Evinrude E-TEC 40, 50, 60, 65 HP Repair Service Manual (2008)

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This complete service repair workshop manual PDF download for the 40, 50, 60, 65 HP Evinrude E-TEC Outboard Motors has easy-to-read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes.


APPLICABLE MODELS :

MODELS COVERED IN THIS MANUAL
This manual covers service information on all 52.7 cubic inch, 2-Cylinder Evinrude E-TEC ® models.
Model Number Shaft Color Style
E40DRLSCB 20” BL Tiller/Rope
E40DTLSCS 20” BL Tiller/Electric
E40DPLSCB 20” BL Remote/Electric
E40DSLSCS 20” WH Remote/Electric
E50DTLSCS 20” BL Tiller/Electric
E50DPLSCB 20” BL Remote/Electric
E50DSLSCS 20” WH Remote/Electric
E60DTLSCS 20” BL Tiller/Electric
E60DPLSCB 20” BL Remote/Electric
E60DSLSCS 20” WH Remote/Electric
E65WDRLSCS 20” BL Tiller/Rope
E65WDRYSCS 22.5” BL Tiller/Rope


TABLE OF CONTENTS :

INTRODUCTION
1 SPECIAL TOOLS
2 INSTALLATION AND PREDELIVERY
3 MAINTENANCE
4 ENGINE COVER SERVICE
5 ENGINE MANAGEMENT MODULE (EMM)
6 SYSTEM ANALYSIS
7 ELECTRICAL AND IGNITION
8 FUEL SYSTEM
9 OILING SYSTEM
10 COOLING SYSTEM
11 POWERHEAD
12 MIDSECTION
13 GEARCASE
14 TRIM AND TILT
15 MANUAL STARTER
SAFETY
INDEX
TROUBLE CHECK CHART
DIAGRAMS
EMM SERVICE CODE CHART


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 369


This (OEM) manual pdf download has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : https://www.sitelux.com

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INTRODUCTION
ABBREVIATIONS USED IN THIS MANUAL
Units of Measurement
List of Abbreviations
ENGINE EMISSIONS INFORMATION
Manufacturer’s Responsibility
Dealer’s Responsibility
Owner’s Responsibility
EPA Emission Regulations
MODEL DESIGNATION
MODELS COVERED IN THIS MANUAL
Identifying Model and Serial Numbers
SERVICE SPECIFICATIONS
STANDARD TORQUE SPECIFICATIONS
PRODUCT REFERENCE AND ILLUSTRATIONS
SPECIAL TOOLS
DIAGNOSTIC TOOLS
UNIVERSAL TOOLS
ELECTRICAL / IGNITION TOOLS
FUEL /OIL SYSTEM TOOLS
POWERHEAD TOOLS
GEARCASE TOOLS
TRIM AND TILT TOOLS
MANUAL STARTER TOOLS
SHOP AIDS
NOTES
Technician’s Notes
Related Documents
INSTALLATION AND PREDELIVERY
BOAT RIGGING
Remote Controls
Battery Installation
Battery Switches and Multiple Batteries
Battery and Switch Wiring Diagrams
Fuel System Requirements
Cable and Hose Installation
OUTBOARD INSTALLATION
Hull Preparation
Transom Measuring and Drilling
Drilling and Hardware Diagrams
Lifting the Outboard
Steering Systems
Outboard Mounting
OUTBOARD RIGGING
Cable, Hose, and Wire Routing
Control Cable Adjustments
Electrical Harness Connections
Water Pressure Gauge
CANbus Connections
FUEL AND OIL PRIMING
Fuel Requirements
Fuel System Priming
Oil Requirements
Oil Injection Rate
Break-In Oiling
Oil Supply Priming
BEFORE START-UP
Gearcase Lubricant
Oil Level
Trim and Tilt Fluid
RUNNING CHECKS
Engine Monitoring System
Fuel System
Emergency Stop / Key Switch
Remote Control Operation
Start-In-Gear Prevention
Tachometer Pulse Setting
Water Pump Overboard Indicator
Operating Temperature
Idle Speed
Break-In
PROPELLERS
Propeller Selection
Propeller Hardware Installation
FINAL ADJUSTMENTS
Trim Sending Unit Adjustment
Trim Tab Adjustment
Dual-Outboard Alignment
MAINTENANCE
INSPECTION AND MAINTENANCE SCHEDULE
ANTI-CORROSION PROTECTION
Sacrificial Anodes
Testing Procedure - Continuity
Metallic Component Protection
Exterior Finishes
COOLING SYSTEM
Flushing
Water Intake Screens
Additional Maintenance
LUBRICATION
Steering System
Swivel Bracket and Trailering Bracket
Tilt Tube
Throttle and Shift Linkage
Propeller Shaft
Gearcase Lubricant
Trim and Tilt
BATTERY AND BATTERY CONNECTIONS
FUEL AND OIL SYSTEMS
Fuel Filter
Oil Filters and Oil Reservoir
Air Silencer
Hoses and Connections
SPARK PLUGS
Removal
Indexing
STORAGE
Fuel System Treatment
Internal Engine Treatment
Additional Recommendations
PRE-SEASON SERVICE
Outboard Mounting Bolts
Gearcase Lubricant
Battery(s)
Power Trim and Tilt
Operational Checks
SUBMERGED ENGINES
Engine Dropped Overboard (Not Running)
Engine Dropped Overboard (Running)
Engine Dropped Overboard (In Salt Water)
Prolonged Submersion (Fresh or Salt Water)
NOTES
Technician’s Notes
Related Documents
ENGINE COVER SERVICE
UPPER COVER SERVICE
Latch Hook Installation
LOWER COVER SERVICE
Lower Cover Removal
Lower Cover Installation
Latch Handle Installation
Trim Switch Installation
ENGINE MANAGEMENT MODULE (EMM)
DESCRIPTION
EMM Functions
EMM Connections
LED Indicators
EMM INPUTS AND OUTPUTS DIAGRAM
INTERNAL SENSORS
EMM Temperature Sensor
55 V Circuit Sensor
12 V Circuit Sensor
Barometric Pressure Sensor
EXTERNAL SENSORS
Air Temperature Sensor
Engine Temperature Sensor
Low Oil Switch
Throttle Position Sensor
Crankshaft Position Sensor
Neutral Switch
INTERNAL EMM FUNCTIONS
ROM Verification
Idle Controller
RPM Limiter
Neutral RPM Limiter
Exhaust Water Valve Activation (60 HP)
Engine Monitor and Warning Systems
Fault Code Creation and Storage
ENGINE MONITORING SYSTEM
System Self-Test
Service Mode
Engine Running
S.A.F.E. WARNING SYSTEM
Activation
Recovery
SHUTDOWN MODE
Recovery
DIAGNOSTIC SOFTWARE FUNCTIONS
Communication
Static Information
Dynamic Information
Stored Service Codes (Faults)
Hard Faults
Persistent Faults
Static Tests
Dynamic Tests
Oil Control Settings
Tiller/Remote Programming
Ignition Timing
TPS Calibration
Idle Speed Control
Fuel Injector Servicing
Reports
Software Replacement
EMM Transfer
EMM SERVICING
Installation
SYSTEM ANALYSIS
DIAGNOSTIC PROCEDURES
Visual Inspections
Operational Inspections
Troubleshooting
DYNAMIC TESTS
Cylinder Drop Tests
Fuel Control Adjustment
Inductive Amp Meter Test
EMM LED INDICATORS
Key ON
Starting
Running
IGNITION OUTPUT TESTS
Ignition System Requirements
Wiring Inspection
Crankshaft Position Sensor (CPS) Test
System Voltage Test
Static Ignition Test
Running Ignition Tests
Ignition Control Circuit Tests
Ignition Coil Tests
Capacitor Test
FUEL DELIVERY TESTS
Fuel Pump Static Test
Fuel Injector Static Test
Running Fuel System Tests
EXHAUST WATER VALVE
Exhaust Water Valve Static Test
Exhaust Water Valve Dynamic Test
ELECTRICAL AND IGNITION
SERVICE CHART
DASH CONNECTIONS, INSTRUMENT HARNESS
ELECTRICAL HARNESS CONNECTIONS
Engine Harness to Stator Connector
EMM J1-A Connector
EMM J1-B Connector
EMM J2 Connector
GROUND CIRCUITS
EMM Ground Tests
Additional Ground Tests
FUSE
SENSOR TESTS
Crankshaft Position Sensor (CPS) Test
Throttle Position Sensor (TPS) Test
Engine Temperature Sensor Test
Air Temperature Sensor (AT) Test
STATOR TESTS
Stator Resistance Tests
Stator Voltage Output Test
CHARGING SYSTEM TESTS
12 V Charging Circuit
55 V Alternator Circuit
ELECTRIC START CIRCUIT
Start Circuit Diagram
Start Circuit Operation
ELECTRIC START TESTS
Starter Solenoid Test
No Load Current Draw Test
REMOTE CONTROL SWITCH TESTS
Key Switch Test
Neutral Start Circuit Test
Neutral Start Switch Test
Emergency Stop Switch Test
TILT/TRIM RELAY TEST
Operation
Test Procedure
EXHAUST WATER VALVE TEST
SystemCheck CIRCUIT TESTS
Gauge Self-Test Check
CHECK ENGINE Circuit Test
WATER TEMP/ HOT Circuit Test
LOW OIL Circuit Test
NO OIL Circuit
TACHOMETER CIRCUIT TESTS
FLYWHEEL AND STATOR SERVICING
Flywheel Removal
Stator Service
Flywheel Installation
TIMING ADJUSTMENTS
Timing Pointer
Timing Verification
TPS Calibration
ELECTRIC STARTER SERVICING
Starter Removal
Starter Disassembly
Starter Cleaning and Inspection
Starter Assembly
Starter Installation
CONNECTOR SERVICING
DEUTSCH Connectors
AMP Connectors
Packard † Connectors
FUEL SYSTEM
SERVICE CHART
FUEL SYSTEM HOSE ROUTING
FUEL SYSTEM CIRCUIT DIAGRAM
COMPONENTS
Fuel Lift Pump
Fuel Filter
Vapor Separator
Fuel Circulation Pump
Fuel Manifolds
Fuel Injectors
FUEL SYSTEM TESTS
Fuel System Pressure Test
Pressure Regulator Test
Vapor Separator Vent Check
Fuel Injector Pressure Test
Fuel Injector Resistance Test
Circulation Pump Resistance Test
Lift Pump Pressure Test
Lift Pump Vacuum Test
Lift Pump Diaphragm Test
Anti-Siphon Valve Test
FUEL COMPONENT SERVICING
Relieving Fuel System Pressure
Fuel Filter Service
Fuel Lift Pump Service
Vapor Separator Service
Fuel Manifold Service
Fuel Injector Service
Intake Manifold Service
OILING SYSTEM
SERVICE CHART
OIL SUPPLY DIAGRAMS
OIL RECIRCULATION DIAGRAM
OILING SYSTEM CIRCUIT DIAGRAM
COMPONENTS
Oil Tank Assembly
Oil Injection Pump
Electrical Circuit (55 V)
LOW OIL Warning
NO OIL Warning
Cylinder and Crankcase
Oil Recirculation System
OIL CONTROL SETTINGS
Oil Priming
Oiling Rates
Break-in Oiling
OILING SYSTEM TESTS
Oil Injection Pump Static Test
Oil Injection Pump Voltage Test
Oil Injection Pump Circuit Resistance Test
Oil Injection Pump Function Test
Oil Injection Fittings Flow Test
LOW OIL Sending Unit Test
OIL COMPONENT SERVICING
Oil Distribution Hoses
Oil Tank Assembly
NOTES
Technician’s Notes
Related Documents
COOLING SYSTEM
HOSE ROUTING AND WATER FLOW DIAGRAMS
COMPONENTS
Water Pump and Intakes
Exhaust Housing
Pressure Relief Valve
Thermostat
Block Venting
Water Pressure Connection
OPERATION
Cylinder Block / Cylinder Head Cooling
EMM and Vapor Separator Cooling
ENGINE TEMPERATURE CHECK
Software Method
Pyrometer Method
Idle Operating Temperature Troubleshooting (Below Range)
THERMOSTAT SERVICING
Disassembly
Inspection
Assembly
PRESSURE RELIEF VALVE SERVICING
Disassembly
Inspection
Assembly
NOTES
Technician’s Notes
Related Documents
POWERHEAD
SERVICE CHART
POWERHEAD REMOVAL
POWERHEAD DISASSEMBLY
General
Throttle Linkage Removal
Shift Linkage Removal
Crankcase Disassembly
Cylinder Head Removal
Connecting Rods and Pistons
Crankshaft Removal
CYLINDER BLOCK CLEANING
POWERHEAD INSPECTION
Cylinder Head
Crankshaft
Cylinder Bore
Pistons
Piston Rings
Bearings
POWERHEAD ASSEMBLY
Crankshaft Assembly
Pistons and Connecting Rods
Cylinder Head Installation
Crankshaft and Connecting Rod Installation
Crankcase Assembly
Shift Linkage Installation
Throttle Linkage Installation
Final Powerhead Assembly
POWERHEAD INSTALLATION
Powerhead Mounting
Shift Linkage Adjustment
POWERHEAD VIEWS
Port Short Block
Starboard Short Block
Port Dressed Powerhead
Starboard Dressed Powerhead
Port Rope Start Models
Starboard Rope Start Models
Front
Rear
Top
Top, Rope Start Models
MIDSECTION
SERVICE CHART
TILT TUBE SERVICE
Removal
Installation
EXHAUST HOUSING SERVICE
Exhaust Housing Removal
Exhaust Water Valve
Exhaust Relief Muffler
Exhaust Housing Installation
STERN BRACKET - Power Tilt Models
Stern Bracket Disassembly (Power Tilt)
Stern Bracket Assembly (Power Tilt)
STERN BRACKET - Manual Tilt Models
Clamp Screw
Stern Bracket Disassembly (Manual Tilt)
Stern Bracket Assembly (Manual Tilt)
Tilt Assist Cylinder
TILLER HANDLE SERVICE - Standard
Removal
Disassembly
Inspection
Assembly
Installation
Throttle Cable Adjustment
TILLER HANDLE SERVICE - Long Handle
Removal
Disassembly
Inspection
Assembly
Installation
Control Cable Installation
MIDSECTION AND TILLER ADJUSTMENTS
Steering Friction Adjustment
Throttle Friction Adjustment
NOTES
Technician’s Notes
Related Documents
GEARCASE
SERVICE CHART
PROPELLER SERVICE
Inspection
GEARCASE LEAK TEST
GEARCASE REMOVAL AND INSTALLATION
Gearcase Removal
Gearcase Installation
WATER PUMP SERVICE
Disassembly
Inspection
Assembly
SHIFT ROD ADJUSTMENT
GEARCASE DISASSEMBLY
Pre-Disassembly Inspection
Propeller Shaft Bearing Housing Removal
Pinion Gear and Driveshaft Removal
Shift Housing, Gear and Propeller Shaft Removal
INTERNAL GEARCASE SERVICE
Pinion Bearing Removal
Pinion Bearing Installation
Shift Housing Disassembly
Shift Housing Assembly
Driveshaft Bearing Housing Service
Propeller Shaft Bearing Housing Service
DRIVESHAFT SHIMMING
GEARCASE ASSEMBLY
Shift Housing, Gear, and Propeller Shaft Installation
Shift Rod Housing Installation
Pinion Gear and Driveshaft Installation
Propeller Shaft Bearing Housing and Gear Installation
NOTES
Technician’s Notes
Related Documents
TRIM AND TILT
SYSTEM DESCRIPTION
ROUTINE INSPECTIONS
General
Reservoir Fluid
Manual Release Valve
Stern Brackets
ELECTRICAL CIRCUIT TESTS
Relay Testing
Trim and Tilt Motor Current Draw Tests
Trim and Tilt Motor No Load Test
Trim Gauge Test
Trim Sender Test
SERVICING
Removal
Disassembly
Assembly
Installation
ADJUSTMENTS
MANUAL STARTER
SERVICE CHART
RECOIL STARTER REMOVAL
RECOIL STARTER DISASSEMBLY
RECOIL STARTER CLEANING AND INSPECTION
RECOIL STARTER ASSEMBLY
RECOIL STARTER INSTALLATION
NOTES
Technician’s Notes
Related Documents
SAFETY
TABLE OF CONTENTS
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM
Outboard Shift Systems and Safety
Outboard Speed Control System and Safety
Outboard Steering Control System and Safety
Outboard Fuel, Electrical System, and Safety
Outboard Mounting System and Safety
If weakened, parts could fail later on the water, when not expected
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
Outboard Emergency Stop System and Safety
Summing up
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM
Handling Outboards
Handling Lead/Acid Batteries
Gasoline - Handle With Care!
Hazardous Products
Safety Awareness Test
INDEX
TROUBLE CHECK CHART
OUTBOARD WILL NOT START
OUTBOARD WILL NOT START
OUTBOARD HARD TO START
OUTBOARD WILL NOT SHUT OFF
OUTBOARD STARTS AND STALLS
OUTBOARD STARTS, LOW MAXIMUM RPM
EXCESSIVE SMOKING
OUTBOARD SURGES, RUNS ROUGH
DIAGRAMS

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