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2007 Johnson Evinrude 40 50 60 Hp E tec Outboards Service Repair Workshop Manual – PDF Download
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Description
2007 Johnson Evinrude 40 50 60 Hp E tec Outboards Service Repair Workshop Manual
FILE DETAILS:
2007 Johnson Evinrude 40 50 60 Hp E tec Outboards Service Repair Workshop Manual
LANGUAGE:ENGLISH
PAGES:357
DOWNLOADABLE:YES
FILE TYPE:PDF
2007 JOHNSON EVINRUDE 40 50 60 HP E TEC OUTBOARDS SERVICE REPAIR WORKSHOP MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
- 2007 Johnson Evinrude 40 50 60 Hp E tec Outboards Service Repair Workshop Manual
- This manual is written for qualified, factory-trained technicians who are already familiar with the use of Evinrude®/Johnson® Special Tools. This manual is not a substitute for work experience. It is an organized guide for reference, repair, and maintenance of the outboard(s). This manual uses the following signal words identifying important safety messages.
- IMPORTANT: Identifies information that will help prevent damage to machinery and appears next to information that controls correct assembly and operation of the product. These safety alert signal words mean: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Always follow common shop safety practices.
- If you have not had training related to common shop safety practices, you should do so to protect yourself, as well as the people around you. It is understood that this manual may be translated into other languages. In the event of any discrepancy, the English version shall prevail. To reduce the risk of personal injury, safety warnings are provided at appropriate times throughout the manual.
- DO NOT make any repairs until you have read the instructions and checked the pictures relating to the repairs. Be careful, and never rush or guess a service procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol use, to name a few.
- Damage to a boat and outboard can be fixed in a short period of time, but injury or death has a lasting effect. When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Using substandard parts could result in injury or product malfunction.
- Torque wrench tightening specifications must be strictly followed. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts. If you use procedures or service tools that are not recommended in this manual, YOU ALONE must decide if your actions might injure people or damage the outboard.
TABLE OF CONTENTS:
2007 Johnson Evinrude 40 50 60 Hp E tec Outboards Service Repair Workshop Manual
<— Return to Menu.............................................................. 0 INTRODUCTION................................................................... 6 MODELS COVERED IN THIS MANUAL.............................................. 7 Identifying Model and Serial Numbers................................... 7 MODEL DESIGNATION.......................................................... 8 TYPICAL PAGE - A........................................................... 9 TYPICAL PAGE - B........................................................... 10 TYPICAL PAGE - C........................................................... 11 TYPICAL PAGE - D........................................................... 12 ABBREVIATIONS USED IN THIS MANUAL.......................................... 13 Units of Measurement................................................... 13 List of Abbreviations.................................................. 13 ENGINE EMISSIONS INFORMATION............................................... 14 Manufacturer’s Responsibility.......................................... 14 Dealer’s Responsibility................................................ 14 Owner’s Responsibility................................................. 14 EPA Emission Regulations............................................... 14 PRODUCT REFERENCE AND ILLUSTRATIONS........................................ 15 SYMBOLS.................................................................... 15 Electrical............................................................. 15 Values................................................................. 16 NOTES...................................................................... 17 Technician’s Notes..................................................... 17 Related Documents...................................................... 17 SERVICE SPECIFICATIONS AND SPECIAL TOOLS....................................... 18 TECHNICAL DATA............................................................. 19 STANDARD TORQUE SPECIFICATIONS............................................. 21 SPECIAL TOOLS.............................................................. 22 Electrical / Ignition.................................................. 22 Fuel System............................................................ 23 Gearcase............................................................... 24 Powerhead.............................................................. 25 Starter................................................................ 26 Universal.............................................................. 27 SHOP AIDS.................................................................. 29 INSTALLATION AND PREDELIVERY................................................... 32 BOAT RIGGING............................................................... 33 Remote Controls........................................................ 33 Battery Installation................................................... 35 Battery Switches and Multiple Batteries................................ 36 Battery and Switch Wiring Diagrams..................................... 38 Fuel System Requirements............................................... 40 Cable and Hose Installation............................................ 42 OUTBOARD INSTALLATION...................................................... 47 Hull Preparation....................................................... 47 Transom Measuring and Drilling......................................... 48 Drilling and Hardware Diagrams......................................... 51 Lifting the Outboard................................................... 53 Steering Systems....................................................... 53 Outboard Mounting...................................................... 55 OUTBOARD RIGGING........................................................... 57 Cable, Hose, and Wire Routing.......................................... 57 Control Cable Adjustments.............................................. 57 Electrical Harness Connections......................................... 59 Water Pressure Gauge................................................... 59 FUEL AND OIL PRIMING....................................................... 60 Fuel Requirements...................................................... 60 Fuel System Priming.................................................... 61 Oil Requirements....................................................... 62 Oil Injection Rate..................................................... 62 SystemCheck Low Oil Warning Test....................................... 62 Oil Supply Priming..................................................... 63 Break-In Oiling........................................................ 63 BEFORE START-UP............................................................ 64 Gearcase Lubricant..................................................... 64 Oil Level.............................................................. 64 Trim and Tilt Fluid.................................................... 64 RUNNING CHECKS............................................................. 65 SystemCheck Operation.................................................. 65 Fuel System............................................................ 65 Emergency Stop / Key Switch............................................ 65 Remote Control Operation............................................... 65 Start-In-Gear Prevention............................................... 65 Tachometer Pulse Setting............................................... 66 Water Pump Overboard Indicator......................................... 66 Operating Temperature.................................................. 66 Idle Speed............................................................. 66 Break-In............................................................... 66 PROPELLERS................................................................. 67 Propeller Selection.................................................... 67 Propeller Hardware Installation........................................ 68 FINAL ADJUSTMENTS.......................................................... 69 Trim Sending Unit Adjustment........................................... 69 Trim Tab Adjustment.................................................... 70 Dual-Outboard Alignment................................................ 71 MAINTENANCE.................................................................... 72 INSPECTION AND MAINTENANCE SCHEDULE........................................ 73 ANTI-CORROSION PROTECTION.................................................. 74 Sacrificial Anodes..................................................... 74 Testing Procedure - Continuity......................................... 74 Metallic Component Protection.......................................... 74 Exterior Finishes...................................................... 74 COOLING SYSTEM............................................................. 75 Flushing............................................................... 75 Water Intake Screens................................................... 76 Additional Maintenance................................................. 76 LUBRICATION................................................................ 76 Steering System........................................................ 76 Swivel Bracket and Trailering Bracket.................................. 77 Tilt Tube.............................................................. 77 Throttle and Shift Linkage............................................. 77 Propeller Shaft........................................................ 78 Gearcase Lubricant..................................................... 78 Trim and Tilt.......................................................... 79 BATTERY AND BATTERY CONNECTIONS............................................ 79 FUEL AND OIL SYSTEMS....................................................... 80 Fuel Filter............................................................ 80 Oil Reservoir.......................................................... 80 Air Silencer........................................................... 80 Hoses and Connections.................................................. 80 SPARK PLUGS................................................................ 81 Indexing............................................................... 81 STORAGE.................................................................... 82 Fuel System Treatment.................................................. 82 Internal Engine Treatment.............................................. 82 Additional Recommendations............................................. 83 PRE-SEASON SERVICE......................................................... 83 Outboard Mounting Bolts................................................ 83 Gearcase Lubricant..................................................... 83 Battery(s)............................................................. 83 Power Trim and Tilt.................................................... 83 Operational Checks..................................................... 83 SUBMERGED ENGINES.......................................................... 84 Engine Dropped Overboard (Not Running)................................. 84 Engine Dropped Overboard (Running)..................................... 84 Engine Dropped Overboard (In Salt Water)............................... 84 Prolonged Submersion (Fresh or Salt Water)............................. 84 NOTES...................................................................... 85 Technician’s Notes..................................................... 85 Related Documents...................................................... 85 ENGINE MANAGEMENT MODULE (EMM)................................................. 86 DESCRIPTION................................................................ 87 EMM Functions.......................................................... 87 EMM Connections........................................................ 87 SENSORS AND FUNCTIONS...................................................... 88 Internal Sensors....................................................... 88 External Sensors....................................................... 89 Internal Functions..................................................... 91 EMM INPUTS AND OUTPUTS DIAGRAM............................................. 92 S.A.F.E. WARNING SYSTEM.................................................... 93 Activation............................................................. 93 Recovery............................................................... 93 SHUTDOWN MODE.............................................................. 93 EMM DIAGNOSTICS............................................................ 94 LED Indicators......................................................... 94 Diagnostic Software Program............................................ 95 Communication.......................................................... 95 Program Information.................................................... 96 Service Codes (Faults)................................................. 96 Static Tests........................................................... 97 Dynamic Tests.......................................................... 98 Oil Control............................................................ 99 Starter Mode (Tiller/Remote Programming)............................... 99 Timing Verification.................................................... 99 TPS Calibration........................................................100 Idle Speed.............................................................100 Fuel Injector Servicing................................................100 Fuel Control Adjustment................................................101 Reports................................................................101 Software Replacement...................................................102 EMM Transfer...........................................................102 SystemCheck ENGINE MONITOR.................................................102 System Self-Test.......................................................103 Service Mode...........................................................103 Engine Running.........................................................103 SYSTEM ANALYSIS................................................................104 ELECTRICAL CONNECTIONS.....................................................105 GROUND CIRCUITS............................................................107 Test Procedure.........................................................107 FUSE.......................................................................107 EMM DIAGNOSTICS............................................................108 LED Indicators.........................................................108 Software Programs......................................................108 DIAGNOSTIC PROCEDURES......................................................109 Symptoms...............................................................110 SPECIALIZED TEST PROCEDURES................................................111 Dynamic Tests..........................................................111 Testing with Timing Light..............................................111 Inductive Amp Meter Test...............................................112 Engine Monitoring Information..........................................112 Voltage Testing........................................................113 START CIRCUIT..............................................................113 Electric Starter Operation.............................................113 Starter Solenoid Activation............................................114 IGNITION AND ELECTRICAL CIRCUITS...........................................115 Stop Circuit...........................................................115 Neutral Switch.........................................................115 Stator Output Voltage..................................................115 EMM....................................................................115 Crankshaft Position Sensor.............................................115 Alternator Output Voltage..............................................115 Capacitor..............................................................115 Ignition Power Supply to EMM...........................................115 Ignition Primary Voltage...............................................115 Ignition Coil..........................................................115 IGNITION OUTPUT............................................................116 Wiring Inspection......................................................116 Ignition Voltage.......................................................116 System Voltage.........................................................117 Static Spark Test......................................................117 Running Ignition Tests.................................................118 Ignition Primary Circuit Resistance Test...............................119 Crankshaft Position Sensor (CPS) Test..................................119 FUEL DELIVERY..............................................................120 Manifold Pressure Test.................................................120 Vapor Separator Checks.................................................121 Fuel Delivery to Lift Pump.............................................121 FUEL INJECTOR OPERATION....................................................121 Neutral Switch.........................................................121 Static Tests...........................................................121 Dynamic Tests..........................................................122 EXHAUST WATER VALVE........................................................123 Static Test............................................................123 Dynamic Test...........................................................123 ELECTRICAL AND IGNITION........................................................124 SERVICE CHART..............................................................125 DASH CONNECTIONS, INSTRUMENT HARNESS.......................................127 IGNITION SYSTEM TESTS......................................................128 Sensor Resistance Tests................................................128 Ignition Coil Tests....................................................129 Stator Tests...........................................................130 Capacitor Test.........................................................131 EXHAUST WATER VALVE TEST...................................................131 CHARGING SYSTEM TESTS......................................................131 12 V Charging Circuit..................................................131 55 V Alternator Circuit................................................132 SystemCheck CIRCUIT TESTS..................................................133 Gauge Self-Test Check..................................................133 CHECK ENGINE Circuit Test..............................................134 WATER TEMP/ HOT Circuit Test...........................................134 LOW OIL Circuit Test...................................................135 NO OIL Circuit Test....................................................135 REMOTE CONTROL SWITCH TESTS................................................135 Key Switch Test........................................................135 Neutral Start Circuit Test.............................................136 Neutral Start Switch Test..............................................136 Emergency Stop Switch Test.............................................137 ELECTRIC STARTER TESTS.....................................................137 Starter Solenoid Test..................................................137 No Load Current Draw Test..............................................138 TILT/TRIM RELAY TEST.......................................................139 Operation..............................................................139 Test Procedure.........................................................139 TACHOMETER CIRCUIT TESTS...................................................140 FLYWHEEL SERVICING.........................................................141 Removal................................................................141 Installation...........................................................142 TIMING ADJUSTMENTS.........................................................143 Timing Pointer.........................................................143 Timing Verification....................................................144 TPS Calibration........................................................144 SPARK PLUGS................................................................145 Inspection.............................................................145 Indexing...............................................................145 ELECTRIC STARTER SERVICING.................................................146 Removal................................................................146 Disassembly............................................................146 Cleaning and Inspection................................................147 Assembly...............................................................148 Installation...........................................................149 CONNECTOR SERVICING........................................................150 DEUTSCH Connectors.....................................................150 AMP Connectors.........................................................151 Packard † Connectors...................................................153 NOTES......................................................................155 Technician’s Notes.....................................................155 Related Documents......................................................155 FUEL SYSTEM....................................................................156 SERVICE CHART..............................................................157 COMPONENTS.................................................................159 Fuel Lift Pump.........................................................159 Fuel Filter............................................................159 Vapor Separator........................................................159 Fuel Circulation Pump..................................................161 Fuel Manifolds.........................................................161 Fuel Injectors.........................................................162 FUEL SYSTEM HOSE ROUTING...................................................163 DIRECT INJECTION ELECTRICAL CIRCUITS.......................................164 Injector / Circulation Pump Circuits Diagram...........................164 FUEL COMPONENT TESTS.......................................................165 Injectors..............................................................165 Fuel Supply............................................................166 FUEL COMPONENT SERVICING...................................................169 Relieving Fuel System Pressure.........................................169 Fuel Filter............................................................170 Fuel Lift Pump.........................................................170 Vapor Separator........................................................171 Fuel Injectors.........................................................171 Fuel Manifolds.........................................................175 INTAKE MANIFOLD............................................................175 Removal................................................................175 Disassembly............................................................175 Inspection.............................................................176 Assembly...............................................................176 Installation...........................................................177 OILING SYSTEM..................................................................178 SERVICE CHART..............................................................179 COMPONENTS.................................................................180 Oil Tank Assembly......................................................180 Electrical Circuit (55 V)..............................................181 SystemCheck LOW and NO OIL Warning Signals.............................181 Oiling System Electrical Diagram.......................................182 Cylinder and Crankcase.................................................183 Oil Supply and Distribution Diagram....................................183 Oil Recirculation System...............................................184 Recirculation Hose Diagram.............................................184 PRIMING....................................................................185 OILING RATES...............................................................185 Oil Injection Rate.....................................................185 Break-in Oiling........................................................185 OILING SYSTEM TESTS........................................................186 Oil Injection Pump Static Test.........................................186 Oil Injection Pump Voltage Test........................................186 Oil Injection Pump Circuit Resistance Test.............................187 Oil Flow Tests.........................................................187 Oil-to-Fuel Check Valve Test...........................................189 LOW OIL Sending Unit Test..............................................189 NO OIL Warning Test....................................................189 OIL COMPONENT SERVICING....................................................190 Oil Distribution Hoses.................................................190 Oil Tank Assembly......................................................191 COOLING SYSTEM.................................................................192 HOSE ROUTING AND WATER FLOW DIAGRAM........................................193 ENGINE TEMPERATURE CHECK...................................................194 Software Method........................................................194 Pyrometer Method.......................................................194 Idle Operating Temperature Troubleshooting (Below Range)...............195 COMPONENTS.................................................................196 General Description....................................................196 Water Pump and Intakes.................................................196 Exhaust Housing........................................................197 Pressure Relief Valve..................................................197 Thermostat.............................................................197 Block Venting..........................................................198 Water Pressure Connection..............................................198 OPERATION..................................................................198 Cylinder Block / Cylinder Head Cooling.................................198 EMM and Vapor Separator Cooling........................................199 THERMOSTAT SERVICING.......................................................199 Disassembly............................................................199 Inspection.............................................................200 Assembly...............................................................200 PRESSURE RELIEF VALVE SERVICING............................................200 Disassembly............................................................200 Inspection.............................................................201 Assembly...............................................................201 POWERHEAD......................................................................202 SERVICE CHART..............................................................203 GENERAL....................................................................205 Cylinder Compression Testing...........................................205 Retaining Ring Pliers..................................................205 REMOVAL....................................................................206 DISASSEMBLY................................................................208 General................................................................208 Shift Linkage..........................................................208 Throttle Linkage.......................................................208 Crankcase..............................................................209 Cylinder Head..........................................................210 Connecting Rods and Pistons............................................210 Crankshaft.............................................................211 CLEANING...................................................................213 INSPECTION.................................................................214 Cylinder Head..........................................................214 Crankshaft.............................................................215 Cylinder Bore..........................................................215 Pistons................................................................215 Piston Rings...........................................................215 Bearings...............................................................216 ASSEMBLY...................................................................217 Crankshaft.............................................................217 Pistons and Connecting Rods............................................219 Cylinder Head..........................................................221 Crankshaft and Connecting Rods.........................................222 Crankcase..............................................................225 Shift Linkage..........................................................227 Throttle Linkage.......................................................228 General................................................................228 INSTALLATION...............................................................229 POWERHEAD VIEWS............................................................233 Port Short Block.......................................................233 Starboard Short Block..................................................233 Port Dressed Powerhead.................................................234 Starboard Dressed Powerhead............................................234 Port Rope Start Models.................................................235 Starboard Rope Start Models............................................235 Front..................................................................236 Rear...................................................................237 Top....................................................................238 Top, Rope Start Models.................................................239 MIDSECTION.....................................................................240 SERVICE CHART..............................................................241 CLEANING AND INSPECTION....................................................244 General................................................................244 Clamp Screw............................................................244 Exhaust Housing........................................................244 EXHAUST HOUSING............................................................245 Removal................................................................245 Servicing..............................................................246 Installation...........................................................247 STERN BRACKET-Power Tilt Models............................................248 Disassembly............................................................248 Assembly...............................................................249 STERN BRACKET- Manual Tilt Models..........................................250 Disassembly............................................................250 Assembly...............................................................253 Tilt Assist Cylinder (Optional)........................................256 STEERING HANDLE............................................................257 Removal................................................................257 Disassembly............................................................258 Inspection.............................................................259 Assembly...............................................................259 Installation...........................................................261 MIDSECTION AND TILLER ADJUSTMENTS..........................................263 Steering Friction Adjustment...........................................263 Throttle Friction Adjustment...........................................263 GEARCASE.......................................................................264 SERVICE CHART..............................................................265 PROPELLER..................................................................266 Inspection.............................................................266 LUBRICANT..................................................................266 Draining...............................................................266 Inspection.............................................................266 Filling................................................................267 LEAK TEST..................................................................267 REMOVAL AND INSTALLATION...................................................268 Removal................................................................268 Installation...........................................................269 WATER PUMP.................................................................270 Disassembly............................................................270 Inspection.............................................................270 Assembly...............................................................271 SHIFT ROD ADJUSTMENT.......................................................273 DISASSEMBLY................................................................273 Pre-Disassembly Inspection.............................................273 Propeller Shaft Bearing Housing Removal................................274 Pinion Gear and Driveshaft Removal.....................................275 Shift Housing, Gear and Propeller Shaft Removal........................276 BEARING AND SEAL REMOVAL...................................................277 Shift Housing..........................................................277 Pinion Gear Bearing....................................................278 Water Intake Screen....................................................279 Driveshaft Bearing Housing.............................................279 Propeller Shaft Bearing Housing........................................279 BEARING AND SEAL INSTALLATION..............................................281 Shift Housing..........................................................281 Water Intake Screen....................................................282 Pinion Gear Bearing....................................................282 Driveshaft Bearing Housing.............................................283 Propeller Shaft Bearing Housing........................................283 DRIVESHAFT SHIMMING........................................................284 ASSEMBLY...................................................................286 Shift Housing, Gear, and Propeller Shaft Installation..................286 Shift Rod Housing Installation.........................................286 Pinion Gear and Driveshaft Installation................................287 Propeller Shaft Bearing Housing and Gear Installation..................288 TRIM AND TILT..................................................................290 SYSTEM DESCRIPTION.........................................................291 ROUTINE INSPECTIONS........................................................292 General................................................................292 Reservoir Fluid........................................................292 Manual Release Valve...................................................292 Stern Brackets.........................................................292 ELECTRICAL CIRCUIT TESTS...................................................293 Relay Testing..........................................................293 Trim and Tilt Motor Current Draw Tests.................................293 Trim and Tilt Motor No Load Test.......................................294 Trim Gauge Test........................................................294 Trim Sender Test.......................................................295 SERVICING..................................................................295 Removal................................................................295 Disassembly............................................................296 Assembly...............................................................297 Installation...........................................................298 ADJUSTMENTS................................................................299 MANUAL STARTER.................................................................300 SERVICE CHART..............................................................301 REMOVAL....................................................................302 DISASSEMBLY................................................................302 CLEANING AND INSPECTION....................................................304 ASSEMBLY...................................................................304 INSTALLATION...............................................................308 NOTES......................................................................309 Technician’s Notes.....................................................309 Related Documents......................................................309 SAFETY.........................................................................310 TABLE OF CONTENTS..........................................................310 MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM......................312 Outboard Shift Systems and Safety......................................313 Outboard Speed Control System and Safety...............................314 Outboard Steering Control System and Safety............................315 Outboard Fuel, Electrical System, and Safety...........................317 Outboard Mounting System and Safety....................................320 If weakened, parts could fail later on the water, when not expected....321 Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety........322 Outboard Emergency Stop System and Safety..............................323 Summing up.............................................................325 MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM......................326 Handling Outboards.....................................................326 Handling Lead/Acid Batteries...........................................330 Gasoline - Handle With Care!...........................................331 Hazardous Products.....................................................332 Safety Awareness Test..................................................333 INDEX..........................................................................334 TROUBLE CHECK CHART............................................................342 OUTBOARD WILL NOT START....................................................342 OUTBOARD WILL NOT START....................................................343 OUTBOARD HARD TO START.....................................................344 OUTBOARD WILL NOT SHUT OFF.................................................345 OUTBOARD STARTS AND STALLS.................................................345 OUTBOARD STARTS, LOW MAXIMUM RPM...........................................346 EXCESSIVE SMOKING..........................................................346 OUTBOARD SURGES, RUNS ROUGH................................................347 DIAGRAMS.......................................................................348
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
2 reviews for 2007 Johnson Evinrude 40 50 60 Hp E tec Outboards Service Repair Workshop Manual – PDF Download
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Adam Danny –
Everett Edison –
Great and easy let’s go beside this stupid review taking up my time when I’m trying to get something done