Evinrude E-TEC 40, 50, 60, 65, 75, 90 HP Repair Service Manual (2012)

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This complete service repair workshop manual PDF download for the 40, 50, 60, 65, 75, 90 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 (.86 L), 2-Cylinder; and 79 cubic inch (1.29
L), 3-Cylinder Evinrude E-TEC models.
Model Displacement Gearcase Height Color Description
E40DRLINC .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Manual Tilt, Tiller Steering, Rope Start
E40DTLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Tiller Steering, Electric Start
E40DPLINC .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Remote Steering, Electric Start
E40DSLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" White Power Tilt, Remote Steering, Electric Start
E40DHLINS .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Remote Steering, Electric Start, H.O. Styling
E40DHSLINS .86 L, 52.7 ci 12:32 / 0.375 F 20" White Power Tilt, Remote Steering, Electric Start, H.O. Styling
E50DTLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Tiller Steering, Electric Start
E50DPLINC .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Remote Steering, Electric Start
E50DSLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" White Power Tilt, Remote Steering, Electric Start
E60DTLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Tiller Steering, Electric Start
E60DPLINC .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Remote Steering, Electric Start
E60DSLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" White Power Tilt, Remote Steering, Electric Start
E65WDRLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Manual Tilt, Tiller Steering, Rope Start
E65WDRYINM .86 L, 52.7 ci 12:32 / 0.375 F 22.5" Blue Manual Tilt, Tiller Steering, Rope Start
E75DPLINC 1.29 L, 79.0 ci 13:26 / 0.50 S 20" Blue Power Tilt, Steel Steering Arm
E75DSLINM 1.29 L, 79.0 ci 13:26 / 0.50 S 20" White Power Tilt, Stainless Steering Arm
E90DPLINC 1.29 L, 79.0 ci 13:26 / 0.50 S 20" Blue Power Tilt, Steel Steering Arm
E90DSLINS 1.29 L, 79.0 ci 13:26 / 0.50 S 20" White Power Tilt, Stainless Steering Arm
E90DPXINC 1.29 L, 79.0 ci 12:27 / 0.444 O 25" White Power Tilt, Stainless Steering Arm
E90WDELINM 1.29 L, 79.0 ci 13:26 / 0.50 S 20" Blue Manual Tilt, Steel Steering Arm, Commercial Model
E90WDEXINM 1.29 L, 79.0 ci 12:27 / 0.444 O 25" White Manual Tilt, Steel Steering Arm, Commercial Model


TABLE OF CONTENTS :

1 REFERENCE INFORMATION
2 ROUTINE SERVICE
3 ENGINE COVER SERVICE
4 ENGINE MANAGEMENT MODULE (EMM)
5 SYSTEM ANALYSIS
6 ELECTRICAL AND IGNITION
7 FUEL SYSTEM
8 OILING SYSTEM
9 COOLING SYSTEM
10 POWERHEAD
11 MIDSECTION
12 GEARCASE
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE SERVICE, 75 – 90 HP MODELS
13 TRIM AND TILT
14 MANUAL STARTER
SAFETY
INDEX
TROUBLE CHECK CHART
DIAGRAMS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 426


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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REFERENCE INFORMATION
SAFETY NOTICE
ABBREVIATIONS USED IN THIS MANUAL
Units of Measurement
List of Abbreviations
EMISSION-RELATED INSTALLATION INSTRUCTIONS
Manufacturer’s Responsibility
Dealer’s Responsibility
Owner’s Responsibility
EPA Emission Regulations
MODEL DESIGNATION
MODELS COVERED IN THIS MANUAL
SERVICE SPECIFICATIONS
STANDARD TORQUE SPECIFICATIONS
PRODUCT REFERENCE AND ILLUSTRATIONS
ROUTINE SERVICE
INSPECTION AND MAINTENANCE SCHEDULE
LIFTING THE OUTBOARD
OUTBOARD RIGGING CONNECTIONS
Common Practices – All Models
Cable, Hose, and Wire Routing
Control Cable Installation
SystemCheck Harness Connections
I-Command Network Connections
Water Pressure Gauge
BATTERY AND BATTERY CONNECTIONS
OETIKER CLAMP SERVICING
Clamp Identification
Clamp Selection
Clamp Installation
Clamp Removal
ADJUSTMENTS
Steering Friction Adjustment
Throttle Friction Adjustment
Tilt Limit Switch Adjustment (75 – 90 HP)
Trim Sending Unit Adjustment (40 – 60 HP)
Trim Sending Unit Adjustment (75 – 90 HP)
Trim Tab Adjustment
Dual-Outboard Alignment
OPERATIONAL CHECKS
Engine Monitoring System
Fuel System
Emergency Stop / Key Switch
Remote Control Operation
Start-In-Gear Prevention
Tachometer Pulse Setting (SystemCheck)
Water Pump Overboard Indicator
Operating Temperature
Idle Speed
COOLING SYSTEM
Water Intake Screens
Engine Flushing
Running the Outboard Using a Hose and Flushing Adapter
LUBRICATION
Steering System
Tiller Handle
Swivel Bracket and Trailering Bracket
Tilt Tube
Throttle and Shift Linkage
Propeller Shaft
Gearcase Lubricant
Trim and Tilt
SPARK PLUGS
Removal
Indexing
FUEL AND OIL SYSTEMS
Fuel Filter
Oil Filters and Oil Reservoir
Air Silencer
Hoses and Connections
ANTI-CORROSION PROTECTION
Sacrificial Anodes
Testing Procedure – Continuity
Metallic Component Protection
Exterior Finishes
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
5 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 - 65 HP)
Engine Monitor and Warning Systems
Fault Code Creation and Storage
ENGINE MONITOR 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
Occurred Service Codes (Faults)
Active Faults
Historical 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
Removal
Installation
NOTES
Technician’s Notes
Related Documents
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
Required Ignition Systems
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 (60–65HP)
Exhaust Water Valve Static Test
Exhaust Water Valve Dynamic Test
ELECTRICAL AND IGNITION
SERVICE CHART
IGNITION SYSTEM CIRCUIT DIAGRAM, 40 – 65 HP
IGNITION SYSTEM CIRCUIT DIAGRAM, 75 – 90 HP
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
Starter Voltage Drop 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
IGNITION COIL SERVICING
Ignition Coil Removal
Ignition Coil Installation
TIMING ADJUSTMENTS
Timing Pointer
Timing Verification
TPS Calibration
ELECTRIC STARTER SERVICING
Starter Removal
Starter Installation
CONNECTOR SERVICING
DEUTSCH Connectors
AMP Connectors
Packard Connectors
NOTES
Technician’s Notes
Related Documents
FUEL SYSTEM
SERVICE CHART
FUEL SYSTEM HOSE ROUTING
FUEL SYSTEM CIRCUIT DIAGRAMS
FUEL SYSTEM REQUIREMENTS
Regulations and Guidelines
Portable Fuel Tanks
Fuel Flow Requirements
Fuel Requirements
COMPONENTS
Fuel Lift Pump
Fuel Filter
Vapor Separator
Fuel Circulation Pump
Fuel Manifolds
Fuel Injectors
FUEL SYSTEM PRIMING
Vent Line Clamp
Priming the Fuel System
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
NOTES
Technician’s Notes
Related Documents
OILING SYSTEM
SERVICE CHART
OIL SUPPLY DIAGRAMS
OIL RECIRCULATION DIAGRAMS
OILING SYSTEM CIRCUIT DIAGRAM
OIL SYSTEM REQUIREMENTS
Recommended Lubricants
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 Injection Rate
Break-In Oiling
Oil Supply Priming
OILING SYSTEM TESTS
Oil Injection Pump Voltage Tests
Oil Injection Pump 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
Oil Injection Pump
COOLING SYSTEM
HOSE ROUTING AND WATER FLOW DIAGRAMS
COMPONENTS
Water Pump and Intakes
Exhaust Housing
Water Supply Tube
Adapter/Inner 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)
TEMPERATURE SENDER SERVICING
Removal
Installation
THERMOSTAT SERVICING
Disassembly
Inspection
Assembly
PRESSURE RELIEF VALVE SERVICING
Disassembly
Inspection
Assembly
POWERHEAD
SERVICE CHART
COMPRESSION TESTING
POWERHEAD REMOVAL
2-Cylinder Models
3-Cylinder Models
POWERHEAD DISASSEMBLY
Systems Removal
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
UPPER MOUNT SERVICING (3-Cylinder)
Removal
Installation
POWERHEAD INSTALLATION
Powerhead Mounting – 2-Cylinder Models
Powerhead Mounting – 3-Cylinder Models
Shift Linkage Adjustment
Final Adjustments
POWERHEAD VIEWS
2-Cylinder Port – Hose Routings
2-Cylinder Starboard – Hose Routings
2-Cylinder Port Dressed Powerhead
2-Cylinder Starboard Dressed Powerhead
2-Cylinder Port Rope Start Models
2-Cylinder Starboard Rope Start Models
2-Cylinder Front
2-Cylinder Rear
2-Cylinder Top
2-Cylinder Top, Rope Start Models
3-Cylinder Port – Hose Routings
3-Cylinder Starboard – Hose Routings
3-Cylinder Port Dressed Powerhead
3-Cylinder Starboard Dressed Powerhead
3-Cylinder Front
3-Cylinder Rear
3-Cylinder Top
MIDSECTION
SERVICE CHARTS
TILT TUBE, 75 – 90 HP
Removal
Installation
EXHAUST HOUSING, 40 – 65 HP
Exhaust Housing Removal
Exhaust Water Valve (60–65 HP)
Exhaust Relief Muffler
Exhaust Housing Installation
EXHAUST HOUSING, 75 – 90 HP
Exhaust Housing Removal
Lower Mount Service
Exhaust Housing Installation
Exhaust Housing Disassembly
Cleaning and Inspection
Exhaust Housing Assembly
STERN BRACKET, 40 – 60 HP Power Tilt
Stern Bracket Disassembly
Stern Bracket Assembly
STERN BRACKET, 75 – 90 HP Power Tilt
Stern Bracket Disassembly
Stern Bracket Assembly
STERN BRACKET, 40 – 60 HP Manual Tilt
Clamp Screw Service
Stern Bracket Disassembly
Stern Bracket Assembly
Tilt Assist Cylinder
STERN BRACKET, 90 HP Manual Tilt
Stern Bracket Disassembly
Stern Bracket Assembly
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
NOTES
Technician’s Notes
Related Documents
GEARCASE
SERVICE CHARTS
GEARCASE TYPES, 75 – 90 HP
PROPELLER SERVICE
Inspection
Propeller Selection
Propeller Hardware Installation
GEARCASE LEAK TEST
GEARCASE SERVICE, 40 – 65 HP MODELS
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
SHIFTER, BEARING AND SEAL 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
Final Assembly and Adjustment
GEARCASE SERVICE, 75 – 90 HP MODELS
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
Driveshaft Service
Shift Housing, Gear and Propeller Shaft Removal
Water Intake Screens
GEARCASE HOUSING INSPECTION
SHIFTER, BEARING AND SEAL 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
Water Intake Screens
Shift Housing, Gear, and Propeller Shaft Installation
Shift Rod Housing Installation
Pinion Gear and Driveshaft Installation
Propeller Shaft Bearing Housing and Gear Installation
Final Assembly and Adjustment
TRIM AND TILT
SERVICE CHART
SYSTEM DESCRIPTION
Manual Adjustment
Trailering Bracket And Tilt Support
ROUTINE INSPECTIONS
General
Reservoir Fluid
Manual Release Valve
Stern Brackets
TROUBLESHOOTING
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
TRIM AND TILT REPLACEMENT
Removal
Installation
TRIM AND TILT SERVICE
Disassembly
Assembly
NOTES
Technician’s Notes
Related Documents
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

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