Evinrude & Johnson Outboard Engine Workshop Repair & Service Manuals - E-TEC 15-300 HP, Ficht 40-250 HP, 1.5-300 HP, PDF Download - Evinrude E-tec 15, 25, 30 HP 2011 Service Manual.pdf
Evinrude/Johnson Outboard Motor Service & Repair Manuals
Evinrude E-tec 15, 25, 30 HP 2011 Service Manual.pdf
Evinrude E-tec 40, 50, 60 HP 2007 Service Manual.pdf
Evinrude E-tec 75, 90 HP 2007 Service Manual.pdf
Evinrude E-tec 115, 130, 150, 175, 200 HP (V4_V6 60 degr.) 2008 Service Manual.pdf
Evinrude E-tec 115, 130, 150, 175, 200 HP (V4_V6 60 degr.) 2010 Service Manual.pdf
Evinrude E-tec 200, 225, 250, 300 HP (V6 90 degr.) 2010 Service Manual.pdf
Evinrude E-tec & Ficht 40-250 HP 2002-2006 (All Engines 40-250 HP, 2-Stroke Fuel Injected Models).pdf
Evinrude E-tech 200, 225, 250 HP (V6, 3.3L, 90 degr.) Service Manual.pdf
Evinrude_Johnson 1.5-70HP Outboard Engine_Motor Service Manual.pdf
Evinrude_Johnson 1.5HP thru 40HP Outboard Engine Tune-Up & Repair Manual.pdf
Evinrude_Johnson 2HP-40HP Outboard Engine Shop Manual (incld. Electric Motor) 1973-1990.pdf
Evinrude_Johnson 48HP-235HP Outboard Engine Service Manual.pdf
Evinrude_Johnson 48HP-235HP Outboard Engine Service Manual (incld. Sea Drives) 1973-1989.pdf
Evinrude_Johnson Outboards 1992-2001 Service Manual 65-300HP SM-05190.pdf
bookmarked, Searchable, Printable, high quality PDF
Complete official service manual for Evinrude/Johnson Outboard Engines, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.
Evinrude/Johnson Outboard Engines Models workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
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Evinrude E-tec & Ficht 40-250 HP 2002-2006 (All Engines 40-250 HP, 2-Stroke Fuel Injected Models)....2
Introduction....2
Covered models....2
Contents....3
Master Index....5
1 General Information, Safety and Tools....12
1 Table of Contents....12
1-2 How to use this Manual....13
1-4 Boating Safety....15
1-10 Boating Equipment (not required but recommended)....21
1-13 Safety in Service....24
1-13 Troubleshooting....24
1-17 Shop Equipment....28
1-19 Tools....30
1-27 Fasteners, Measurements and Conversions....38
1-28 Specifications....39
2 Maintenance & Tune-up....42
2 Table of Contents....42
2-2 General Information....43
2-5 Lubrication Service....46
2-9 Engine Maintenance....50
2-26 Boat Maintentance....67
2-30 Tune-Up....71
2-37 Timing and Synchronization....78
2-43 Storage (what to do before and after)....84
2-47 Clearing a Submerged motor....88
2-48 Specifications....89
3 Fuel & Ignition Systems....96
3 Table of Contents....96
3-2 Fuel System Basics....97
3-6 Fuel Tank and lines....101
3-11 FICHT Fuel Injection (DI/FFI) & Ignition System....106
3-54 E-TEC Fuel Injection & Ignition System....149
3-92 Specificatons....187
4 Electrical Systems....188
4 Table of Contents....188
4-2 Understanding and Troubleshooting Electrical Systems....189
4-8 Charging Circuit....195
4-18 Starting Circuit....205
4-35 Warning System....222
4-38 Wiring Diagrams Index....225
4-60 Specifications....247
5 Lubrication and Cooling....248
5 Table of Contents....248
5-2 Oil Injection System - DI/FICHT Motors....249
5-10 Oil Inection System - E-TEC Motors....257
5-18 Cooling System....265
5-38 Specifications....285
6 Powerhead....286
6 Table of Contents....286
6-2 Powerhead....287
6-29 Powerhead Break-in....314
6-30 Powerhead Exploded Views....315
6-38 Specifations....323
7 Lower Unit....326
7 Table of Contents....326
7-2 Gearcase....327
8 TRIM and TILT....364
8 Table of Content....364
8-2 TRIM/TILT Systems....365
9 Remote Controls....384
9 Table of Contents....384
9-2 Remote Controls....385
10 Hand Rewind Starter....400
10 Table of Contents....400
10-2 Hand Rewind Starter....401
10-4 Disassembly & Assembly....403
Evinrude E-tec 115, 130, 150, 175, 200 HP (V4_V6 60 degr.) 2008 Service Manual....407
INTRODUCTION....411
ABBREVIATIONS USED IN THIS MANUAL....414
Units of Measurement....414
List of Abbreviations....414
ENGINE EMISSIONS INFORMATION....415
Manufacturer’s Responsibility....415
Dealer’s Responsibility....415
Owner’s Responsibility....415
EPA Emission Regulations....415
MODEL DESIGNATION....416
MODELS COVERED IN THIS MANUAL....417
Identifying Model and Serial Numbers....417
SERVICE SPECIFICATIONS....418
STANDARD TORQUE SPECIFICATIONS....420
PRODUCT REFERENCE AND ILLUSTRATIONS....420
SPECIAL TOOLS....421
DIAGNOSTIC TOOLS....422
UNIVERSAL TOOLS....422
ELECTRICAL / IGNITION TOOLS....424
FUEL /OIL SYSTEM TOOLS....425
POWERHEAD TOOLS....425
GEARCASE TOOLS....426
TRIM AND TILT TOOLS....430
SHOP AIDS....431
NOTES....434
Technician’s Notes....434
Related Documents....434
INSTALLATION AND PREDELIVERY....435
BOAT RIGGING....436
Remote Controls....436
Battery Installation....437
Battery Switches and Multiple Batteries....438
Auxiliary Battery Charging....440
Battery and Switch Wiring Diagrams....441
Fuel System Requirements....443
Oiling System Set-Up....445
Cable and Hose Installation....448
OUTBOARD INSTALLATION....452
Hull Preparation....452
Transom Measuring and Drilling....454
Drilling and Hardware Diagrams....456
Lifting the Outboard....457
Steering Systems....457
Outboard Mounting....459
OUTBOARD RIGGING....460
Cable, Hose, and Wire Routing....460
Control Cable Installation....461
Electrical Harness Connections....463
Water Pressure Gauge....464
CANbus Connections....464
FUEL AND OIL PRIMING....466
Fuel Requirements....466
Fuel System Priming....467
Oil Requirements....467
Oil Injection Rate....468
Break-In Oiling....469
Oil Supply Priming....469
BEFORE START-UP....471
Gearcase Lubricant....471
Oil Level....471
Trim and Tilt Fluid....471
RUNNING CHECKS....472
Engine Monitoring System....472
Fuel System....472
Emergency Stop / Key Switch....472
Remote Control Operation....472
Start-In-Gear Prevention....472
Tachometer Pulse Setting....473
Water Pump Overboard Indicator....473
Operating Temperature....473
Idle Speed....473
Break-In....473
PROPELLERS....474
Propeller Selection....474
Propeller Hardware Installation....475
FINAL ADJUSTMENTS....476
Tilt Limit Switch Adjustment....476
Trim Sending Unit Adjustment....477
Trim Tab Adjustment....478
Dual-Outboard Alignment....479
NOTES....480
Technician’s Notes....480
Related Documents....480
MAINTENANCE....481
INSPECTION AND MAINTENANCE SCHEDULE....482
ANTI-CORROSION PROTECTION....483
Sacrificial Anodes....483
Testing Procedure - Continuity....483
Metallic Component Protection....483
Exterior Finishes....483
COOLING SYSTEM....484
Flushing....484
Water Intake Screens....485
Additional Maintenance....485
LUBRICATION....485
Steering System....485
Swivel Bracket and Trailering Bracket....486
Tilt Tube....486
Throttle and Shift Linkage....486
Propeller Shaft....487
Gearcase Lubricant....487
Trim and Tilt....489
BATTERY AND BATTERY CONNECTIONS....490
FUEL AND OIL SYSTEMS....490
Fuel Filter....490
Oil Filters and Oil Reservoir....491
Air Silencer....491
Hoses and Connections....491
SPARK PLUGS....492
Indexing....492
EXHAUST PRESSURE FITTING....493
Operation Test....493
Cleaning....493
STORAGE....494
Fuel System Treatment....494
Internal Engine Treatment....494
Additional Recommendations....495
PRE-SEASON SERVICE....495
Outboard Mounting Bolts....495
Gearcase Lubricant....495
Battery(s)....495
Power Trim and Tilt....495
Operational Checks....495
SUBMERGED ENGINES....496
Engine Dropped Overboard (Not Running)....496
Engine Dropped Overboard (Running)....496
Engine Dropped Overboard (In Salt Water)....496
Prolonged Submersion (Fresh or Salt Water)....496
ENGINE COVER SERVICE....497
UPPER COVER SERVICE....498
Latch Hook Installation....498
Upper Cover Cap Replacement....498
LOWER COVER SERVICE....499
Lower Cover Removal....499
Lower Cover Installation....499
Latch Handle Installation....500
Trim Switch Installation....500
ENGINE MANAGEMENT MODULE (EMM)....501
DESCRIPTION....502
EMM Functions....502
EMM Connections....502
LED Indicators....502
EMM INPUTS AND OUTPUTS DIAGRAM....503
INTERNAL SENSORS....504
EMM Temperature Sensor....504
55 V Circuit Sensor....504
12 V Circuit Sensor....504
Barometric Pressure Sensor....505
Exhaust Pressure Sensor....505
EXTERNAL SENSORS....505
Air Temperature Sensor....505
Engine Temperature Sensor....505
Oil Pressure Sensor....506
Throttle Position Sensor....507
Crankshaft Position Sensor....507
Neutral Switch (V4 Models)....507
INTERNAL EMM FUNCTIONS....508
Start Assist Circuit (SAC)....508
ROM Verification....508
Idle Controller....508
RPM Limiter....508
Exhaust Valve (V4 Models)....508
Engine Monitor and Warning Systems....508
Fault Code Creation and Storage....508
ENGINE MONITORING SYSTEM....509
System Self-Test....509
Service Mode....509
Engine Running....509
S.A.F.E. WARNING SYSTEM....510
Activation....510
Recovery....510
SHUTDOWN MODE....510
Recovery....510
DIAGNOSTIC SOFTWARE FUNCTIONS....511
Communication....511
Static Information....511
Dynamic Information....512
Stored Service Codes (Faults)....512
Hard Faults....512
Persistent Faults....512
Static Tests....512
Dynamic Tests....513
Oil Control Settings....514
Tiller/Remote Programming....514
Ignition Timing....515
TPS Calibration....515
Fuel Injector Servicing....516
Reports....516
Software Replacement....517
EMM Transfer....517
EMM SERVICING....518
Removal....518
Installation....518
SYSTEM ANALYSIS....519
DIAGNOSTIC PROCEDURES....520
Visual Inspections....520
Operational Inspections....520
Troubleshooting....521
DYNAMIC TESTS....522
Cylinder Drop Tests....522
Fuel Control Adjustment....522
Inductive Amp Meter Test....522
EMM LED INDICATORS....523
Key ON....523
Starting....523