Download 2010 Evinrude E-tec Repair Manual 15 25 30 Hp
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Download 2010 Evinrude E-tec Repair Manual 15 25 30 Hp
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. Exceptions include manufacturer’s prescribed changes, such as altitude adjustments, for example. Owner’s Responsibility The owner/operator is required to have outboard maintenance performed to maintain emission levels within prescribed certification standards.
- The owner/operator is not to, and should not allow anyone to, modify the outboard in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. Tampering with the fuel system to change horsepower or modify emission levels beyond factory settings or specifications will void the product warranty.
TABLE OF CONTENTS:
Download 2010 Evinrude E-tec Repair Manual 15 25 30 Hp
SECTION PAGE
INTRODUCTION3
1 SPECIAL TOOLS 13
2 INSTALLATION AND PREDELIVERY23
3 MAINTENANCE 67
4 ENGINE COVER SERVICE 81
5 ENGINE MANAGEMENT MODULE (EMM) 87
6 SYSTEM ANALYSIS 105
7 ELECTRICAL AND IGNITION119
8 FUEL SYSTEM 153
9 OILING SYSTEM177
10 COOLING SYSTEM 191
11 POWERHEAD201
12 MIDSECTION229
13 GEARCASE 277
14 TRIM AND TILT 299
15 MANUAL STARTER 311
SAFETY S–1
INDEXI–1
TROUBLE CHECK CHART T–1
DIAGRAMS
INDEX DETAILS:
Download 2010 Evinrude E-tec Repair Manual 15 25 30 Hp
Abbreviations 6
Accessories
Fuel Filter Assembly, P/N 174176 33
XD100 Outboard Oil Decal, P/N 352369 58
Adjustments
Control Cable 53, 271
Shift Linkage 223, 297
Steering Friction 274
Throttle Friction 274
TPS Calibration 144
Trim Sending Unit 65
Trim Tab 66
Air Silencer 76
Air Temperature Sensor
Description 91
Resistance Test 126
Alternator Circuit Test 131
AMP Connector Servicing 150
Anodes
Anti-Corrosion 69
Continuity Check 69
Gearcase 286
Stern Bracket 241
Batteries
Battery Charge Isolator 30
Battery Switches 29
Cable Routing 35
Cables 28
Charging System Tests 129
Connections 75
Installation 28
Maintenance 75
Multiple Batteries 29
Requirements 11, 28
Storage 79
Wiring Diagrams 31
Bearing
Crankshaft 208, 210, 213, 214
Driveshaft 289, 293
Forward Gear 289, 292
Pinion Gear 289, 292
Propeller Shaft 291
Break-In
EMM Programming 59, 62, 184, 223
Gearcase 282, 298
Oiling 59
Procedure 62, 100
Cable, Hose, and Wire Routing 53
Clamp Screw Service 234
Connecting Rods
Installation on Piston 215
Removal from Crankshaft 208
Removal from Piston 208
Control Cable
Adjustments 53, 271
Installation 53
Routing 25
Cooling System
Components 193
EMM and Vapor Separator Cooling 195
Engine Temperature Check 196
Exhaust Housing 193
Flushing 70
Hose Routing and Water Flow 192
Operating Temperatures 11, 62
Operation 195
Pressure Relief Valve 194, 198
Thermostat 11, 194, 198
Turbulence 38
Vapor Separator 159
Water Intake Screens 70, 71
Water Pump 193, 282
Corrosion
Anodes 69, 241, 286
Cylinder walls 211
Long Term Storage 78
Metal components 69
Steering Cable 71
Cover Service 82
I–2
INDEX
Crankcase
Assembly 216
Disassembly 207
Crankshaft
Assembly 213, 216
Disassembly 207, 208
Crankshaft Position Sensor
Description 93
Operation Test 112
Resistance Test 125
Cylinder Bore
Honing 210
Inspection 212
Cylinder Head
Inspection 211
Installation 218
Removal 207
Deutsch Connector Servicing 149
Diagnostic Procedures
Dynamic Tests 108
Fuel Delivery Tests 116
Ignition Tests 111
LED Indicators 109
Strategy 106
Diagnostic Software
Break-In Programming 59, 62, 184
Communication With Outboard 96
Crankshaft Position Sensor 112
Cylinder Drop Tests 108
Diagnostic Procedures Overview 106
Fuel Injector Programming 102, 169
Fuel Injector Tests 116
Fuel Pump Test 116
Oil Injector Test 185
Oil Priming 59, 190
Oiling Rate 57, 59, 100
Reports 102
Sensor Monitoring 125
Service Codes 98
Static Ignition Test 113
Timing Verification 101, 144
TPS Calibration 101, 144
Driveshaft Bearing
Installation 293
Removal 289
Driveshaft Seals
Installation 293
Removal 289
Electrical Circuits
EMM Pin Locations 123
Fuse 124
Ground Circuits 124
Key Switch 134
Start Circuit 132
SystemCheck 139
Electrical Connectors
AMP Connectors 150
Deutsch Connectors 149
Packard Connectors 152
Electrical Harness
Connections 55
Emergency Stop Switch
Installation 24
Operation Check 61
Test 137
Emissions Information 7
EMM
12 V Circuit Sensor 90
Connections 88, 123
Diagnostics 96, 106
Functions 88, 94
LED Indicators 109
Sensors 90, 91
Service Codes 98
Servicing 104
Software Replacement 103
Timing Verification 144
TPS Calibration 144
Transfer 103
Engine Monitor
Description 94
Low Oil Warning 92, 183, 187
No Oil Warning 183
Operation Check 61
Requirement 26
I–3
INDEX
Engine Temperature Check 196
Engine Temperature Sensor
Description 92
Resistance Test 126
Exhaust Housing
Installation 235
Removal 235
Exterior Finish Protection 69
Flushing, Cooling System 70
Flywheel
Installation 142
Removal 141
Forward Bearing
Installation 292
Removal 289
Fuel Filter
Requirements 33
Fuel Injectors
Crush Ring Replacement 169
Electrical Circuits 157
EMM Programming 169, 170
Installation 170
Removal 169
Tests 162, 163
Fuel System
Additives 10, 56
Components 158
Filter 33, 158, 167
Fuel Circulation Pump 159, 163
Fuel Filter 76
Fuel Lift Pump 158, 163, 167
Fuel Requirements 56
Hose Routing 156
Injector Servicing 102
Intake Manifold 173
Minimum Octane 10, 56
Pressure Tests 161
Priming 57
Relieving Pressure 166
Requirements 32
Troubleshooting 108, 116, 161
Vapor Separator 158, 168
Fuse 124
Gauges
see Information Display Systems 26
Tachometer 61
Gearcase
Assembly 294
Bearings
Disassembly 285
Inspection 285
Installation 281
Leak Test 279
Lubricant 11, 73
Removal 280
Seal
Water Pump Service 282
Grommet 53
Honing 210
Hoses
Fuel System 32, 35
Inspection 76
Oil Distribution 188, 189
Oil Recirculation System 184
Routing, Cooling System 192
Routing, Fuel System 156
Idle Speed 10, 94
Ignition
Control Circuit Tests 115
Electrical Circuits 122
Ignition Coil Servicing 143
Ignition Coil Tests 115
Required Systems 111
Running Tests 114
Static IgnitionTest 113
Timing 101
Information Display Systems
Engine Monitor 26
SystemCheck Gauges 26
I–4
INDEX
Intake Manifold
Assembly 174
Disassembly 174
Inspection 174
Installation 175
Removal 173
Key Switch
Operation Check 61
Start Circuit 134
LED Indicators 109
Lower Cover
Installation 83
Removal 83
Lubrication
Engine Oil 10, 57
Gearcase 11, 73
Power Trim 11
Propeller Shaft 73
Swivel Bracket 72
Throttle and Shift Linkage 72
Tiller handle 71
Tilt Tube 72
Trailering Bracket 72
Trim and Tilt 74
Maintenance Schedule 68
Manual Starter
Assembly 318
Installation 314
Rope Replacement 315, 319
Models
Included Models 9
Model Designation 8
Serial Number Location 8
Motor Mounts
Lower Mount Servicing 237
Upper Mount Servicing 236
Mounting the Engine
Hull Preparation 38
Mounting Height 50
Muffler
Servicing 238
New Engines
Fuel and Oil Priming 56
Outboard Rigging Procedure 52
Oetiker Clamp Servicing 36
Oil Injector
Electrical Circuit (55 V) 182
Electrical Tests 185
Functional Test 186
Oiling Rate 57, 58, 100, 184
Oiling System
Components 182
Electrical Circuits 181
Engine Lubricant 10, 57
Low Oil Switch 92
New Engine Set-Up 57
Oil Distribution 179
Oil Distribution Hoses 179, 188, 189
Oil Filters 76
Oil Recirculation 184
Oil Tank 182, 189
Oiling Rate 57, 100, 184
Priming 59, 184
Servicing 188
Tests 185
Outboard Excessive Smoking T–5
Outboard Hard to Start T–3
Outboard Starts and Stalls T–4
Outboard Starts, Low Maximum RPM T–5
Outboard Surges, Runs Rough T–6
Outboard Will Not Start T–1
Outboard Won’t Shut Off T–4
Packard Connector Servicing 152
Pinion Bearing
Installation 292
Removal 289
I–5
INDEX
Piston Rings
End Gap 212, 215
Installation 215
Removal 208
Pistons
Assembly 214
Inspection 212
Installation 215
Removal 208
Powerhead
Assembly 213
Cleaning 210
Disassembly 206
Inspection 211
Installation 221
Removal 204
Predelivery Checks 60
Pre-Season Service 79
Pressure Relief Valve
Assembly 199
Disassembly 198
Inspection 199
Priming
Fuel System 57
Oiling System 184
Propeller
Inspection 279
Installation 63
Selection 63
Propeller Shaft
Installation 294
Lubrication 73
Removal 287
Propeller Shaft Bearing Housing
Bearing Installation 291
Installation 297
Removal 286
Seal Installation 291
Seal Removal 290
Relays
Trim and Tilt 138, 303
Remote Controls
Cable Adjustment 53
Cable routing 25
Installation 24
Selection 24
Rigging
Boat 24
Outboard 52
RPM Limit 11, 93, 94
S.A.F.E.
Description 95
Low Oil 92
No Oil 183
Temperature 90, 92
Safety S–1
Seal Installer, P/N 350958 243, 255
Sensor Tests 125
Sensors
Air Temperature Sensor 91, 126
Barometric Pressure Sensor 91
Crankshaft Position Sensor 93, 112, 125
EMM 90
Engine Temperature Sensor 92, 126, 198
Throttle Position Sensor 93, 125
Service Charts
Electrical and Ignition 120
Fuel System 154
Gearcase 278
Midsection 230
Oiling System 178
Powerhead 202
Shift Cable Adjustment, Tiller 271
Shift Linkage
Adjustment 223
Installation 219
Lubrication 72
Removal 206
Shift Rod Bushing
Installation 292
Removal 290
Shift Rod Connector 204, 280, 281
Shift Rod O-ring
Installation 292
Removal 290
I–6
INDEX
Shifter
Installation 294
Removal 287
Shutdown 96
No Oil 183
Spark Plugs
Gap 11, 77
Indexing 77
Maintenance Schedule 68
Recommendation 11, 77
Replacement 77
Service 77
Special Tools 13
Specifications 10
Starter
Assembly 147, 318
Circuit Description 132
Cleaning and Inspection 146
Current Draw Test 135
Disassembly 145
Installation 149, 314
Removal 145
Rope Replacement 315, 319
Solenoid Test 134
Start-In-Gear Protection 61
Stator
Resistance Test 127
Service 142
Voltage Output Test 127
Steering Handle
Assembly 263
Disassembly 259
Inspection 263
Installation 270
Removal 257
Steering System
Lubrication 71
Requirements 49
Steering Arm and Shaft 239, 247
Steering Friction 274
Steering Torque 66
Stern Bracket
Assembly 241, 251
Disassembly 239, 247
Removal 249
Stop Circuit 137
Storage 78
Submerged Engines 80
Swivel Bracket
Lubrication 72
SystemCheck
Circuits 139
LOW OIL Warning Signal 183
NO OIL Warning Signal 183
Outboard connections 55
Tests 139, 140
Tachometer
Pulse Setting 61
Technical Data 10
Temperature
Operating 62, 196
Operation below freezing 57
Sensors 91, 92
Temperature Sender
Service 198
Thermostat
Assembly 199
Description 194
Disassembly 198
Inspection 199
Temperature 11
Throttle Linkage
Installation 220
Lubrication 72
Removal 206
Throttle Position Sensor
Description 93
Resistance Test 125
Tiller Adjustments
Steering Friction Adjustment 274
Tiller handle
Lubrication 71
Tilt Support 301
Tilt Tube
Lubrication 72
Timing Adjustments
Timing Pointer 144
Timing Verification 144
TPS Calibration 144
I–7
INDEX
Tools
Ball Socket Installer tool, P/N 342225 272
Ball Socket Remover Tool, P/N 342226
173, 258
Bearing Cup Installer, P/N 319929 292
Bearing Installer, P/N 321428 – 25/30 291
Bearing Installer, P/N 322923 – 25/30 293
Bearing Installer, P/N 335820 – 25/30 291
Bearing Puller, P/N 432130 289
Bootstrap Tool, P/N 586551 103
Connector Service Tool, P/N 342667 149
Crankshaft Bearing/Sleeve Installer, P/N
339749 213
Crimp Tool, AMP, P/N 777281 151
Crimping Pliers, P/N 322696 150
Diagnostic Interface Cable, P/N 437955 96
Diagnostic Power Supply, P/N 587005 97,
112
Drive Handle, P/N 311880 292
Electrical Test Probe Kit, P/N 342677 131
Flywheel Holder, P/N 771311 142
Fuel Pressure Gauge, P/N 5007100 161
Guide Pin, P/N 383175 297
Lifting Eye, P/N 321537 204
Lifting Tool, P/N 354717 48
Oetiker Pincers, P/N 787145 37
Peak Reading Voltmeter, P/N 507972 128
Plate, P/N 318122 – 25/30 293
Plug, P/N 315391 162
Primary Lock Tool, P/N 777077 150
Puller Bridge, P/N 432127 289, 290
Retaining Ring Pliers, P/N 331045 287, 297
Seal Installer, P/N 326552 – 25/30 293
Seal Installer, P/N 335821 – 25/30 291
Secondary Lock Installer, P/N 777079 151
Secondary Lock Tool, P/N 777078 150
Shift Detent Sleeve, P/N 328081 295
Shift Rod Bushing Installer, P/N 304515
292
Shift Rod Bushing Remover, P/N 327693
290
Slide Hammer Adapter, P/N 340624 306
Slide Hammer Adaptor Kit, P/N 390898 169
Slide Hammer, P/N 391008 169, 213, 290,
306
Slide Hammer, P/N 432128 209, 289
Small Puller Jaws, P/N 432131 289, 290
Starter Winder/Installer Kit, P/N 342682
318
Stator Test Adaptor, P/N 354719 127, 128
Syringe, P/N 346936 187
Temperature Gun, P/N 772018 196, 197
Thermal Joint Compound, P/N 322170 197
Transom Drill Fixture, P/N 434367 40
Twist-Grip Remover, P/N 390767 261
Universal Pinion Bearing Remover and Installer,
P/N 5005927 289, 292
Universal Puller Set, P/N 378103 142, 204,
286
Wrench, P/N 334359 289
Wrist Pin Pressing Tool, P/N 326356 208
Wrist Pin Retainer Installation Tool, P/N
354720 215
Torque Charts
see Service Charts
Standard 12
TPS Calibration 144
Trailering Bracket 301
Lubrication 72
Trim and Tilt
Assembly 308
Disassembly 306
Inspection 302
Installation 309
Lubrication 74
Removal 305
Reservoir Fluid 11, 302
Troubleshooting 302, 303
Trim Gauge Test 304
Trim Sender
Adjustment 65
Test 305
Trim Tab
Adjustment 66
Removal 280
I–8
INDEX
Troubleshooting
Charging System Tests 129
Cylinder Drop Tests 108
Diagnostic Procedures 106
Fuel Control Adjustment 108
Fuel System 116, 161
Ignition 111, 114
Oiling System 185
Sensors 125
Stator Resistance Test 127
Strategy 107
Trim and Tilt 302, 303
Vapor Separator
Description 158
Installation 171
Removal 168
Water Intake Screens 70
Inspection 71
Installation 282
Water Pump
Assembly 283
Description 193
Disassembly 282
Inspection 283
Winterizing 78
Wrist Pin
Installation 215
Removal 208
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.