when removing tion. Tip the rear of the gearcase slightly down-
bearing housing to avoid damaging the seals. Use ward to assist in the installation of the shaft
Driveshaft Seal Protector, P/N 318674. assembly.
Check clearance again. The measurement Be sure the thrust bearing and the thrust washer
between the gauge bar and pinion should be are in the proper position. Insert the shaft assem-
0.020 in. (0.508 mm). bly fully into the gearcase while aligning shift
housing pin with hole in forward end of gearcase
housing.
005417
Remove the nut and pinion from the driveshaft. 005427
Discard the nut.
338
GEARCASE ASSEMBLY
Shift Rod Housing Installation Apply Gasket Sealing Compound to both sides of
a new shift rod cover gasket. Place the gasket on
Lubricate a new shift rod cover O-ring with Triple-
the gearcase.
Guard grease. Install the O-ring into the shift rod
cover. Thread the shift rod into the shifter detent about
four turns.
IMPORTANT: Make sure O-ring is fully seated
in groove.
2
1 2
1

2. Grommet
1. O-ring 006780
2. Groove
Move shift rod from side to side while pushing on
the propeller shaft to ensure proper alignment of
Place the shift rod grommet on the shift rod. the bearing housing locator pin into the pin hole in
Install shift rod spacer under grommet on 25 in. the gearcase.
models. Apply Gasket Sealing Compound to the threads of
the shift rod cover screws. Tighten the screws to a
2 torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
1. Grommet COA3568
2. Shift rod spacer
COA3569
Apply Triple-Guard grease to the threaded end of
the shift rod and insert it through the cover. Turn
the shift rod while pushing it through the cover to
Refer to SHIFT ROD ADJUSTMENT on p. 323. 12
avoid damaging the O-ring.
339
GEARCASE ASSEMBLY
Pinion Gear and Driveshaft IMPORTANT: The inside taper of the pinion
gear and the driveshaft taper MUST be com-
Installation pletely free of grease. Clean the tapers with
Refer to DRIVESHAFT SHIMMING on p. 337 Cleaning Solvent. Use a shop towel free of grease
before proceeding. and lint.
Install new seals in driveshaft bearing housing. Place the pinion gear into the gearcase. Insert the
Refer to Driveshaft Bearing Housing Service on driveshaft into the gearcase and through the pin-
p. 334. ion gear.
Place the driveshaft thrust bearing, thrust washer, Lightly coat the threads of a new pinion nut with
and correct shim(s) on the driveshaft as shown. outboard lubricant. Use Pinion Nut Starting Tool,
P/N 342216, to install nut on the driveshaft. Turn
the driveshaft by hand to thread the nut on to
shaft.
3
1
2
1. Thrust bearing COA3168

2. Thrust washer
3. Shim(s)
Using Driveshaft Seal Protector, P/N 318674, 42230

slide the driveshaft bearing housing onto the
driveshaft and into position in the gearcase. Apply Gasket Sealing Compound to the threads of
the driveshaft bearing housing screws. Tighten
screws in stages to a torque of 120 to 144 in. lbs.
1 (13.5 to 16.5 N·m).
1 1
1. Seal protector COA3130

Adjust shift rod to move clutch dog as far forward
as possible. Be sure excess grease is removed
from the pinion bearing.
340
GEARCASE ASSEMBLY
Use Driveshaft Holding Socket, P/N 311875, Pin- Lightly apply Gasket Sealing Compound to a new
ion Nut Holder, P/N 334455, and Wrench bearing housing O-ring. Install O-ring in groove in
Retainer, P/N 341438, to tighten the pinion nut to the housing.
a torque of 100 to 110 ft. lbs. (136 to 149 N·m).
Pad handle of holder to prevent damage to gear- Install housing into gearcase. Align screw holes
case. with retainer slots in gearcase.
Housing must be completely seated to install

1 retainer tabs.
1. Holding socket 42229

2. Pinion holder
3. Retainer
Retainer Tab Notch 50106a
Propeller Shaft Bearing Housing
and Gear Installation Install two retainers, washers and screws. Apply
Ultra Lock to threads and tighten screws to a
Oil and install thrust bearing and thrust washer on torque of 18 to 20 ft. lbs. (24 to 27 N·m).
hub of reverse gear. Slide the gear assembly onto
the propeller shaft until it engages the pinion gear.
1
2
1. Retainer tab screws 001989

2. Thrust washer
12
341
GEARCASE ASSEMBLY
“O” Type Gearcases Re-tighten two retainer screws to 18 to 20 ft. lbs.

Loosen retainer screws 1/4 turn. (24 to 27 N·m).
Install wedge, screw, and washer. Apply Ultra Confirm that torque on the wedge screw is 15 to
Lock to threads and tighten screw to a torque of 20 in. lbs. (1.7 to 2.3 N·m).
15 to 20 in. lbs. (1.7 to 2.3 N·m).
Final Assembly and Adjustment
To complete gearcase assembly, refer to:
• GEARCASE LEAK TEST on p. 295
• WATER PUMP SERVICE on p. 320
• SHIFT ROD ADJUSTMENT on p. 323
• GEARCASE REMOVAL AND INSTALLATION
on p. 318
• Gearcase Lubricant on p. 39
• Propeller Hardware Installation on p. 294
• Trim Tab Adjustment on p. 31.
DSM02291
During break-in period of a reassembled gear-
DSC02361 case, change the gearcase lubricant between 10
to 20 hours of operation.
342
TRIM AND TILT
TRIM AND TILT

TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
MANUAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
TRAILERING BRACKET AND TILT SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
ROUTINE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
RESERVOIR FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
MANUAL RELEASE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
STERN BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
ELECTRICAL CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
RELAY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
TRIM AND TILT MOTOR CURRENT DRAW TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
TRIM AND TILT MOTOR NO LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
TRIM GAUGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
TRIM SENDER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
TRIM AND TILT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
TRIM AND TILT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
13
343
TRIM AND TILT
SERVICE CHART
SERVICE CHART
40 - 60 HP MODELS
30 to 50 in. lbs.
(4 to 5.6 N·m)
45 to 55 in. lbs.
(5 to 6 N·m)
W
45 to 55 in. lbs.
(5 to 6 N·m)
A
W
007632 W Biodegradable TNT Fluid
344
TRIM AND TILT
SERVICE CHART
75 - 90 HP MODELS
30 to 50 In. lbs.
(4 to 5.6 N·m)
45 to 55 In. lbs.
(5 to 6 N·m) W
45 to 55 In. lbs.
(5 to 6 N·m)
13
005002 W Biodegradable TNT Fluid
345
TRIM AND TILT
SYSTEM DESCRIPTION
SYSTEM DESCRIPTION
The power trim/tilt hydraulic system is completely
contained between the outboard's stern brackets.
The system consists of:

• Electric motor 1
• Oil reservoir
• Pump manifold assembly
• Cylinder body assembly
Optimal boat and outboard performance can be
achieved by adjusting (trimming) the angle of out- 1. Manual release valve, 40-60 HP 008018
board propeller thrust. The first 15° of outboard

movement is considered trim range. Trailering Bracket And Tilt
Outboard movement beyond the trim range is
Support
considered tilting. Tilting of the outboard may be 40 – 60 HP MODELS
desired for shallow water drive and for traile-
These outboards are equipped with combination
ring/storage. The tilt cylinder moves the outboard
tilt support/trailering brackets.
through the tilt range.
Tilt the outboard up fully, engage the bracket, then
IMPORTANT: When in tilt range, make sure
tilt the outboard down until the bracket is firmly in
water is available to gearcase water pickups.
position.
Manual Adjustment
The outboard can be manually raised or lowered 1
through its entire trim and tilt range by opening the
manual release valve a minimum of three turns.
When this cycle is complete, the manual release
valve must be closed and tightened to a torque of
45 to 55 in. lbs. (5 to 6 N·m) before normal opera-
tion can be resumed.

1
1. Manual release valve, 75-90 HP 001988
346
TRIM AND TILT
SYSTEM DESCRIPTION
75 – 90 HP MODELS For mooring or storing the boat with the outboard

Use the trailering bracket to support the outboard tilted, a tilt support is provided to support the out-
when trailering in the tilted position. This bracket board.
protects the hydraulic system from damage.
Tilt the outboard up fully, engage the bracket, then

tilt the outboard down until the bracket is firmly in
position. 1
1. Tilt Support 002279
IMPORTANT: The tilt support must not be used

to support the outboard while trailering.
Trailering Bracket 001987
13
347
TRIM AND TILT
ROUTINE INSPECTIONS
ROUTINE INSPECTIONS TROUBLESHOOTING

General Use the following guidelines to check a single pis-
ton trim/tilt unit that is not working correctly.
Check for external signs of fluid leakage. Correct
causes as necessary. Cylinder Leakdown:
• Manual release valve seals
Check the battery to be sure it is in good operating
condition. • External leaks
No reverse lock:
Reservoir Fluid • External leaks
Check reservoir fluid level at least every three
years or 300 operating hours. System capacity is No operation, motor runs:
approximately: • Manual release valve open
• 40 - 60 HP: 15.2 fl. oz. (450 ml) • Fluid level low
• 75 - 90 HP: 21 fl. oz. (620 ml) • Pump coupler
• Hydraulic pump
IMPORTANT: Use only Evinrude/Johnson Bio-
degradable TNT Fluid to fill the hydraulic system. No tilt down:
• Manual release valve
Refer to Trim and Tilt on p. 41 for filling proce- • Fluid level
dure.
Slow performance:
Manual Release Valve • Manual release valve
Check the manual release valve with a torque • Fluid level low
wrench. • Mechanical binding
• Electric motor
IMPORTANT: Tighten valve to a torque of 45 to • Hydraulic pump
55 in. lbs. (5 to 6 N·m).
Unit locked in tilt up:
Stern Brackets • Mechanical binding
Inspect the stern brackets for binding. • Hydraulic pump
Tighten starboard tilt tube nut to a torque of 45 to
50 ft. lbs. (61 to 68 N·m).
348
TRIM AND TILT
ELECTRICAL CIRCUIT TESTS
ELECTRICAL CIRCUIT Connect a 0 to 100 A DC ammeter in series

between the battery side of the starter 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 motor wire returns to a
grounded position.
When the trim-DOWN button 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 released, the green 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. 106 for Compare test results to the values listed:
relay testing procedure.
75 - 90 HP MODELS
Trim and Tilt Motor Normal Time in
Current Draw Tests Mode Current Draw Seconds
Careful analysis of the electric motor's current Full Range UP <30 A 12-18
draw and trim/tilt unit operating speed aids evalu-
Full Range DOWN <30 A <18
ation of the electric motor and certain mechanical
components. Stall <40 A –
Use a battery rated at 360 CCA (50 Ah) or higher 40 - 60 HP MODELS

that is in good condition and fully charged to per-
form this test. Normal Time in
Mode Current Draw Seconds
IMPORTANT: Specifications are for static Stall UP 11 to 16 Amps –
hydraulic tests. DO NOT attempt to perform the
following tests while the boat is moving. Stall DOWN 16 to 22 Amps –
Full Range UP – 13 to 19
Full Range DOWN – 10 to 16
13
349
TRIM AND TILT
Test results include three basic possibilities: Monitor motor RPM and current draw.
A. Low current draw – Check for:

• Valves leaking
• Pump damaged
• O-rings leaking
• Manual release valve damaged
B. High current draw – Check for:
• Valves sticking
• Pump binding
• Motor binding
• Cylinder binding
30957
C. Normal current draw, slow operating
speed – Check for: The motor shaft must rotate clockwise, as viewed
• Manual release valve damaged from the pump end, when positive (+) is applied to
the blue lead, and negative (–) is connected to
Trim and Tilt Motor No Load Test green lead.
IMPORTANT: Securely fasten motor in a suit- The motor shaft must rotate counterclockwise, as
able fixture before proceeding with this test. viewed from the pump end, when positive (+) is
applied to the green lead, and negative (–) is
Use a battery rated at 360 CCA (50 Ah) or higher applied to the blue lead.
that is in good condition and fully charged to per-
form this test. Blue lead (+) Green lead (+)
Green lead (-) Blue lead (-)
Connect a 0 to 25 A ammeter in series with the
battery positive (+) terminal, ammeter red lead
toward terminal.
Attach or hold a vibration or mechanical tachome-
ter to the motor while performing this test.
DR4238r
If test results vary, replace the motor.
350
TRIM AND TILT
Trim Gauge Test Trim Sender Test

STEP 1 IMPORTANT: To avoid immediate meter dam-
Turn key switch ON. Using a voltmeter, check for age, never apply an ohmmeter to an electrical cir-
voltage between the trim gauge “I” and “G” termi- cuit where voltage is present.
nals.
Disconnect the 3-pin connector between the
• If no voltage, check condition of instrument har-
instrument harness and engine trim harness.
ness, key switch, and engine 20 A fuse.
Connect an ohmmeter between the white/tan wire,
• If voltage is shown, go to STEP 2. terminal “C,” of the engine harness and a clean
engine ground.
With the outboard fully DOWN, meter must show

a reading above 80 ohms.
With the outboard fully UP, meter must show a
reading below 10 ohms.
• If results agree, refer to Trim Gauge Test on
p. 351.
• If results are different, replace trim sender.
DRC6245
STEP 2
Remove the white/tan lead from the trim gauge
“S” terminal. With key switch ON, gauge should
indicate full-trim DOWN position. Now connect a
jumper wire between terminals “S” and “G.” Gauge
should indicate full-trim UP position.
• If results are different, replace the trim gauge.
• If results agree, refer to Trim Sender Test. DRC6247
DRC6246A
13
351
TRIM AND TILT
TRIM AND TILT REPLACEMENT
TRIM AND TILT Separate the trim/tilt unit wires in the braided tube
to permit removal through the hole in the stern
REPLACEMENT bracket.
Removal
Raise the outboard and engage the tilt support.
Remove the rubber grommet from the blue/green

trim/tilt cable connector.
25078
40 – 60 HP MODELS
Remove the spring clip from the cylinder pin.
000686
Remove the terminals from the connector 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.
15493
Thread Adapter, P/N 340624, onto Slide Hammer,

P/N 391008. Screw the adapter into the cylinder
pin and remove the pin.
1
000687
2
1. Thread adapter 39434

2. Slide hammer
3. Cylinder pin
352
TRIM AND TILT
Remove one of the locknuts from the angle adjust- Use a punch to remove the upper pin.
ment rod. Remove the rod from the stern brack-
ets.
25065
Retract the tilt cylinder rod.

18941
Remove the external snap rings from the lower
Remove the unit from the stern brackets far pin.
enough to remove the ground lead from the pump
motor mounting screw.
25077
1. Ground lead 007640

Use a punch to remove the lower pin and remove
75 – 90 HP MODELS the trim/tilt unit from the stern brackets.
Remove the external snap rings from the upper
pin.
25076
25064
13
353
TRIM AND TILT
Remove the unit from the stern brackets far Lubricate the angle adjustment rod with Triple-
enough to remove the ground lead from the pump Guard grease. Install the rod. Tighten the locknuts
motor mounting screw. to a torque of 20 to 25 ft. lbs. (27 to 34 N·m).
1. Ground lead 002527

18941
Installation Loosen the manual release valve if necessary and

extend tilt cylinder rod to match with holes in
40 – 60 HP MODELS swivel bracket.
Lubricate the cylinder and thrust rod bushings with
Triple-Guard grease. Install the bushings. Apply Triple-Guard grease to upper pin and install
the pin.
Secure the cylinder pin with cotter clip.
15591
Install the ground lead.

15493
Place trim/tilt unit into position.
354
TRIM AND TILT
75 – 90 HP MODELS ALL MODELS

Install the ground lead. Place trim/tilt wires in braided tube and install
through hole in the stern bracket.
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.
25079
Install connector on trim/tilt cable and reconnect

trim connectors to engine wire harness.
25077 Release the tilt support and lower the outboard.
Tighten the manual release valve to a torque of 45
Loosen the manual release valve if necessary and to 55 in. lbs. (5 to 6 N·m).
extend tilt cylinder rod to match with holes in
swivel bracket.
Apply Triple-Guard grease to upper pin and install
the pin.
Install external snap rings onto upper pin with

sharp edge facing out.
25064
13
355
TRIM AND TILT
TRIM AND TILT SERVICE
TRIM AND TILT SERVICE Screw the manual release valve in. Remove the
retaining ring using a small pick or screwdriver.
Disassembly Discard the retaining ring.
Thoroughly clean the unit before disassembling.
Scrub all outside surfaces with a stiff brush and
hot, soapy water to prevent surface dirt from con-
taminating internal parts.
Always use a lint free shop cloth when handling

power trim/tilt components.
If painting the unit is required, paint it after it is

completely assembled. Painting of individual com-
ponents may cause flakes of paint to enter the
hydraulic passages during assembly. Tape the 40 - 60 HP Models 002528
trim/tilt piston rods before painting.
WARNING
There may be high pressure behind some
power trim valves. To avoid injury when
removing manual release valve, be sure to
cover valve with a shop cloth until the
pressure is released. Wear safety glasses.
IMPORTANT: Before removing manual release

valve, relieve pressure by fully extending cylinder.
75 - 90 HP Models 004279
356
TRIM AND TILT
Slowly remove the manual release valve. There Remove the four large motor flange retaining
may be pressure behind the valve—wear safety screws. Remove the motor and discard O-ring,
glasses. screws, and washers.
40 - 60 HP Models 002529 40 - 60 HP Models 002531
75 - 90 HP Models 004285 75 - 90 HP Models 004282
Inspect the manual release valve. Discard the O- Remove drive coupler from either the motor or the
rings on the housing. pump assembly.
007108
002532
13
357
TRIM AND TILT
Assembly Oil O-rings and install them on the manual release

valve. Oil and install the manual release valve.
IMPORTANT: Use only Evinrude/Johnson Bio- Tighten the valve to a torque of 45 to 55 in. lbs. (5
degradable TNT Fluid to fill the hydraulic system. to 6 N·m).
Install drive coupler in pump assembly.
Install a new motor O-ring.
40 - 60 HP Models 002529
002533
Position the motor on the manifold and install four

new screws and lock washers. Tighten the screws
35 to 50 in. lbs. (4 to 5.6 N·m).
75 - 90 HP Models 004285
Install new retaining ring in groove.
40 - 60 HP Models 002531
1
1. Retaining ring 002534
75 - 90 HP Models 004282
358
TRIM AND TILT
Fill the oil reservoir up to the fill plug with

Evinrude/Johnson Biodegradable TNT Fluid.
Install the fill plug.
40 - 60 HP Models 007646
75 - 90 HP Models 004278
Run the motor, then recheck oil level. Cycle the

unit several times and check the oil level when the
cylinder is fully extended. Oil should be level with
bottom of fill port. Install and tighten the fill plug to
a torque of 45 to 55 in. lbs. (5 to 6 N·m).
13
359
TRIM AND TILT
NOTES
NOTES
Bulletins
Instruction Sheets
Other
360
MANUAL STARTER
MANUAL STARTER
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
RECOIL STARTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
RECOIL STARTER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
RECOIL STARTER CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
RECOIL STARTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
RECOIL STARTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
14
361
MANUAL STARTER
SERVICE CHART
SERVICE CHART
60 to 84 in lbs.
(7 to 9.5 N·m)
F
120 to 144 in lbs.

(13.5 to 16 N·m)
E
96 to 120 in lbs.
(11 to 13.5 N·m)
120 to 144 in lbs.

(13.5 to 16 N·m)
F
E Red Ultra Lock

F Blue Nut Lock
003724 V Lubriplate 777
362
MANUAL STARTER
RECOIL STARTER REMOVAL
RECOIL STARTER RECOIL STARTER

REMOVAL DISASSEMBLY
WARNING WARNING
To prevent accidental starting while ser- Wear safety glasses while disassembling
vicing, twist and remove all spark plug and assembling manual starters because
leads. of rewind spring tension.
Remove the clamp holding the oiling system wir- Pull the starter rope out far enough to tie a slip
ing harness. knot in the rope. Remove the end of the starter
rope from the handle anchor and remove the han-
Remove the three starter housing screws and dle. Release the slip knot and ease the rope back
washers. in until the rewind spring is fully unwound. If nec-
essary, remove the starter handle bracket from the
1 starter housing.
2
2
1
2
1. Clamp 002515
2. Starter housing screws (3)
1. Slip knot 007853

Lift starter housing from outboard. 2. Rope anchor
Remove three screws and remove starter ratchet

from flywheel. Remove the rope guide and pulley support from
the starter housing.
1
1
2
1. Ratchet 006483
1. Rope guide 007854
2. Pulley support
14
363
MANUAL STARTER
RECOIL STARTER DISASSEMBLY
Remove the nut from the starter pawl retaining Use a screwdriver to pry open the pulley lock ring,
screw. and remove ring from the starter.
1
1
1. Lock ring COA1368
1. Nut 007855
Remove the friction plates and friction plate spring
washer.
Remove the starter pawl retaining screw, washer,
and starter pawl plate with plate return spring from
the starter assembly.
1 2
4
2
3 1
1. Friction plates 34854
2. Friction plate spring washer
1. Screw 007856 Hold the pulley in the starter housing while turning
2. Washer the starter over, legs down. Hold fingers clear of
3. Plate
4. Spring the pulley and jar the starter housing against a
bench to dislodge the rewind spring and pulley.
Remove starter housing spring and starter pawl Remove the pulley bushing from the pulley.
with spring washer from the starter assembly.
2 3
007857
1. Spring 34855
2. Starter pawl
3. Spring washer (under starter pawl)
364
MANUAL STARTER
RECOIL STARTER CLEANING AND INSPECTION
RECOIL STARTER RECOIL STARTER

CLEANING AND ASSEMBLY
INSPECTION WARNING
Wash metal components in solvent and dry with Wear safety glasses while disassembling
compressed air. and assembling manual starters because
Inspect the rewind spring for broken end loops of rewind spring tension.
and weak tension.
Place starter spring shield and pulley bushing into
Examine the starter pawl for wear. the starter housing.
Inspect the starter components for wear. Replace
as necessary.
Inspect starter rope. Replace rope if frayed. Cut
new rope 96.5 in. (245 cm) in length. Fuse ends of
rope to a length of 1/2 in. (12 mm).
Examine the pulley and the starter housing. Look
for sharp edges and rough surfaces that could 1
fray the starter rope. File and polish to remove.
Examine the starter and starter lockout parts.

Replace any worn or damaged parts. 1. Shield COA1360
Clamp base of Starter Spring Winder and Installer,

P/N 392093, in a vise. Insert release plate into
spring winder base.
2
1
1. Base CO3593
2. Plate
14
365
MANUAL STARTER
RECOIL STARTER ASSEMBLY
Apply Triple-Guard grease or Lubriplate 777 to the Install the rewind spring into the starter housing.
rewind spring. Install the rewind spring into the Locate the outer loop of the rewind spring on the
spring winder base with open loop of spring facing pin in the starter housing. Press down through the
inward. Insert the pin of the crank and pin assem- holes in the spring winder base to transfer the
bly into the loop of the rewind spring. Secure the rewind spring into the starter housing.
crank and pin assembly to the starter winder base
with the crank retainer screw.
1
1. Outer loop CO3584
2. Pin
CO3591
Apply Triple-Guard grease or Lubriplate 777 to the
Rotate the crank and pin assembly in the direction pulley bushing. Install the pulley bushing in the
shown on the tool. Wind the spring into the starter pulley. Place the pulley shim on the pulley.
winder base until end of spring contacts the starter
winder base.
Remove the crank retainer screw and the crank 1

and pin assembly from the starter winder base.
Remove the starter winder base from the vise.
2
1. Bushing COA1364
2. Shim
Bend the inside loop of the rewind spring in

toward the center of the starter housing. Place the
CO3589
366
MANUAL STARTER
inner loop of the spring in the slot of the pulley, Place the starter housing spring in the starter
and install the pulley in the starter housing. housing.
2
2
1 3
1. Inside loop COA1365 1. Lock ring COA1361

2. Slot 2. Spring washer (under starter pawl)
3. Spring
Place the friction plate spring washer between the

two friction plates on the pulley hub. Secure the Install the starter pawl plate return spring on the
friction plate and friction plate spring washer with starter pawl plate. Press the other end of spring
the pulley lock ring. on the boss of the pulley. Position the starter pawl
plate on the pulley.
2
1
1
2
1. Friction plate spring washer 34854

2. Friction plates 1. Spring 46767
2. Plate
Make sure the starter pawl bushing is installed in

the pulley. Apply Triple-Guard grease or Lubriplate Clean threads of the starter pawl plate retaining
777 to boss of the starter pawl. Place spring screw and nut to remove adhesive.
washer on the boss of the starter pawl. Place the
starter pawl in the pulley.
14
367
MANUAL STARTER
Install the starter pawl plate retaining screw and If removed, install the starter handle bracket to the
washer into the starter housing. Tighten screw to starter housing. Tighten screws securely.
1 1
1. Starter handle bracket 002517

1. Screw COA1375
Tie a knot in one end of the starter rope. With the
Spray threads of starter pawl plate retaining screw starter housing upside down on a bench, wind the
and nut with Locquic Primer. Apply Nut Lock to the pulley counterclockwise until the rewind spring is
threads of the nut. Install and tighten the nut tight.
securely.
Back off the rewind spring until the rope cavity of
Install the rope guide and pulley support to the the pulley is aligned with the rope guide. Thread
starter housing. Tighten the screws securely. the starter rope through the pulley, rope guide,
and outlet in the starter handle bracket.
Seat the knotted end of the starter rope in the pul-

1 ley. Tie a slip knot in the starter rope to hold rope
in position.
2
Apply Triple-Guard grease or Lubriplate 777 to the
handle end of the starter rope. Using Starter Rope
Threading Tool, P/N 378774, thread the starter
rope through the handle.
1. Rope guide 007854

2. Pulley support
COA1373
368
MANUAL STARTER
RECOIL STARTER INSTALLATION
Press the starter rope into the channel of the rope

anchor, with end of starter rope firmly against end
RECOIL STARTER
of channel. Press the anchor into the handle. INSTALLATION
Apply Nut Lock to the threads of starter ratchet
screws. Install washers and ratchet on flywheel.
Tighten screws to a torque of 120 to 144 in. lbs.
(13.5 to 16 N·m).
007858
Check operation of the starter pawl when the

starter rope is pulled out. The starter pawl should
extend when the starter rope is pulled and retract
when the starter rope recoils. 006654
Place the starter assembly onto the outboard.

Install the starter housing retaining screws, wash-
ers, and lock washers. Be sure to place washers
between the starter housing and the flywheel
cover. Apply Ultra Lock to threads and tighten the
three starter housing screws to a torque of 120 to
144 in. lbs. (14 to 16 N·m).
Install clamp for oiling system wiring harness.
2
1
1
1. Starter housing screws (3) 002515

2. Clamp
14
369
MANUAL STARTER
NOTES
NOTES
Bulletins
Instruction Sheets
Other
370
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
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 all shop technicians. Always
follow common shop safety practices. If you have not had training related to common shop
safety practices, you should do so not only to protect yourself, but also to protect the people
around you.
It is impossible for this manual to cover every potentially hazardous situation you may
encounter. However, your understanding and adherence to the recommendations 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 and how you can help make it safe. Some of these safety issues
you will know, others you may not.
First!
A word about parts... Plain parts; special parts; all parts!
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 bolts and nuts are often used to hold steering, shift, and throttle remote control
cables to the outboard.
• When you take any outboard off a boat, keep track of special nuts and bolts. Do not mix with other
parts. Store them on the outboard, then they are there when you need them.
• When the outboard is returned to the boat, use only the special nuts and bolts to hold remote steer-
ing, shift, and throttle cables to the outboard.
S–3
SAFETY
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 propeller 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 Operator cannot slow down the outboard or shift into NEUTRAL gear (stop propeller), Operator
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 apart, 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 speed), loose steering could lead to loss of
boat control.
S–6
SAFETY
How can loss of steering control be minimized?

• Use a steering system recommended by the outboard manufacturer which meets
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 touch other boat, outboard,
or accessory parts in transom area.
Why? A hard blow to the outboard’s
gearcase can result in damage to steer-
transom ing parts.
mounted
steerer stop stop
to
Be aware that raising or lowering outboard on

transom can change a set-up which was OK
earlier. If moved up or down even one-half inch,
run test again 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, swivel brack-
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 fuel or electrical systems parts with other parts which may look the 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... GA
outside the boat
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
GASOLINE
Check for leaks
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 transom, boat occupants 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 engine speed below 2000 RPM.
With no load, outboard will run too fast
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
DANGER
DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to
accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled,
can cause serious brain damage or death.
• Whenever running the engine, assure there is proper ventilation to avoid the accumulation of carbon
monoxide (CO), which is odorless, colorless, and tasteless, and can lead to unconsciousness, brain
damage, or death if inhaled in sufficient concentrations. CO accumulation can occur while docked,
anchored, or underway, and in many confined areas such as the boat cabin, cockpit, swim platform,
and heads. It can be worsened or caused by weather, mooring and operating conditions, and other
boats. Avoid exhaust fumes from the engine or other boats, provide proper ventilation, shut off the
engine when not needed, and be aware of the risk of backdrafting and conditions that create CO accu-
mulation. In high concentrations, CO can be fatal within minutes. Lower concentrations are just as
lethal over long periods of time.
S–19
SAFETY
Running outboards: Propellers
DANGER
Contact with a rotating propeller is likely to result in serious injury or death. Assure the
engine and prop area is clear of people and objects before starting engine or operating boat.
Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and
the propeller can continue to turn even after the engine is off. Always shut off the engine
when near people in the water.
Eye protection
Eyes need protection when:
• 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 charger plug out of 110 V
posts. You will make sparks and outlet
serious burns are possible. • Take charger cables off battery
posts
S–21
SAFETY
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 take responsibility for the safe maintenance practices and proce-
dures of your repair shop, co-workers, and technicians?
3) Do you understand all the safety precautions and instructions contained in this entire
service manual?
4) Will you follow all safety warnings, precautions, instructions and recommendations
outlined in this service manual?
5) Do you understand that the service manual as a whole and this Safety section, in par-
ticular, contain essential information to help prevent personal injury and damage to
equipment and your customers?
6) Have you received training related to common shop safety practices to protect your-
self and others around you?
7) When replacement parts are required, will you use Evinrude ®/Johnson ® Genuine
Parts or parts with equivalent characteristics, including type, strength and material?
8) Are you ready to follow the recommendations in this service manual before you ser-
vice any boat or outboard?
9) Do you understand that safety-related accidents 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 Pinion Gear 305, 329
Abbreviations 6 Propeller Shaft 310, 335, 336
Accessories Wrist Pin 197, 205
Battery Cable, P/N 584348 64 Break-In
XD100 Outboard Oil Decal, P/N 352369 EMM Programming 165, 220
164 Gearcase 298, 317, 320, 342
Adjustments Oiling 165
Control Cable 19, 276, 286 Procedure 67
Shift Linkage 220
Shift Rod 11, 13, 300, 323 C
Steering Friction 27 Capacitor Test 83
Throttle Friction 27 Clamp Screw 258
Tilt Limit Switch 28 Connecting Rods
Timing Pointer 113 Installation on Crankshaft 209
TPS Calibration 114 Installation on Piston 205
Trim Sending Unit 29, 30 Orientation 205, 209
Trim Tab 31 Removal from Crankshaft 196
Air Silencer 43 Removal from Piston 197
Air Temperature Sensor TIghtening 209
Connections 92 Control Cable
Description 57 Adjustments 19
Resistance Test 96 Installation 19
Alternator Circuit Test 99 Cooling System
AMP Connector Servicing 117 Adapter Housing 177
Anodes Components 176
Anti-Corrosion 44 Cylinder Block Venting 178
Continuity Check 44 EMM and Vapor Separator Cooling 179
Gearcase 301, 324 Engine Temperature Check 180
Propeller Shaft Bearing Housing 310, 335 Exhaust Housing 176
Stern Bracket 252, 254, 257 Flushing 35
Hose Routing and Water Flow 174
B Operating Temperatures 11, 13, 34
Batteries Operation 179
Charging System Tests 98 Pressure Relief Valve 177, 183
Connections 24 Running on a hose 36
Maintenance 24 Thermostat 11, 13, 177
Requirements 11, 13 Thermostats 177, 182
Storage 46 Vapor Separator 133
Bearing Water Intake Screens 34, 305, 328, 338
Connecting Rod 209 Water Pump 176, 298, 320
Crankshaft 198, 199, 203, 204 Water Supply Tube 176, 248, 249
Driveshaft 309, 334 Corrosion
I–1
INDEX
Anodes 44, 252, 254, 257, 301, 310, 324, 335 Oiling Rate 66, 164
Cylinder walls 200 Reports 69
Long Term Storage 45 Sensor Monitoring 95
Metal components 44 Service Codes 65
Steering Cable 37 Static Ignition Test 81
Cover Service 50 Timing Verification 67, 114
Crankcase TPS Calibration 68, 114
Assembly 211 Driveshaft
Disassembly 195 Installation 314, 340
Crankshaft Removal 303, 325
Assembly 203, 208 Service 327
Disassembly 197 Shimming 312, 337
Inspection 201 Driveshaft Bearing Housing 309, 334
Crankshaft Position Sensor Dual-Outboard
Description 59 Alignment 32
Operation Test 80 I-Command settings 23
Resistance Test 95
Cylinder Bore E
Honing 200 Electrical Circuits
Inspection 201 EMM Pin Locations 92
Cylinder Head Fuse 94
Inspection 201 Ground Circuits 94
Installation 207 Key Switch 102
Removal 196 Start Circuit 100
SystemCheck 107
D Electrical Connectors
Deutsch Connector Servicing 116 AMP Connectors 117
Diagnostic Procedures Deutsch Connectors 116
Dynamic Tests 76 Packard Connectors 119
Fuel Delivery Tests 84 Electrical Harness
Ignition Tests 79 Connections 20, 21
LED Indicators 77 Emergency Stop Switch
Strategy 74 Operation Check 33
Diagnostic Software Test 105
Break-In Programming 165 Emissions Information 7
Communication With Outboard 63 EMM
Crankshaft Position Sensor 80 12 V Circuit Sensor 56
Cylinder Drop Tests 76 Connections 54, 55, 92
Diagnostic Procedures Overview 74 Diagnostics 63, 74
Fuel Injector Programming 68, 146 Functions 54, 60
Fuel Injector Tests 84 LED Indicators 77
Fuel Pump Test 84 Sensors 56, 57
I-Command settings 23 Service Codes 65
Idle Speed Control 68 Servicing 70
Oil Injector Test 167 Software Replacement 69
Oil Priming 170 Timing Verification 114
I–2
INDEX
TPS Calibration 114 Pressure Tests 137

Transfer 70 Priming 136
Engine Monitor Relieving Pressure 142
Description 61 Requirements 130
Low Oil Warning 58, 162, 168 Troubleshooting 76, 84, 137
No Oil Warning 162 Vapor Separator 132, 144
Operation Check 33 Fuse 94
Engine Temperature Check 180
Engine Temperature Sensor G
Description 57 Gearcase
Resistance Test 96 Assembly 313, 338
Exhaust Housing Disassembly 301, 324
Assembly 249 Inspection 301, 324
Cleaning and Inspection 249 Installation 297, 319
Installation 245, 247 Leak Test 295
Removal 243, 246 Lubricant 11, 13, 39
Exhaust Water Valve Removal 296, 318
Service 244 Grommet 18, 19
Tests 86, 106
Exterior Finish Protection 44 H
Honing 200
F Hoses
Flushing, Cooling System 35 Grommet 18
Flywheel Inspection 43
Installation 111 Oil Distribution 169
Removal 110 Oil Recirculation System 163
Fuel Injectors Routing, Cooling System 174
Crush Ring Replacement 146 Routing, Fuel System 126
Electrical Circuits 128
EMM Programming 146, 147 I
Installation 147 I-Command
Removal 146 Outboard connections 21
Tests 138, 139 System settings 23
Fuel System Water Pressure Gauge 23
Additives 10, 12, 131 Idle Speed 10, 60, 68
Components 132 Ignition
Filter 132, 143 Control Circuit Tests 83
Fuel Circulation Pump 84, 134, 139 Electrical Circuits 90, 91
Fuel Filter 43 Ignition Coil Servicing 112
Fuel Lift Pump 132, 139, 141, 143 Ignition Coil Tests 83
Fuel Manifolds 145 Required Systems 79
Fuel Requirements 131 Running Tests 82
Hose Routing 126 Static Ignition Test 81
Injector Servicing 68 Timing 67
Intake Manifold 149 Information Display Systems
Minimum Octane 10, 12, 131 Tachometer Setting 33
I–3
INDEX
Intake Manifold Muffler

Assembly 150 Installation 219
Disassembly 150 Removal 192
Inspection 150 Servicing 244
Installation 151
Removal 149 N
New Engines
K Outboard Rigging Procedure 17
Key Switch
Operation Check 33 O
Start Circuit 102 Oetiker Clamp Servicing 25
Oil Injector
L Electrical Circuit (55 V) 161
LED Indicators 77 Electrical Tests 166
Lower Cover Functional Test 168
Installation 51 Oiling Rate 66, 164
Removal 50 Oiling System
Lubrication Components 160
Engine Oil 10, 12, 160 Electrical Circuits 159
Gearcase 11, 13, 39 Engine Lubricant 10, 12, 160
Power Trim 11, 13 Low Oil Switch 58
Propeller Shaft 39 New Engine Set-Up 160
Swivel Bracket 38 Oil Distribution 156
Throttle and Shift Linkage 38 Oil Distribution Hoses 156, 169
Tiller handle 37 Oil Filters 43
Tilt Tube 38 Oil Recirculation 163
Trailering Bracket 38 Oil Tank 160, 169
Trim and Tilt 41 Oiling Rate 66, 164
Priming 165
M Servicing 169
Maintenance Schedule 16 Tests 166
Manual Starter Outboard Excessive Smoking T–5
Assembly 365 Outboard Hard to Start T–3
Installation 369 Outboard Starts and Stalls T–4
Rope Replacement 368 Outboard Starts, Low Maximum RPM T–5
Manual Tilt Outboard Surges, Runs Rough T–6
Assembly 268 Outboard Will Not Start T–1
Disassembly 265 Outboard Won’t Shut Off T–4
Models
Included Models 9 P
Model Designation 8 Packard Connector Servicing 119
Serial Number Location 8 Pinion Gear
Motor Mounts Bearing Installation 305, 329
Lower Mount Servicing 243, 245, 246, 247 Bearing Removal 305, 329
Upper Mount Servicing 215, 243, 245, 251, Installation 314, 340
253, 258 Removal 303, 325
I–4
INDEX
Piston Rings RPM Limit 11, 13, 59, 60

End Gap 202, 206
Installation 206 S
Removal 197 S.A.F.E.
Pistons Description 62
Assembly 205 Low Oil 58
Inspection 202 No Oil 162
Installation 206 Temperature 56, 57
Removal 196 Safety 1
Powerhead Sensor Tests 95
Assembly 203 Sensors
Cleaning 200 Air Temperature Sensor 57, 96
Cylinder Compression Testing 190 Barometric Pressure Sensor 57
Disassembly 193 Crankshaft Position Sensor 59, 80, 95
Inspection 201 EMM 56
Installation 216 Engine Temperature Sensor 57, 96, 182
Removal 190 Throttle Position Sensor 59, 95
Predelivery Checks 33 Service Charts
Pre-Season Service 46 Electrical and Ignition 88
Pressure Relief Valve Fuel System 122
Assembly 184 Gearcase 290
Disassembly 183 Manual Starter 362
Inspection 184 Midsection 234
Priming Oiling System 154
Fuel System 136 Shift Cable Adjustment, Tiller 286
Propeller Shift Housing
Inspection 293 Assembly 307, 332
Installation 294 Installation 313, 338
Selection 293 Removal 304, 328
Propeller Shaft Shift Linkage
Installation 313, 338 Adjustment 220
Lubrication 39 Installation 212
Removal 304, 328 Lubrication 38
Propeller Shaft Bearing Housing Removal 194
Disassembly 310, 335 Shift Rod
Installation 316, 341 Housing Installation 339
Removal 302, 325 Shift Rod Adjustment 11, 13, 300, 323
Shimming, Driveshaft 312, 337
R Shutdown 62
Relays No Oil 162
Trim and Tilt 106, 349 Spark Plugs
Remote Controls Gap 11, 42
Cable Adjustment 19 Indexing 42
Rigging Maintenance Schedule 16
Outboard 17 Recommendation 11, 13, 42
Rope Replacement 368 Removal 42
I–5
INDEX
Replacement 42 Tests 107, 108, 109

Service 42 Winterization Procedure 45
Specifications 10
Starter T
Assembly 365 Tachometer
Circuit Description 100 Pulse Setting 33
Current Draw Test 103 Technical Data 10
Installation 115, 369 Temperature
Removal 115 Operating 34, 180
Rope Replacement 368 Operation below freezing 160
Solenoid Test 102 Sensors 57
Voltage Drop Test 103 Temperature Sender
Start-In-Gear Protection 33 Service 182
Stator Thermostat
Resistance Test 97 Assembly 183
Service 111 Description 177
Voltage Output Test 97 Disassembly 182
Steering Handle Inspection 183
Assembly 273, 281 Temperature 11, 13
Disassembly 272, 278 Throttle Cable Adjustment, Tiller 276, 287
Inspection 273, 281 Throttle Linkage
Installation 275, 285 Installation 213
Removal 271, 277 Lubrication 38
Steering System Removal 194
Lubrication 37 Throttle Position Sensor
Steering Arm and Shaft 251, 253, 257, 259 Description 59
Steering Friction 27, 259 Resistance Test 95
Steering Torque 31 Tiller Adjustments
Stern Bracket Steering Friction Adjustment 27
Assembly 252, 256, 261 Tiller handle
Disassembly 251, 253, 258 Lubrication 37
Manual Tilt 265 Tilt Limit Switch
Removal 252, 260 Adjustment 30
Stop Circuit 105 Cam Installation 241, 242
Storage 45 Tilt Support 346
Submerged Engines 47 Tilt Tube
Swivel Bracket Installation 242, 253
Installation 257 Lubrication 38
Lubrication 38 Removal 241, 252
Manual Tilt 265 Timing Adjustments
Removal 254 Timing Verification 114
SystemCheck TPS Calibration 114
Circuits 107 Timing Pointer Adjustment 113
LOW OIL Warning Signal 162 Tools
NO OIL Warning Signal 162 Accessory Power Cable Kit, P/N 5008092
Outboard connections 20 63
I–6
INDEX
Backing Plate, P/N 325867 304, 326 Key Switch Assembly, P/N 176408 64
Ball Socket Installer tool, P/N 342225 276, Large Puller Jaws, P/N 432129 199, 309,
287 310, 334, 335
Ball Socket Remover tool, P/N 342226 149, Lifting Fixture, P/N 396748 191, 192, 216,
271, 277 218
Battery Cable, P/N 584348 64 Lower Driveshaft Puller, P/N 342681 326
Bearing Installation Tool, P/N 326562 311, Oetiker Pincers, P/N 787145 26
336 Peak Reading Voltmeter, P/N 507972 98
Bearing Installation Tool, P/N 339750 336 Pinion Bearing Remover and Installer, P/N
Bearing Puller, P/N 432130 310 5005927 305
Bootstrap Tool, P/N 586551 69 Pinion Bearing Remover/Installer, P/N
Collar, P/N 328363 312 5005927 305, 329
Collar, P/N 341440 337 Pinion Nut Holder, P/N 334455 325, 341
Connector Service Tool, P/N 342667 116 Pinion Nut Starting Tool, P/N 320675 315
Crankshaft Bearing/Sleeve Installer, P/N Pinion Nut Starting Tool, P/N 342216 340
338647 203 Piston Stop Tool, P/N 342679 113
Crimp Tool, AMP 117 Primary Lock Tool, P/N 777077 117
Crimping Pliers, P/N 322696 116 Puller Bridge, P/N 432127 309, 310, 334,
Diagnostic Interface Cable, P/N 437955 63 335
Diagnostic Power Supply, P/N 587005 63, Puller, P/N 387206 304
80 Retaining Ring Pliers, P/N 331045 302, 316
Driveshaft Holding Socket, P/N 311875 Rod Cap Alignment Fixture, P/N 396749
325, 341 209
Driveshaft Holding Socket, P/N 334995 Seal Installation Tool, P/N 326551 311, 336
303, 316 Seal Installation Tool, P/N 330268 334
Driveshaft Puller, P/N 390706 326 Seal Installation Tool, P/N 336311 336
Driveshaft Seal Protector, P/N 312403 312, Seal Installer, P/N 342665 309
313, 315 Secondary Lock Installer, P/N 777079 117
Driveshaft Seal Protector, P/N 318674 337, Secondary Lock Tool, P/N 777078 117
338, 340 Shim Gauge Bar, P/N 328366 312
Driveshaft Shimming Tool, P/N 5005925 Shim Gauge Bar, P/N 328367 337
312, 337 Slide Hammer Adapter, P/N 340624 352
Electrical Test Probe Kit, P/N 342677 99 Slide Hammer Adaptor Kit, P/N 390898 146
Flywheel Holder, P/N 771311 111 Slide Hammer, P/N 391008 146, 203, 326,
Fuel Pressure Gauge, P/N 5006397 139 352
Fuel Pressure Gauge, P/N 5007100 137, Slide Hammer, P/N 432128 199, 242
142 Small Puller Jaws, P/N 432131 335
Gauging Head, P/N 352879 328 Starter Rope Threading Tool, P/N 378774
Gearcase Alignment Gauge Kit, P/N 368
5006349 328 Starter Winder/Installer Kit, P/N 392093
Gearcase Filler, P/N 501882 40 365
Gearcase Pressure Tester, P/N 507977 Stator Test Adaptor, P/N 5005799 97, 98
295 Syringe, P/N 346936 168
Gearcase Vacuum Tester, P/N 507982 295 Temperature Gun, P/N 772018 180, 181
Guide Pins, P/N 383175 317 Terminal Release Tool, P/N 351413 118
Injector Test Fitting Kit, P/N 5005844 138 Thermal Joint Compound, P/N 322170 181
I–7
INDEX
Tilt Tube Service Kit, P/N 434523 241 Strategy 75

Torquing Socket, P/N 331638 196, 210 Trim and Tilt 348, 349
Twist-Grip Remover, P/N 390767 272, 279
Universal Puller Set, P/N 378103 111, 302, U
325 Upper Mount Servicing 215
Universal Shift Rod Height Gauge, P/N
389997 300, 323 V
Wrench Retainer, P/N 341438 325, 341 Vapor Separator
Wrist Pin Bearing Tool, P/N 336660 205 Description 132
Wrist Pin Cone, P/N 318600, 206 Installation 144
Wrist Pin Pressing Tool, P/N 326356 197 Removal 144
Wrist Pin Retaining Ring Driver, P/N Voltage Drop Test 103
318599 206
Torque Charts W
see Service Charts Water Intake Screens 34, 305, 328, 338
TPS Calibration 114 Inspection 34
Trailering Bracket 346 Water Pressure Gauge 23
Lubrication 38 Water Pump
Trim and Tilt Assembly 299, 321
Assembly 358 Description 176
Disassembly 356 Disassembly 298, 320
Electrical Circuit Tests 106 Inspection 298, 320
Inspection 348 Water Tube 248, 249
Installation 354 Winterizing 45
Lubrication 41 Wrist Pin
Removal 352 Bearing 197
Reservoir Fluid 11, 348 Installation 205
Troubleshooting 348, 349 Removal 197
Trim Gauge Test 351
Trim Sender
Adjustment 29, 30
Test 351
Trim Tab
Adjustment 31
Installation 297
Removal 296, 318
Troubleshooting
Charging System Tests 98
Cylinder Drop Tests 76
Diagnostic Procedures 74
Fuel Control Adjustment 76
Fuel System 84, 137
Ignition 79, 82
Oiling System 166
Sensors 95
Stator Resistance Test 97
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.
In gear–Tiller models Make sure outboard is in neutral
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
FUEL SYSTEM
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 control
Check cranking RPM (300 minimum), refer to
signal from EMM to ignition
SYSTEM ANALYSIS
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)
Neutral switch, tiller models Check neutral switch operation
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
Check for air in fuel supply manifold, refer to
Air in fuel system FUEL SYSTEM (vapor separator venting and fuel
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
Outboard eventually Low or no alternator output Check voltage on 55 V circuit, refer to SYSTEM
starts, may or may not (55 V) ANALYSIS and ELECTRICAL AND IGNITION
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
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

SystemCheck light Outboard is in S.A.F.E. Check Service Codes and SystemCheck 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
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 Weak or erratic ignition Check ignition, refer to SYSTEM ANALYSIS and
outboard at lower operation ELECTRICAL AND IGNITION
speeds appears Fuel injector electrical circuit or Check voltage at injectors, refer to SYSTEM
normal 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
quality
Excessive fuel or oil Check fuel system for fuel supply air leaks or
May coincide with consumption leaking fuel injectors
increased oil Outboard in break-in mode Use diagnostics program to check
consumption
Outboard mounted too low Check installation height of outboard
(normal if occurs after
winterization) Check vapor separator assembly for proper
Vapor separator vent
venting/float valve operation
Faulty/leaking fuel injector(s) Check injectors, refer to FUEL SYSTEM
Damaged fuel lift pump Check for internal leaks
T–5
TROUBLE CHECK CHART
OUTBOARD SURGES, RUNS ROUGH
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
Check for air in fuel supply manifold, refer to FUEL
Air in fuel system SYSTEM (vapor separator venting and fuel
supply)
May be erratic or Check injectors, refer to FUEL SYSTEM
injector(s)
inconsistent
Faulty wiring, connections, Check all grounds, connections, and wiring. Check
grounds, or CPS air gap CPS air gap.
Check voltage on 55 V circuit, refer to SYSTEM
Low alternator output (55 V)
ANALYSIS and ELECTRICAL AND IGNITION
operation
Weak or erratic ignition Check ignition, refer to SYSTEM ANALYSIS and
operation ELECTRICAL AND IGNITION
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
Audible noise
Damaged gearcase Inspect gearcase and lubricate
T–6
Hose Routing and Water Flow Diagram
40 – 65 E-TEC Inline 2 Cylinder
8
6 5
9
10
3 60, 65 HP
1. Intake water screens

2. Water pump
3. Water tube
4. Cylinder block
5. Pressure valve
6. Thermostat
2 8. Water supply, EMM to
vapor separator
9. Overboard indicator,
outgoing water from
vapor separator
10. Water valve
1
002222E
Hose Routing and Water Flow Diagram 8
75-90 HP EVINRUDE ETEC
9
10 4
1. Intake water screens

2. Water pump
3. Water tube
4. Adaptor housing
5. Cylinder block
6. Pressure valve
7. Thermostat
9. Water supply, EMM to
vapor separator
10. Overboard indicator,
outgoing water from
vapor separator
001818
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
MWS Key Switch and Neutral Safety Switch
B B B
M M M M M M
C A C A C
A S S S
OFF ON START
B
M
C
M
S
A
4 5 6
3 2 1 000691
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
2 2
3
40 – 65 HP E-TEC B
A 1
1 1 9
6 7 8 1 2
1 1
2 2
13 13
A
B
12
1. Air Temperature Sensor C 11
10
2. Throttle Position Sensor 2
3. Neutral Switch CA B
4. Stator 4 14 1 14 1
2 5 3 4 16 123 4 2 2
3
5. Crankshaft Position Sensor 6 532 1 4
BAC 21 3
6. Trim/Tilt Connector 5
1 1
7. SystemCheck Connector 2 2
8. Key Switch Connector
9. High Pressure Fuel Pump FUSE
15
10. CANbus Connector
11. Diagnostic Connector 16
12. Temperature Sensor A B
17
13. Ignition Coil
14. Fuel Injector 18 NEG
15. Fuse (10 Amp) 1 2 –

16. Starter Solenoid A B BA
17. Main Harness Ground
18. Electric Starter
21 20
19. EMM
20. Oil Injector 123
21. Low Oil Switch
BA
22. Trim/Tilt Relay Module 26
27
18
19
10
10
11
11
1
2
28 3
23. Capacitor 29
20 12
12
13
13 4
30 21
5 J1-A
24. Trim/Tilt Motor 31 22
23
14
14
15
15 6 19
32 7
33 24 16
16
8
25. Water Valve Connector 34 25 17
17 9
26. Trim Sending Unit 20 14 8 1

21 2
15 9
27. Trim/Tilt Switch 6 543 21
22
23
16 10
3
4 J1-B
17 11 5
24
22 25
18 12 6
26 19 13 7
A B
2 1
25
23 6 5 4 3 2 1
9
1
24 10
2
11
3
12
A B 2 1 12 4
13
5
J2
14
6
15
7
16
8
26
1 1
2 2
3 3
3 3
27 2 2
1 1
008037
2 2
3 1 2 3
75 – 90 HP E-TEC B
A
1
1 1 9
6 8 13 13 13
7 1
2
A 12
B 11
1. Air Temperature Sensor C
10
2. Throttle Position Sensor
2
3. Neutral Switch CA B 14 14 14
4. Stator 4
2 5 3 4 16 123 4
5. Crankshaft Position Sensor BAC
21
6 532 1 4
6. Trim/Tilt Connector 1
2
321 1
2
321 1
2
321
7. SystemCheck Connector 5
8. Key Switch Connector
9. High Pressure Fuel Pump
15 FUSE
10. CANbus Connector
11. Diagnostic Connector
16
12. Temperature Sensor
A B
13. Ignition Coil 17 +
14. Fuel Injector
18
15. Fuse (10 Amp) 1 2
NEG
16. Starter Solenoid
–
17. Main Harness Ground A B BA
18. Electric Starter

19. EMM 21 20
20. Oil Injector
21. Low Oil Switch 12
22. Tilt Limit Switch 26 1

BA
18 10
10
23. Trim/Tilt Relay Module 27
28
19
20
11
11
12
12
2
3
29 13
13 4
24. Capacitor 30
31
21
22 14
14 5 J1-A
23 15
15 6
32
25. Trim/Tilt Motor 33
34
24
25
16
16
17
17
7
8 19
9
26. Trim Sending Unit
1
27. Trim/Tilt Switch 20
21
14
15
8
9
2
3
22 6 543 21
22
23
16 10 4 J1-B
17 11 5
23 24
25
18 12 6
26 19 13 7
A B
2 1
24 6 5 4 3 2 1
9
1
10
2
25 11
3
12
A B 2 1 4
13
5
J2
14
6
15
7
16
8
26 2 2
1 1
1 1
2 2
3 3
3 3
27 2 2
1 1
008038
EVINRUDE 40 – 90 HP EMM SERVICE CODE CHART
INTERNAL
SENSOR
S.A.F.E
DOWN
CODE DASHBOARD
SHUT
TIME TO
EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION
ACTIVATE
DISPLAY
Throttle Position Sensor TPS Voltage > 0.78 V with key ON (or cranking). Becomes stored fault when outboard starts.
11 - - 2 seconds
(TPS) out of idle range When both hard and stored faults are present, check for improperly adjusted throttle cable.
Throttle Position Sensor TPS Voltage: < 0.14 V, or > 4.92 V. Engine limited to idle speed.
12 LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 0.8 seconds
(TPS) circuit fault Check sensor resistance—3000 to 7000 Ω (between pins A and B) & 4000 to 8000 Ω (between pins A and C)
13 TPS below range LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 8 seconds TPS Voltage < 0.2 V. Check linkage and IDLE stop.
14 TPS above range LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 8 seconds TPS Voltage > 4.85 V. Check linkage and WOT stop.
15 ROM (EMM program) 3 - - - ROM “CHECKSUM” failure. Check software program number in EMM. Reload or replace with proper program.
Crankshaft Position Sensor (CPS) LED 2: OFF (Cranking) EMM counts losses of synchronization with crankshaft sensor. Check CPS mounting and resistance. Air gap range: 00.036 to
16 - 10 instances
Intermittent loss of SYNC LED 3: ON (Running) 0.110 in. (1 to 2.8 mm), nominal 0.073 in. (1.85 mm) Resistance: 560 Ω ± 10% @ 77°F (25°C)
17 55 V circuit BELOW range 3 3 LED 1: ON (Running) CHECK ENGINE 1 minute System Voltage < 45 V. Engine limited to 1200 RPM. Perform stator/charging tests.
System Voltage > 57 V. Engine limited to 1200 RPM. Perform stator/charging tests.
18 55 V circuit ABOVE range 3 3 LED 1: ON (Running) CHECK ENGINE 1 minute
Check for loose connections in 55 V circuit. Check capacitor.
19 Start-in-gear LED 3: OFF (Cranking) CHECK ENGINE - Attempted engine start while in gear. Engine will not start.
21 Winterization activated All LEDs FLASHING All Lights FLASHING - Engine is speed limited, and stops after 360 oil pulses. Refer to Maintenance or Operator’s Guide.
23 EMM Temperature Sensor circuit fault 3 LED 3: OFF (Cranking) / ON (Running) - 8 seconds EMM Temperature < -71° F (-57.4° C), or > 313° F (156° C).
24 EMM Temperature BELOW range 3 LED 3: OFF (Cranking) / ON (Running) - 8 seconds EMM Temperature < -22 ° F (-30° C).
25 EMM Temperature ABOVE range 3 3 LED 4: ON (Running) WATER TEMP/HOT 8 seconds EMM Temperature > 176°F (80°C). Engine limited to 1200 RPM. See Code 29.
26 12 V circuit BELOW range 3 LED 1: ON (Running) LOW BATTERY 5 minutes Battery voltage < 12.5 V. Perform stator/charging tests.
27 12 V circuit ABOVE range 3 LED 1: ON (Running) LOW BATTERY 5 minutes Battery voltage > 15.5 V. Check battery connections and wiring.
WATER TEMP/HOT EMM Temperature > 212° F (100° C). Engine SHUTDOWN. Will NOT restart until EMM temperature
29 EMM Temperature OVER range 3 3 LED 4: FLASHING
(FLASHING)
4 seconds
returns to operating range. Check outboard and EMM cooling systems.
2-Cylinder models: Engine Temperature > 248° F (120° C)
WATER TEMP/HOT 3-Cylinder models: Engine Temperature > 212° F (100° C) above 3500 RPM, or
31 Engine temperature OVER range 3 LED 4: FLASHING
(FLASHING)
8 seconds
3-Cylinder models: Engine Temperature > 230° F (110° C) below 3500 RPM
Engine SHUTDOWN. Check cooling system. Check temperature sensor resistance—9000 to 11000 Ω @ 77°F (25°C).
33 Critical NO OIL detected 3 3 LED 4: FLASHING NO OIL (FLASHING) 3 hours Outboard has run three hours with code 34 or 117. Engine SHUTDOWN. Will restart and run for 1 minute intervals.
34 Oil injection pump circuit OPEN 3 LED 4: ON (Running) NO OIL 4 seconds Engine limited to 1200 RPM. Check oil injection pump circuit resistance—22 Ω.
40 Engine Temperature ABOVE range–Low speed 3 LED 4: ON (Running) WATER TEMP/HOT 8 seconds 3-Cylinder models only. Engine Temperature > 212° F (100° C) below 3500 RPM.
Engine Temperature < -15° F (-26.2° C), or > 332° F (166.5° C).
41 Engine Temperature Sensor circuit fault LED 3: OFF (Cranking) / ON (Running) - 8 seconds
Check 5 V circuit and ground (NEG), and sensor resistance—9000 to 11000 Ω @ 77°F (25°C).
42 Engine Temperature BELOW range LED 3: OFF (Cranking) / ON (Running) - 8 seconds Engine Temperature < -4° F (-20° C). Check engine temperature and sensor resistance.
2-Cylinder models: Engine Temperature > 212° F (100° C).
43 Engine Temperature ABOVE range 3 LED 4: ON (Running) WATER TEMP/HOT 8 seconds 3-Cylinder models: Engine Temperature > 194° F (90° C) above 3500 RPM
Engine limited to 1200 RPM. Check cooling system.
Pressure < 3.9 in. Hg (13.3 kPa), or > 35.1 in. Hg (119.0 kPa). Make sure EMM BP sensor tube is NOT plugged.
44 Barometric Pressure (BP) Sensor circuit fault 3 - - 8 seconds
Check atmospheric condition for comparison. Clear code and retest.
45 BP Sensor BELOW range 3 - - 8 seconds Pressure < 20.7 in. Hg (70 kPa).
46 BP Sensor ABOVE range 3 - - 8 seconds Pressure > 31 in. Hg (105 kPa).
Rev 01/10 page 1

INTERNAL
SENSOR
S.A.F.E
DOWN
DASHBOARD
CODE
SHUT
TIME TO
EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION
ACTIVATE
DISPLAY
Air temperature < -58° F (-49.9° C), or > 218° F (103.2° C).
47 Air Temperature (AT) circuit fault LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 8 seconds
Check 5 V circuit and ground (NEG), and sensor resistance—9000 to 11000 Ω @ 77°F (25°C).
48 Air Temperature BELOW range LED 3: OFF (Cranking) / ON (Running) - 8 seconds Air temperature < -22° F (-30° C).
49 Air Temperature ABOVE range LED 3: OFF (Cranking) / ON (Running) - 8 seconds Air temperature > 158° F (70° C).
51 Fuel injector circuit #1 OPEN LED 2: ON (Running) - 2 seconds
52 Fuel injector circuit #2 OPEN LED 2: ON (Running) - 2 seconds Check injector/circuit resistance—2 to 3 Ω @ 72°F (22°C).
53 Fuel injector circuit #3 OPEN LED 2: ON (Running) - 2 seconds
CHECK ENGINE TPS < 5% and RPM > 3000. Engine SHUTDOWN. Will NOT restart until code has been cleared. The problem could be caused by
57 High RPM with low TPS setting 3 3 LED 3: FLASHING
(FLASHING)
10 seconds
uncontrolled fuel entering the engine. DO NOT attempt to start the outboard until the problem has been found and repaired.
Engine temperature < 104° F (40° C) with engine speed < 2300 RPM.
58 Operating temperature not reached LED 3: OFF (Cranking) / ON (Running) - 10 minutes
Check thermostat and pressure relief valve.
61 Fuel injector circuit #1 SHORTED LED 2: ON (Running) - 8 seconds
62 Fuel injector circuit #2 SHORTED LED 2: ON (Running) - 8 seconds Check injector/circuit resistance—2 to 3 Ω @ 72°F (22°C).
63 Fuel injector circuit #3 SHORTED LED 2: ON (Running) - 8 seconds
78 Sensor supply voltage fault 3 LED 3: OFF (Cranking) / ON (Running) - 10 seconds Sensor voltage < 4.75 V. Check sensors and related wiring. Check for pinched or chafed wiring.
81 Ignition timing circuit #1 OPEN LED 2: ON (Running) - 10 instances
82 Ignition timing circuit #2 OPEN LED 2: ON (Running) - 10 instances EMM counts failed ignition events. Check wiring. Test with known good ignition coil.
83 Ignition timing circuit #3 OPEN LED 2: ON (Running) - 10 instances
90 Water injection solenoid SHORTED LED 2: ON (Running) - 8 seconds Check circuit resistance—295 Ω ± 20 @ 77°F (25°C).
91 Fuel pump circuit OPEN LED 2: ON (Running) - 8 seconds Check pump/circuit resistance—2 to 3 Ω @ 77°F (25°C).
93 Water injection solenoid OPEN LED 2: ON (Running) - 8 seconds Check circuit resistance—295 Ω ± 20 @ 77°F (25°C).
94 Fuel pump circuit SHORTED LED 2: ON (Running) - 2 seconds Check pump/circuit resistance—2 to 3 Ω @ 77°F (25°C).
101 Ignition timing circuit #1 SHORTED LED 2: ON (Running) - 20 instances
102 Ignition timing circuit #2 SHORTED LED 2: ON (Running) - 20 instances EMM counts failed ignition events. Check wiring. Test with known good ignition coil.
103 Ignition timing circuit #3 SHORTED LED 2: ON (Running) - 20 instances
4800 Pulses (2-Cyl) EMM counts oil pump pulses after LOW OIL switch closes. Engine limited to 1200 RPM.
117 Critical LOW OIL detected 3 3 LED 4: ON (Running) NO OIL
6000 Pulses (3-Cyl) Stop outboard and add oil to tank. Warning resets after three oil pump pulses.
NOTE: Always note service codes before clearing codes. Clear stored codes using diagnostic software. Clearing some codes requires turning EMM “OFF” and then “ON” again.
Rev 01/10 page 2

40-90 HP

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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 replacement parts are required, use

Always wear EYE PROTECTION AND APPRO-

IMPORTANT: Identifies information that controls

ABBREVIATIONS USED IN THIS MANUAL

EMISSION-RELATED Owner’s Responsibility

Manufacturer’s Responsibility EPA Emission Regulations

1. Model and serial number 002224 1. Serial number 002225

MODELS COVERED IN THIS MANUAL

Evinrude/Johnson XD100, XD50, XD30; or

Thermostat 143°F (62°C)

Maximum Temperature 212°F (100°C)

Water pressure 12 to 14 psi @ 5000 RPM

Type Capacitor Discharge

RPM Limit in Gear 6250

HPF XR Gearcase Lube

Lubrication Evinrude/Johnson Biodegradable TNT Fluid

Fluid Capacity 15.2 fl. oz. (450 ml)

Trim Range 0° to 15°

Tilt Range 16° to 65°

Evinrude/Johnson XD100, XD50, XD30; or

Maximum Temperature 212°F (100°C)

Thermostat 143°F (62°C)

Water pressure 19 to 21 psi @ 5000 RPM

Type Capacitor Discharge

RPM Limit in Gear 6250

Lubricant HPF XR Gearcase Lube

Lubrication Single Piston System–Evinrude/Johnson Biodegradable TNT Fluid

Fluid Capacity 21 fl. oz. (620 ml)

Trim Range 0° to 15°

Tilt Range 16° to 65°

STANDARD TORQUE PRODUCT REFERENCE

INSPECTION AND MAINTENANCE SCHEDULE

A HPF Pro Gearcase Lubricant

LIFTING THE OUTBOARD RIGGING

Extend the control cables and lubricate them with

1. Lifting fixture 002098

NOTICE Use only the 1 1/8 in. (short)

Fasten appropriate chain hook to eye of tool.

Cable Retainer Clip Installation Cable, Hose, and Wire Routing

1. Throttle cable 001998

Locked Retainer Clip DP0817a

When grommet is in place and all cables have

IMPORTANT: DO NOT secure cables to throttle 1. Throttle lever pin 002101

Make sure the remote control is in NEUTRAL, and 1

Pull firmly on shift cable casing to remove slack.

1. Throttle lever stop – 3 Cylinder models 005111

1. Shift lever pin 002100

1. Throttle lever stop – 2 Cylinder models 005114

After grommet has been installed in lower engine

SystemCheck Harness 001999

,' 31 &ODPSLQJ5DQJH

+RVH PP