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2009-2011 Johnson Evinrude 25hp 30hp E-Tec Outboard Service Repair Manual – PDF Download
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Description
2009-2011 Johnson Evinrude 25hp 30hp E-Tec Outboard Service Repair Manual
FILE DETAILS:
2009-2011 Johnson Evinrude 25hp 30hp E-Tec Outboard Service Repair Manual
LANGUAGE:ENGLISH
PAGES:365
DOWNLOADABLE:YES
FILE TYPE:PDF
2009-2011 JOHNSON EVINRUDE 25HP 30HP E-TEC OUTBOARD SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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SAMPLE PAGE FROM THE MANUAL:
2009-2011 Johnson Evinrude 25hp 30hp E-Tec Outboard Service Repair Manual
Manufacturer’s Responsibility
Beginning with 1999 model year outboards, manufacturers of marine outboards must determine the exhaust emission levels for each outboard horsepower family and certify these outboards with the United States of America Environmental Protection Agency (EPA).
An emissions control information label, showing emission levels and outboard specifications, must be placed on each outboard at the time of manufacture.
Dealer’s Responsibility
When performing service on all 1999 and more recent Evinrude/Johnson outboards that carry an emissions control information label, adjustments must be kept within published factory specifications.
Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed certification standards.
Dealers are not to modify the outboard in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications.
TABLE OF CONTENTS:
2009-2011 Johnson Evinrude 25hp 30hp E-Tec Outboard Service Repair Manual
INTRODUCTION................................................................... 5 ABBREVIATIONS USED IN THIS MANUAL.......................................... 8 Units of Measurement................................................... 8 List of Abbreviations.................................................. 8 ENGINE EMISSIONS INFORMATION............................................... 9 Manufacturer’s Responsibility.......................................... 9 Dealer’s Responsibility................................................ 9 Owner’s Responsibility................................................. 9 EPA Emission Regulations............................................... 9 MODEL DESIGNATION.......................................................... 10 MODELS COVERED IN THIS MANUAL.............................................. 11 Identifying Model and Serial Numbers................................... 11 SERVICE SPECIFICATIONS..................................................... 12 STANDARD TORQUE SPECIFICATIONS............................................. 14 PRODUCT REFERENCE AND ILLUSTRATIONS........................................ 14 SPECIAL TOOLS.................................................................. 15 DIAGNOSTIC TOOLS........................................................... 16 UNIVERSAL TOOLS............................................................ 16 ELECTRICAL / IGNITION TOOLS................................................ 18 FUEL /OIL SYSTEM TOOLS..................................................... 19 POWERHEAD TOOLS............................................................ 19 GEARCASE TOOLS............................................................. 20 SHOP AIDS.................................................................. 22 INSTALLATION AND PREDELIVERY................................................... 25 BOAT RIGGING............................................................... 26 Remote Controls........................................................ 26 Battery Installation................................................... 27 Battery Switches and Multiple Batteries................................ 28 Battery and Switch Wiring Diagrams..................................... 30 Fuel System Requirements............................................... 31 Cable and Hose Installation............................................ 33 OUTBOARD INSTALLATION...................................................... 37 Hull Preparation....................................................... 37 Transom Measuring and Drilling......................................... 38 Drilling and Hardware Diagrams......................................... 40 Lifting the Outboard................................................... 42 Steering Systems....................................................... 43 Outboard Mounting...................................................... 44 OUTBOARD RIGGING........................................................... 46 Cable, Hose, and Wire Routing.......................................... 46 Control Cable Adjustments.............................................. 46 Electrical Harness Connections......................................... 48 Battery Cable.......................................................... 49 FUEL AND OIL PRIMING....................................................... 50 Fuel Requirements...................................................... 50 Fuel System Priming.................................................... 51 Oil Requirements....................................................... 51 Oil Injection Rate..................................................... 52 Break-In Oiling........................................................ 53 Oil Supply Priming..................................................... 53 BEFORE START-UP............................................................ 54 Gearcase Lubricant..................................................... 54 Oil Level.............................................................. 54 Trim and Tilt Fluid.................................................... 54 RUNNING CHECKS............................................................. 55 Fuel System............................................................ 55 Emergency Stop / Key Switch............................................ 55 Remote Control Operation............................................... 55 Start-In-Gear Prevention............................................... 55 Tachometer Pulse Setting............................................... 55 Water Pump Overboard Indicator......................................... 56 Operating Temperature.................................................. 56 Idle Speed............................................................. 56 Break-In............................................................... 56 PROPELLERS................................................................. 57 Propeller Selection.................................................... 57 Propeller Hardware Installation........................................ 58 FINAL ADJUSTMENTS.......................................................... 59 Trim Sending Unit Adjustment........................................... 59 Trim Tab Adjustment.................................................... 60 MAINTENANCE.................................................................... 61 INSPECTION AND MAINTENANCE SCHEDULE........................................ 62 ANTI-CORROSION PROTECTION.................................................. 63 Sacrificial Anodes..................................................... 63 Testing Procedure - Continuity......................................... 63 Metallic Component Protection.......................................... 63 Exterior Finishes...................................................... 63 COOLING SYSTEM............................................................. 64 Flushing............................................................... 64 Water Intake Screens................................................... 65 Additional Maintenance................................................. 65 LUBRICATION................................................................ 65 Steering System........................................................ 65 Tiller Handle.......................................................... 65 Swivel Bracket and Trailering Bracket.................................. 66 Tilt Tube.............................................................. 66 Throttle and Shift Linkage............................................. 66 Propeller Shaft........................................................ 67 Gearcase Lubricant..................................................... 67 Trim and Tilt.......................................................... 68 BATTERY AND BATTERY CONNECTIONS............................................ 69 FUEL AND OIL SYSTEMS....................................................... 70 Fuel Filter............................................................ 70 Oil Filters and Oil Reservoir.......................................... 70 Air Silencer........................................................... 70 Hoses and Connections.................................................. 70 SPARK PLUGS................................................................ 71 Indexing............................................................... 71 STORAGE.................................................................... 72 Fuel System Treatment.................................................. 72 Internal Engine Treatment.............................................. 72 Additional Recommendations............................................. 73 PRE-SEASON SERVICE......................................................... 73 Outboard Mounting Bolts................................................ 73 Gearcase Lubricant..................................................... 73 Battery(s)............................................................. 73 Power Trim and Tilt.................................................... 73 Operational Checks..................................................... 73 SUBMERGED ENGINES.......................................................... 74 Engine Dropped Overboard (Not Running)................................. 74 Engine Dropped Overboard (Running)..................................... 74 Engine Dropped Overboard (In Salt Water)............................... 74 Prolonged Submersion (Fresh or Salt Water)............................. 74 ENGINE COVER SERVICE........................................................... 75 UPPER COVER SERVICE........................................................ 76 Latch Hook Installation................................................ 76 LOWER COVER SERVICE........................................................ 77 Lower Cover Removal.................................................... 77 Lower Cover Installation............................................... 77 Latch Handle Installation.............................................. 79 NOTES...................................................................... 80 Technician’s Notes..................................................... 80 Related Documents...................................................... 80 ENGINE MANAGEMENT MODULE (EMM)................................................. 81 DESCRIPTION................................................................ 82 EMM Functions.......................................................... 82 EMM Connections........................................................ 82 LED Indicators......................................................... 82 EMM INPUTS AND OUTPUTS DIAGRAM............................................. 83 INTERNAL SENSORS........................................................... 84 EMM Temperature Sensor................................................. 84 55 V Circuit Sensor.................................................... 84 12 V Circuit Sensor.................................................... 84 Barometric Pressure Sensor............................................. 85 EXTERNAL SENSORS........................................................... 85 Air Temperature Sensor................................................. 85 Engine Temperature Sensor.............................................. 86 Low Oil Switch......................................................... 86 Throttle Position Sensor............................................... 87 Crankshaft Position Sensor............................................. 87 Neutral Switch (Tiller models only).................................... 87 INTERNAL EMM FUNCTIONS..................................................... 88 ROM Verification....................................................... 88 Idle Controller........................................................ 88 RPM Limiter............................................................ 88 Neutral RPM Limiter.................................................... 88 Engine Monitor and Warning Systems..................................... 88 Fault Code Creation and Storage........................................ 88 ENGINE MONITORING SYSTEM................................................... 88 System Self-Test....................................................... 89 Service Mode........................................................... 89 Engine Running......................................................... 89 S.A.F.E. WARNING SYSTEM.................................................... 89 Activation............................................................. 89 Recovery............................................................... 89 SHUTDOWN MODE.............................................................. 90 Recovery............................................................... 90 DIAGNOSTIC SOFTWARE FUNCTIONS.............................................. 90 Communication.......................................................... 90 Static Information..................................................... 91 Dynamic Information.................................................... 92 Stored Service Codes (Faults).......................................... 92 Hard Faults............................................................ 92 Persistent Faults...................................................... 92 Static Tests........................................................... 92 Dynamic Tests.......................................................... 93 Oil Control Settings................................................... 94 Tiller/Remote Programming.............................................. 94 Ignition Timing........................................................ 95 TPS Calibration........................................................ 95 Fuel Injector Servicing................................................ 96 Reports................................................................ 96 Software Replacement................................................... 97 EMM Transfer........................................................... 97 EMM SERVICING.............................................................. 98 Removal................................................................ 98 Installation........................................................... 98 SYSTEM ANALYSIS................................................................ 99 DIAGNOSTIC PROCEDURES......................................................100 Visual Inspections.....................................................100 Operational Inspections................................................100 Troubleshooting........................................................101 DYNAMIC TESTS..............................................................102 Cylinder Drop Tests....................................................102 Fuel Control Adjustment................................................102 Inductive Amp Meter Test...............................................102 EMM LED INDICATORS.........................................................103 Key ON.................................................................103 Starting...............................................................103 Running................................................................104 IGNITION OUTPUT TESTS......................................................105 Required Ignition Systems..............................................105 Wiring Inspection......................................................105 Crankshaft Position Sensor (CPS) Test..................................106 System Voltage Test....................................................106 Static Ignition Test...................................................107 Running Ignition Tests.................................................108 Ignition Control Circuit Tests.........................................109 Ignition Coil Tests....................................................109 FUEL DELIVERY TESTS........................................................110 Fuel Pump Static Test..................................................110 Fuel Injector Static Test..............................................110 Running Fuel System Tests..............................................111 NOTES......................................................................112 Technician’s Notes.....................................................112 Related Documents......................................................112 ELECTRICAL AND IGNITION........................................................113 SERVICE CHART..............................................................114 IGNITION SYSTEM CIRCUIT DIAGRAM............................................116 DASH CONNECTIONS, INSTRUMENT HARNESS.......................................117 ELECTRICAL HARNESS CONNECTIONS.............................................118 Engine Harness to Stator Connector.....................................118 EMM J1-A Connector.....................................................118 GROUND CIRCUITS............................................................119 EMM Ground Tests.......................................................119 Additional Ground Tests................................................119 FUSE.......................................................................119 SENSOR TESTS...............................................................120 Crankshaft Position Sensor (CPS) Test..................................120 Throttle Position Sensor (TPS) Test....................................120 Engine Temperature Sensor Test.........................................121 Air Temperature Sensor (AT) Test.......................................121 STATOR TESTS...............................................................122 Stator Resistance Tests................................................122 Stator Voltage Output Test.............................................122 CHARGING SYSTEM TESTS......................................................123 Charging System Circuit Diagram........................................123 12 V Charging Circuit..................................................124 55 V Alternator Circuit................................................125 ELECTRIC START CIRCUIT.....................................................126 Start Circuit Diagram..................................................126 Start Circuit Operation................................................127 ELECTRIC START TESTS.......................................................128 Starter Solenoid Test..................................................128 No Load Current Draw Test..............................................129 REMOTE CONTROL SWITCH TESTS................................................130 Key Switch Test........................................................130 Neutral Start Circuit Test.............................................130 Neutral Start Switch Test..............................................131 Emergency Stop Switch Test.............................................131 TILT/TRIM RELAY TEST.......................................................132 Operation..............................................................132 Test Procedure.........................................................132 SystemCheck CIRCUIT TESTS..................................................133 Gauge Self-Test Check..................................................133 LOW OIL Circuit Test...................................................134 TACHOMETER CIRCUIT TESTS...................................................135 FLYWHEEL AND STATOR SERVICING..............................................135 Flywheel Removal.......................................................135 Stator Service.........................................................136 Flywheel Installation..................................................136 TIMING ADJUSTMENTS.........................................................137 Timing Pointer.........................................................137 Timing Verification....................................................137 TPS Calibration........................................................138 ELECTRIC STARTER SERVICING.................................................138 Starter Removal........................................................138 Starter Disassembly....................................................139 Starter Cleaning and Inspection........................................139 Starter Assembly.......................................................140 Starter Installation...................................................142 CONNECTOR SERVICING........................................................143 DEUTSCH Connectors.....................................................143 AMP Connectors.........................................................144 Packard † Connectors...................................................145 FUEL SYSTEM....................................................................147 SERVICE CHART..............................................................148 FUEL SYSTEM HOSE ROUTING...................................................150 FUEL SYSTEM CIRCUIT DIAGRAM................................................151 COMPONENTS.................................................................152 Fuel Lift Pump.........................................................152 Fuel Filter............................................................152 Vapor Separator........................................................152 Fuel Circulation Pump..................................................153 Fuel Manifold..........................................................154 Fuel Injectors.........................................................154 FUEL SYSTEM TESTS..........................................................155 Fuel System Pressure Test..............................................155 Vapor Separator Vent Check.............................................156 Fuel Injector Pressure Test............................................156 Fuel Injector Resistance Test..........................................156 Circulation Pump Resistance Test.......................................157 Lift Pump Pressure Test................................................157 Lift Pump Vacuum Test..................................................158 Lift Pump Diaphragm Test...............................................158 Anti-Siphon Valve Test.................................................159 FUEL COMPONENT SERVICING...................................................160 Relieving Fuel System Pressure.........................................160 Fuel Filter Service....................................................161 Fuel Lift Pump Service.................................................161 Vapor Separator and Fuel Injector Service..............................162 Intake Manifold Service................................................167 NOTES......................................................................170 Technician’s Notes.....................................................170 Related Documents......................................................170 OILING SYSTEM..................................................................171 SERVICE CHART..............................................................172 OIL SUPPLY DIAGRAMS........................................................173 OIL RECIRCULATION DIAGRAM..................................................174 OILING SYSTEM CIRCUIT DIAGRAM..............................................175 COMPONENTS.................................................................176 Oil Tank Assembly......................................................176 Oil Injection Pump.....................................................176 Electrical Circuit (55 V)..............................................176 LOW OIL Warning........................................................177 NO OIL Warning.........................................................177 Cylinder and Crankcase.................................................177 Oil Recirculation System...............................................178 OIL CONTROL SETTINGS.......................................................178 Oil Priming............................................................178 Oiling Rates...........................................................178 Break-in Oiling........................................................178 OILING SYSTEM TESTS........................................................179 Oil Injection Pump Static Test.........................................179 Oil Injection Pump Voltage Test........................................179 Oil Injection Pump Circuit Resistance Test.............................180 Oil Injection Pump Function Test.......................................180 Oil Injection Fittings Flow Test.......................................181 LOW OIL Sending Unit Test..............................................181 OIL COMPONENT SERVICING....................................................182 Oil Distribution Hoses.................................................182 Oil Distribution Manifold and Hose Retainer............................182 Oil Tank Assembly......................................................183 Oil Injection Pump.....................................................184 COOLING SYSTEM.................................................................185 HOSE ROUTING AND WATER FLOW DIAGRAMS.......................................186 COMPONENTS.................................................................187 Water Pump and Intakes.................................................187 Exhaust Housing........................................................187 Pressure Relief Valve..................................................188 Thermostat.............................................................188 OPERATION..................................................................189 Cylinder Block / Cylinder Head Cooling.................................189 Vapor Separator, EMM and Battery Charge Module Cooling.................189 ENGINE TEMPERATURE CHECK...................................................190 Software Method........................................................190 Pyrometer Method.......................................................190 Idle Operating Temperature Troubleshooting (Below Range)...............191 TEMPERATURE SENDER SERVICING...............................................192 Removal................................................................192 Installation...........................................................192 THERMOSTAT AND PRESSURE RELIEF VALVE SERVICING.............................192 Disassembly............................................................192 Inspection.............................................................193 Assembly...............................................................193 NOTES......................................................................194 Technician’s Notes.....................................................194 Related Documents......................................................194 POWERHEAD......................................................................195 SERVICE CHART..............................................................196 POWERHEAD REMOVAL..........................................................198 POWERHEAD DISASSEMBLY......................................................200 General................................................................200 Throttle Linkage Removal...............................................200 Shift Linkage Removal..................................................200 Cylinder Head Removal..................................................201 Crankcase Disassembly..................................................201 Crankshaft Assembly Removal............................................201 Connecting Rods and Pistons............................................202 Crankshaft.............................................................202 CYLINDER BLOCK CLEANING....................................................204 POWERHEAD INSPECTION.......................................................205 Cylinder Head..........................................................205 Bearings...............................................................205 Cylinder Bore..........................................................206 Pistons................................................................206 Piston Rings...........................................................206 POWERHEAD ASSEMBLY.........................................................207 Crankshaft Assembly....................................................207 Pistons and Connecting Rods............................................208 Crankshaft Assembly Installation.......................................210 Crankcase Assembly.....................................................210 Cylinder Head Installation.............................................212 Megaphone and Inner Exhaust Housing Installation.......................212 Shift Linkage Installation.............................................213 Throttle Linkage Installation..........................................214 Final Powerhead Assembly...............................................215 POWERHEAD INSTALLATION.....................................................215 Powerhead Mounting.....................................................215 Shift Linkage Adjustment...............................................217 POWERHEAD VIEWS............................................................218 Port Electric Start Models.............................................218 Starboard Electric Start Models........................................218 Port Rope Start Models.................................................219 Starboard Rope Start Models............................................219 Front..................................................................220 Rear...................................................................221 Top....................................................................222 MIDSECTION.....................................................................223 SERVICE CHART..............................................................224 EXHAUST HOUSING SERVICE....................................................228 Exhaust Housing Removal................................................228 Exhaust Housing Installation...........................................228 Mount Service..........................................................229 Exhaust Relief Muffler.................................................231 STERN BRACKET - Power Tilt Models..........................................232 Stern Bracket Disassembly (Power Tilt).................................232 Stern Bracket Assembly (Power Tilt)....................................234 Trim Sending Unit Removal..............................................238 Trim Sending Unit Installation.........................................239 STERN BRACKET - Manual Tilt Models.........................................240 Clamp Screw............................................................240 Stern Bracket Disassembly (Manual Tilt)................................241 Stern Bracket Assembly (Manual Tilt)...................................245 TILLER HANDLE SERVICE......................................................251 Removal................................................................251 Disassembly............................................................253 Inspection.............................................................257 Assembly...............................................................257 Installation...........................................................264 MIDSECTION AND TILLER ADJUSTMENTS..........................................268 Throttle Friction Adjustment...........................................268 Steering Friction Adjustment...........................................268 Tiller Height Adjustment...............................................269 Tiller Handle Ratchet..................................................269 Tiller Handle Friction.................................................269 NOTES......................................................................270 Technician’s Notes.....................................................270 Related Documents......................................................270 GEARCASE.......................................................................271 SERVICE CHART..............................................................272 PROPELLER SERVICE..........................................................273 Inspection.............................................................273 GEARCASE LEAK TEST.........................................................273 TRIM TAB SERVICE...........................................................274 Removal................................................................274 Installation...........................................................274 GEARCASE REMOVAL AND INSTALLATION..........................................274 Gearcase Removal.......................................................274 Gearcase Installation..................................................275 WATER PUMP SERVICE.........................................................276 Disassembly............................................................276 Inspection.............................................................277 Assembly...............................................................277 GEARCASE DISASSEMBLY.......................................................279 Propeller Shaft Bearing Housing Removal................................280 Shifter, Gear and Propshaft Removal....................................281 BEARING AND SEAL REMOVAL...................................................283 Driveshaft Seals.......................................................283 Driveshaft Bearing.....................................................283 Pinion Bearings........................................................283 Forward Bearing........................................................283 Shift Rod Bushing and O-ring...........................................284 Prop Shaft Bearing Housing Seals and O-ring............................284 SEAL AND BEARING INSTALLATION..............................................285 Propeller Shaft Bearing Housing Bearings...............................285 Propeller Shaft Bearing Housing Seals and O-ring.......................285 Shift Rod Bushing and O-ring...........................................286 Forward Bearing........................................................286 Pinion Bearings........................................................286 Driveshaft Bearing.....................................................287 Driveshaft Seals.......................................................287 GEARCASE ASSEMBLY..........................................................288 Propshaft, Gear and Shifter Installation...............................288 Propeller Shaft Bearing Housing Installation...........................291 TRIM AND TILT..................................................................293 SERVICE CHART..............................................................294 SYSTEM DESCRIPTION.........................................................295 ROUTINE INSPECTIONS........................................................296 General................................................................296 Reservoir Fluid........................................................296 Manual Release Valve...................................................296 Stern Brackets.........................................................296 ELECTRICAL CIRCUIT TESTS...................................................296 Relay Testing..........................................................296 Trim and Tilt Motor Current Draw Tests.................................296 Trim and Tilt Motor No Load Test.......................................297 Trim Gauge Test........................................................298 Trim Sender Test.......................................................298 TRIM AND TILT SERVICE......................................................299 Removal................................................................299 Disassembly............................................................300 Assembly...............................................................301 Installation...........................................................302 ADJUSTMENTS................................................................303 NOTES......................................................................304 Technician’s Notes.....................................................304 Related Documents......................................................304 MANUAL STARTER.................................................................305 SERVICE CHART..............................................................306 RECOIL STARTER REMOVAL.....................................................307 RECOIL STARTER INSTALLATION................................................308 RECOIL STARTER DISASSEMBLY.................................................309 RECOIL STARTER CLEANING AND INSPECTION.....................................311 RECOIL STARTER ASSEMBLY....................................................312 PULLEY MODIFICATION........................................................315 Starter Assembled Method...............................................315 Starter Disassembled Method............................................316 SAFETY.........................................................................317 TABLE OF CONTENTS..........................................................317 MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM......................319 Outboard Shift Systems and Safety......................................320 Outboard Speed Control System and Safety...............................321 Outboard Steering Control System and Safety............................322 Outboard Fuel, Electrical System, and Safety...........................324 Outboard Mounting System and Safety....................................327 If weakened, parts could fail later on the water, when not expected....328 Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety........329 Outboard Emergency Stop System and Safety..............................330 Summing up.............................................................332 MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM......................333 Handling Outboards.....................................................333 Handling Lead/Acid Batteries...........................................337 Gasoline - Handle With Care!...........................................338 Hazardous Products.....................................................339 Safety Awareness Test..................................................340 INDEX..........................................................................341 TROUBLE CHECK CHART............................................................349 OUTBOARD WILL NOT START....................................................349 OUTBOARD WILL NOT START....................................................350 OUTBOARD HARD TO START.....................................................351 OUTBOARD WILL NOT SHUT OFF.................................................352 OUTBOARD STARTS AND STALLS.................................................352 OUTBOARD STARTS, LOW MAXIMUM RPM...........................................353 EXCESSIVE SMOKING..........................................................353 OUTBOARD SURGES, RUNS ROUGH................................................354 DIAGRAMS.......................................................................355 Return to Main Menu............................................................ 0
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.
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