Johnson Evinrude 40hp 50hp 60hp 65hp 75hp 90hp E TEC Outboard Shop Manual 2012 – 2015 – PDF DOWNLOAD

Description

Johnson Evinrude 40hp 50hp 60hp 65hp 75hp 90hp E TEC Outboard Shop Manual 2012 – 2015

FILE DETAILS:

LANGUAGE:ENGLISH
PAGES:426
DOWNLOADABLE:YES
FILE TYPE:PDF

JOHNSON EVINRUDE 40HP 50HP 60HP 65HP 75HP 90HP E TEC OUTBOARD SHOP MANUAL 2012 – 2015 – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Johnson Evinrude 40hp 50hp 60hp 65hp 75hp 90hp E TEC Outboard Shop Manual 2012 – 2015

EMISSION-RELATED INSTALLATION INSTRUCTIONS:

• Failing to follow these instructions when installing a certified engine in a vessel violates federal law (40 CFR 1068.105 (b)), subject to fines or other penalties as described in the Clean Air Act. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine SI (spark ignition) engine repair establishment or individual.
• 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.

TABLE OF CONTENTS:

Johnson Evinrude 40hp 50hp 60hp 65hp 75hp 90hp E TEC Outboard Shop Manual 2012 – 2015

REFERENCE INFORMATION..........................................................  5
	SAFETY NOTICE..............................................................  6
	ABBREVIATIONS USED IN THIS MANUAL..........................................  8
		Units of Measurement...................................................  8
		List of Abbreviations..................................................  8
	EMISSION-RELATED INSTALLATION INSTRUCTIONS.................................  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
	SERVICE SPECIFICATIONS..................................................... 12
	STANDARD TORQUE SPECIFICATIONS............................................. 16
	PRODUCT REFERENCE AND ILLUSTRATIONS........................................ 16
ROUTINE SERVICE................................................................ 17
	INSPECTION AND MAINTENANCE SCHEDULE........................................ 18
	LIFTING THE OUTBOARD....................................................... 19
	OUTBOARD RIGGING CONNECTIONS............................................... 19
		Common Practices – All Models.......................................... 19
		Cable, Hose, and Wire Routing.......................................... 20
		Control Cable Installation............................................. 21
		SystemCheck Harness Connections........................................ 22
		I-Command Network Connections.......................................... 23
		Water Pressure Gauge................................................... 25
	BATTERY AND BATTERY CONNECTIONS............................................ 26
	OETIKER CLAMP SERVICING.................................................... 27
		Clamp Identification................................................... 27
		Clamp Selection........................................................ 27
		Clamp Installation..................................................... 28
		Clamp Removal.......................................................... 28
	ADJUSTMENTS................................................................ 29
		Steering Friction Adjustment........................................... 29
		Throttle Friction Adjustment........................................... 29
		Tilt Limit Switch Adjustment (75 – 90 HP).............................. 30
		Trim Sending Unit Adjustment (40 – 60 HP).............................. 31
		Trim Sending Unit Adjustment (75 – 90 HP).............................. 32
		Trim Tab Adjustment.................................................... 33
		Dual-Outboard Alignment................................................ 34
	OPERATIONAL CHECKS......................................................... 35
		Engine Monitoring System............................................... 35
		Fuel System............................................................ 35
		Emergency Stop / Key Switch............................................ 35
		Remote Control Operation............................................... 35
		Start-In-Gear Prevention............................................... 35
		Tachometer Pulse Setting (SystemCheck)................................. 36
		Water Pump Overboard Indicator......................................... 36
		Operating Temperature.................................................. 36
		Idle Speed............................................................. 36
	COOLING SYSTEM............................................................. 36
		Water Intake Screens................................................... 36
		Engine Flushing........................................................ 37
		Running the Outboard Using a Hose and Flushing Adapter................. 38
	LUBRICATION................................................................ 39
		Steering System........................................................ 39
		Tiller Handle.......................................................... 39
		Swivel Bracket and Trailering Bracket.................................. 40
		Tilt Tube.............................................................. 40
		Throttle and Shift Linkage............................................. 40
		Propeller Shaft........................................................ 41
		Gearcase Lubricant..................................................... 41
		Trim and Tilt.......................................................... 43
	SPARK PLUGS................................................................ 44
		Removal................................................................ 44
		Indexing............................................................... 44
	FUEL AND OIL SYSTEMS....................................................... 45
		Fuel Filter............................................................ 45
		Oil Filters and Oil Reservoir.......................................... 45
		Air Silencer........................................................... 45
		Hoses and Connections.................................................. 45
	ANTI-CORROSION PROTECTION.................................................. 46
		Sacrificial Anodes..................................................... 46
		Testing Procedure – Continuity......................................... 46
		Metallic Component Protection.......................................... 46
		Exterior Finishes...................................................... 46
	STORAGE.................................................................... 47
		Fuel System Treatment.................................................. 47
		Internal Engine Treatment.............................................. 47
		Additional Recommendations............................................. 48
	PRE-SEASON SERVICE......................................................... 48
		Outboard Mounting Bolts................................................ 48
		Gearcase Lubricant..................................................... 48
		Battery(s)............................................................. 48
		Power Trim and Tilt.................................................... 48
		Operational Checks..................................................... 48
	SUBMERGED ENGINES.......................................................... 49
		Engine Dropped Overboard (Not Running)................................. 49
		Engine Dropped Overboard (Running)..................................... 49
		Engine Dropped Overboard (In Salt Water)............................... 49
		Prolonged Submersion (Fresh or Salt Water)............................. 49
	NOTES...................................................................... 50
		Technician’s Notes..................................................... 50
		Related Documents...................................................... 50
ENGINE COVER SERVICE........................................................... 51
	UPPER COVER SERVICE........................................................ 52
		Latch Hook Installation................................................ 52
	LOWER COVER SERVICE........................................................ 52
		Lower Cover Removal.................................................... 52
		Lower Cover Installation............................................... 53
		Latch Handle Installation.............................................. 54
		Trim Switch Installation............................................... 54
ENGINE MANAGEMENT MODULE (EMM)................................................. 55
	DESCRIPTION................................................................ 56
		EMM Functions.......................................................... 56
		EMM Connections........................................................ 56
		LED Indicators......................................................... 56
	EMM INPUTS AND OUTPUTS DIAGRAM............................................. 57
	INTERNAL SENSORS........................................................... 58
		EMM Temperature Sensor................................................. 58
		55 V Circuit Sensor.................................................... 58
		12 V Circuit Sensor.................................................... 58
		5 V Circuit Sensor..................................................... 59
		Barometric Pressure Sensor............................................. 59
	EXTERNAL SENSORS........................................................... 59
		Air Temperature Sensor................................................. 59
		Engine Temperature Sensor.............................................. 59
		Low Oil Switch......................................................... 60
		Throttle Position Sensor............................................... 61
		Crankshaft Position Sensor............................................. 61
		Neutral Switch......................................................... 61
	INTERNAL EMM FUNCTIONS..................................................... 62
		ROM Verification....................................................... 62
		Idle Controller........................................................ 62
		RPM Limiter............................................................ 62
		Neutral RPM Limiter.................................................... 62
		Exhaust Water Valve Activation (60 - 65 HP)............................ 62
		Engine Monitor and Warning Systems..................................... 62
		Fault Code Creation and Storage........................................ 62
	ENGINE MONITOR SYSTEM...................................................... 63
		System Self-Test....................................................... 63
		Service Mode........................................................... 63
		Engine Running......................................................... 63
	S.A.F.E. WARNING SYSTEM.................................................... 64
		Activation............................................................. 64
		Recovery............................................................... 64
	SHUTDOWN MODE.............................................................. 64
		Recovery............................................................... 64
	DIAGNOSTIC SOFTWARE FUNCTIONS.............................................. 65
		Communication.......................................................... 65
		Static Information..................................................... 66
		Dynamic Information.................................................... 66
		Occurred Service Codes (Faults)........................................ 67
		Active Faults.......................................................... 67
		Historical Faults...................................................... 67
		Static Tests........................................................... 67
		Dynamic Tests.......................................................... 68
		Oil Control Settings................................................... 68
		Tiller/Remote Programming.............................................. 69
		Ignition Timing........................................................ 69
		TPS Calibration........................................................ 70
		Idle Speed Control..................................................... 70
		Fuel Injector Servicing................................................ 70
		Reports................................................................ 71
		Software Replacement................................................... 71
		EMM Transfer........................................................... 72
	EMM SERVICING.............................................................. 72
		Removal................................................................ 72
		Installation........................................................... 73
	NOTES...................................................................... 74
		Technician’s Notes..................................................... 74
		Related Documents...................................................... 74
SYSTEM ANALYSIS................................................................ 75
	DIAGNOSTIC PROCEDURES...................................................... 76
		Visual Inspections..................................................... 76
		Operational Inspections................................................ 76
		Troubleshooting........................................................ 77
	DYNAMIC TESTS.............................................................. 78
		Cylinder Drop Tests.................................................... 78
		Fuel Control Adjustment................................................ 78
		Inductive Amp Meter Test............................................... 78
	EMM LED INDICATORS......................................................... 79
		Key ON................................................................. 79
		Starting............................................................... 79
		Running................................................................ 80
	IGNITION OUTPUT TESTS...................................................... 81
		Required Ignition Systems.............................................. 81
		Wiring Inspection...................................................... 81
		Crankshaft Position Sensor (CPS) Test.................................. 82
		System Voltage Test.................................................... 82
		Static Ignition Test................................................... 83
		Running Ignition Tests................................................. 84
		Ignition Control Circuit Tests......................................... 85
		Ignition Coil Tests.................................................... 85
		Capacitor Test......................................................... 85
	FUEL DELIVERY TESTS........................................................ 86
		Fuel Pump Static Test.................................................. 86
		Fuel Injector Static Test.............................................. 86
		Running Fuel System Tests.............................................. 87
	EXHAUST WATER VALVE (60–65HP).............................................. 88
		Exhaust Water Valve Static Test........................................ 88
		Exhaust Water Valve Dynamic Test....................................... 88
ELECTRICAL AND IGNITION........................................................ 89
	SERVICE CHART.............................................................. 90
	IGNITION SYSTEM CIRCUIT DIAGRAM, 40 – 65 HP................................ 92
	IGNITION SYSTEM CIRCUIT DIAGRAM, 75 – 90 HP................................ 93
	ELECTRICAL HARNESS CONNECTIONS............................................. 94
		Engine Harness to Stator Connector..................................... 94
		EMM J1-A Connector..................................................... 94
		EMM J1-B Connector..................................................... 95
		EMM J2 Connector....................................................... 95
	GROUND CIRCUITS............................................................ 96
		EMM Ground Tests....................................................... 96
		Additional Ground Tests................................................ 96
	FUSE....................................................................... 96
	SENSOR TESTS............................................................... 97
		Crankshaft Position Sensor (CPS) Test.................................. 97
		Throttle Position Sensor (TPS) Test.................................... 97
		Engine Temperature Sensor Test......................................... 98
		Air Temperature Sensor (AT) Test....................................... 98
	STATOR TESTS............................................................... 99
		Stator Resistance Tests................................................ 99
		Stator Voltage Output Test............................................. 99
	CHARGING SYSTEM TESTS......................................................100
		12 V Charging Circuit..................................................100
		55 V Alternator Circuit................................................101
	ELECTRIC START CIRCUIT.....................................................102
		Start Circuit Diagram..................................................102
		Start Circuit Operation................................................103
	ELECTRIC START TESTS.......................................................104
		Starter Solenoid Test..................................................104
		Starter Voltage Drop Test..............................................105
		No Load Current Draw Test..............................................105
	REMOTE CONTROL SWITCH TESTS................................................106
		Key Switch Test........................................................106
		Neutral Start Circuit Test.............................................106
		Neutral Start Switch Test..............................................107
		Emergency Stop Switch Test.............................................107
	TILT/TRIM RELAY TEST.......................................................108
		Operation..............................................................108
		Test Procedure.........................................................108
	EXHAUST WATER VALVE TEST...................................................108
	SystemCheck CIRCUIT TESTS..................................................109
		Gauge Self-Test Check..................................................109
		CHECK ENGINE Circuit Test..............................................110
		WATER TEMP/ HOT Circuit Test...........................................110
		LOW OIL Circuit Test...................................................111
		NO OIL Circuit.........................................................111
	TACHOMETER CIRCUIT TESTS...................................................111
	FLYWHEEL AND STATOR SERVICING..............................................112
		Flywheel Removal.......................................................112
		Stator Service.........................................................113
		Flywheel Installation..................................................113
	IGNITION COIL SERVICING....................................................114
		Ignition Coil Removal..................................................114
		Ignition Coil Installation.............................................114
	TIMING ADJUSTMENTS.........................................................115
		Timing Pointer.........................................................115
		Timing Verification....................................................116
		TPS Calibration........................................................116
	ELECTRIC STARTER SERVICING.................................................117
		Starter Removal........................................................117
		Starter Installation...................................................117
	CONNECTOR SERVICING........................................................118
		DEUTSCH Connectors.....................................................118
		AMP Connectors.........................................................119
		Packard Connectors.....................................................121
	NOTES......................................................................122
		Technician’s Notes.....................................................122
		Related Documents......................................................122
FUEL SYSTEM....................................................................123
	SERVICE CHART..............................................................124
	FUEL SYSTEM HOSE ROUTING...................................................128
	FUEL SYSTEM CIRCUIT DIAGRAMS...............................................130
	FUEL SYSTEM REQUIREMENTS...................................................132
		Regulations and Guidelines.............................................132
		Portable Fuel Tanks....................................................132
		Fuel Flow Requirements.................................................132
		Fuel Requirements......................................................133
	COMPONENTS.................................................................134
		Fuel Lift Pump.........................................................134
		Fuel Filter............................................................134
		Vapor Separator........................................................134
		Fuel Circulation Pump..................................................136
		Fuel Manifolds.........................................................136
		Fuel Injectors.........................................................136
	FUEL SYSTEM PRIMING........................................................138
		Vent Line Clamp........................................................138
		Priming the Fuel System................................................138
	FUEL SYSTEM TESTS..........................................................139
		Fuel System Pressure Test..............................................139
		Pressure Regulator Test................................................140
		Vapor Separator Vent Check.............................................140
		Fuel Injector Pressure Test............................................140
		Fuel Injector Resistance Test..........................................141
		Circulation Pump Resistance Test.......................................141
		Lift Pump Pressure Test................................................141
		Lift Pump Vacuum Test..................................................142
		Lift Pump Diaphragm Test...............................................143
		Anti-Siphon Valve Test.................................................143
	FUEL COMPONENT SERVICING...................................................144
		Relieving Fuel System Pressure.........................................144
		Fuel Filter Service....................................................145
		Fuel Lift Pump Service.................................................145
		Vapor Separator Service................................................146
		Fuel Manifold Service..................................................147
		Fuel Injector Service..................................................148
		Intake Manifold Service................................................151
	NOTES......................................................................154
		Technician’s Notes.....................................................154
		Related Documents......................................................154
OILING SYSTEM..................................................................155
	SERVICE CHART..............................................................156
	OIL SUPPLY DIAGRAMS........................................................158
	OIL RECIRCULATION DIAGRAMS.................................................160
	OILING SYSTEM CIRCUIT DIAGRAM..............................................161
	OIL SYSTEM REQUIREMENTS....................................................162
		Recommended Lubricants.................................................162
	COMPONENTS.................................................................162
		Oil Tank Assembly......................................................162
		Oil Injection Pump.....................................................163
		Electrical Circuit (55 V)..............................................163
		LOW OIL Warning........................................................164
		NO OIL Warning.........................................................164
		Cylinder and Crankcase.................................................164
		Oil Recirculation System...............................................165
	OIL CONTROL SETTINGS.......................................................166
		Oil Injection Rate.....................................................166
		Break-In Oiling........................................................167
		Oil Supply Priming.....................................................167
	OILING SYSTEM TESTS........................................................168
		Oil Injection Pump Voltage Tests.......................................168
		Oil Injection Pump Resistance Test.....................................169
		Oil Injection Pump Function Test.......................................170
		Oil Injection Fittings Flow Test.......................................170
		LOW OIL Sending Unit Test..............................................170
	OIL COMPONENT SERVICING....................................................171
		Oil Distribution Hoses.................................................171
		Oil Tank Assembly......................................................171
		Oil Injection Pump.....................................................173
COOLING SYSTEM.................................................................175
	HOSE ROUTING AND WATER FLOW DIAGRAMS.......................................176
	COMPONENTS.................................................................178
		Water Pump and Intakes.................................................178
		Exhaust Housing........................................................178
		Water Supply Tube......................................................178
		Adapter/Inner Exhaust Housing..........................................179
		Pressure Relief Valve..................................................179
		Thermostat.............................................................179
		Block Venting..........................................................180
		Water Pressure Connection..............................................180
	OPERATION..................................................................181
		Cylinder Block / Cylinder Head Cooling.................................181
		EMM and Vapor Separator Cooling........................................181
	ENGINE TEMPERATURE CHECK...................................................182
		Software Method........................................................182
		Pyrometer Method.......................................................182
		Idle Operating Temperature Troubleshooting (Below Range)...............183
	TEMPERATURE SENDER SERVICING...............................................184
		Removal................................................................184
		Installation...........................................................184
	THERMOSTAT SERVICING.......................................................184
		Disassembly............................................................184
		Inspection.............................................................185
		Assembly...............................................................185
	PRESSURE RELIEF VALVE SERVICING............................................185
		Disassembly............................................................185
		Inspection.............................................................186
		Assembly...............................................................186
POWERHEAD......................................................................187
	SERVICE CHART..............................................................188
	COMPRESSION TESTING........................................................192
	POWERHEAD REMOVAL..........................................................192
		2-Cylinder Models......................................................192
		3-Cylinder Models......................................................194
	POWERHEAD DISASSEMBLY......................................................195
		Systems Removal........................................................195
		Throttle Linkage Removal...............................................196
		Shift Linkage Removal..................................................196
		Crankcase Disassembly..................................................197
		Cylinder Head Removal..................................................198
		Connecting Rods and Pistons............................................198
		Crankshaft Removal.....................................................199
	CYLINDER BLOCK CLEANING....................................................202
	POWERHEAD INSPECTION.......................................................203
		Cylinder Head..........................................................203
		Crankshaft.............................................................203
		Cylinder Bore..........................................................203
		Pistons................................................................204
		Piston Rings...........................................................204
		Bearings...............................................................204
	POWERHEAD ASSEMBLY.........................................................205
		Crankshaft Assembly....................................................205
		Pistons and Connecting Rods............................................207
		Cylinder Head Installation.............................................209
		Crankshaft and Connecting Rod Installation.............................210
		Crankcase Assembly.....................................................213
		Shift Linkage Installation.............................................214
		Throttle Linkage Installation..........................................215
		Final Powerhead Assembly...............................................216
	UPPER MOUNT SERVICING (3-Cylinder).........................................217
		Removal................................................................217
		Installation...........................................................217
	POWERHEAD INSTALLATION.....................................................218
		Powerhead Mounting – 2-Cylinder Models.................................218
		Powerhead Mounting – 3-Cylinder Models.................................220
		Shift Linkage Adjustment...............................................222
		Final Adjustments......................................................222
	POWERHEAD VIEWS............................................................223
		2-Cylinder Port – Hose Routings........................................223
		2-Cylinder Starboard – Hose Routings...................................223
		2-Cylinder Port Dressed Powerhead......................................224
		2-Cylinder Starboard Dressed Powerhead.................................224
		2-Cylinder Port Rope Start Models......................................225
		2-Cylinder Starboard Rope Start Models.................................225
		2-Cylinder Front.......................................................226
		2-Cylinder Rear........................................................227
		2-Cylinder Top.........................................................228
		2-Cylinder Top, Rope Start Models......................................229
		3-Cylinder Port – Hose Routings........................................230
		3-Cylinder Starboard – Hose Routings...................................230
		3-Cylinder Port Dressed Powerhead......................................231
		3-Cylinder Starboard Dressed Powerhead.................................231
		3-Cylinder Front.......................................................232
		3-Cylinder Rear........................................................233
		3-Cylinder Top.........................................................234
MIDSECTION.....................................................................235
	SERVICE CHARTS.............................................................236
	TILT TUBE, 75 – 90 HP......................................................243
		Removal................................................................243
		Installation...........................................................244
	EXHAUST HOUSING, 40 – 65 HP................................................245
		Exhaust Housing Removal................................................245
		Exhaust Water Valve (60–65 HP).........................................246
		Exhaust Relief Muffler.................................................246
		Exhaust Housing Installation...........................................247
	EXHAUST HOUSING, 75 – 90 HP................................................248
		Exhaust Housing Removal................................................248
		Lower Mount Service....................................................248
		Exhaust Housing Installation...........................................249
		Exhaust Housing Disassembly............................................250
		Cleaning and Inspection................................................251
		Exhaust Housing Assembly...............................................251
	STERN BRACKET, 40 – 60 HP Power Tilt.......................................253
		Stern Bracket Disassembly..............................................253
		Stern Bracket Assembly.................................................254
	STERN BRACKET, 75 – 90 HP Power Tilt.......................................255
		Stern Bracket Disassembly..............................................255
		Stern Bracket Assembly.................................................258
	STERN BRACKET, 40 – 60 HP Manual Tilt......................................260
		Clamp Screw Service....................................................260
		Stern Bracket Disassembly..............................................260
		Stern Bracket Assembly.................................................263
		Tilt Assist Cylinder...................................................266
	STERN BRACKET, 90 HP Manual Tilt...........................................267
		Stern Bracket Disassembly..............................................267
		Stern Bracket Assembly.................................................270
	TILLER HANDLE SERVICE – Standard...........................................273
		Removal................................................................273
		Disassembly............................................................274
		Inspection.............................................................275
		Assembly...............................................................275
		Installation...........................................................277
		Throttle Cable Adjustment..............................................278
	TILLER HANDLE SERVICE – Long Handle........................................279
		Removal................................................................279
		Disassembly............................................................280
		Inspection.............................................................283
		Assembly...............................................................283
		Installation...........................................................287
		Control Cable Installation.............................................288
	NOTES......................................................................290
		Technician’s Notes.....................................................290
		Related Documents......................................................290
GEARCASE.......................................................................291
	SERVICE CHARTS.............................................................292
	GEARCASE TYPES, 75 – 90 HP.................................................295
	PROPELLER SERVICE..........................................................295
		Inspection.............................................................295
		Propeller Selection....................................................295
		Propeller Hardware Installation........................................296
	GEARCASE LEAK TEST.........................................................297
GEARCASE SERVICE, 40 – 65 HP MODELS............................................298
	GEARCASE REMOVAL AND INSTALLATION..........................................298
		Gearcase Removal.......................................................298
		Gearcase Installation..................................................299
	WATER PUMP SERVICE.........................................................300
		Disassembly............................................................300
		Inspection.............................................................300
		Assembly...............................................................301
	SHIFT ROD ADJUSTMENT.......................................................302
	GEARCASE DISASSEMBLY.......................................................303
		Pre-Disassembly Inspection.............................................303
		Propeller Shaft Bearing Housing Removal................................304
		Pinion Gear and Driveshaft Removal.....................................305
		Shift Housing, Gear and Propeller Shaft Removal........................306
	SHIFTER, BEARING AND SEAL SERVICE..........................................307
		Pinion Bearing Removal.................................................307
		Pinion Bearing Installation............................................307
		Shift Housing Disassembly..............................................308
		Shift Housing Assembly.................................................309
		Driveshaft Bearing Housing Service.....................................311
		Propeller Shaft Bearing Housing Service................................312
	DRIVESHAFT SHIMMING........................................................314
	GEARCASE ASSEMBLY..........................................................315
		Shift Housing, Gear, and Propeller Shaft Installation..................315
		Shift Rod Housing Installation.........................................315
		Pinion Gear and Driveshaft Installation................................316
		Propeller Shaft Bearing Housing and Gear Installation..................318
		Final Assembly and Adjustment..........................................319
GEARCASE SERVICE, 75 – 90 HP MODELS............................................320
	GEARCASE REMOVAL AND INSTALLATION..........................................320
		Gearcase Removal.......................................................320
		Gearcase Installation..................................................321
	WATER PUMP SERVICE.........................................................322
		Disassembly............................................................322
		Inspection.............................................................322
		Assembly...............................................................323
	SHIFT ROD ADJUSTMENT.......................................................325
	GEARCASE DISASSEMBLY.......................................................326
		Pre-Disassembly Inspection.............................................326
		Propeller Shaft Bearing Housing Removal................................327
		Pinion Gear and Driveshaft Removal.....................................327
		Driveshaft Service.....................................................329
		Shift Housing, Gear and Propeller Shaft Removal........................330
		Water Intake Screens...................................................330
	GEARCASE HOUSING INSPECTION................................................330
	SHIFTER, BEARING AND SEAL SERVICE..........................................331
		Pinion Bearing Removal.................................................331
		Pinion Bearing Installation............................................331
		Shift Housing Disassembly..............................................332
		Shift Housing Assembly.................................................334
		Driveshaft Bearing Housing Service.....................................336
		Propeller Shaft Bearing Housing Service................................337
	DRIVESHAFT SHIMMING........................................................339
	GEARCASE ASSEMBLY..........................................................340
		Water Intake Screens...................................................340
		Shift Housing, Gear, and Propeller Shaft Installation..................340
		Shift Rod Housing Installation.........................................341
		Pinion Gear and Driveshaft Installation................................342
		Propeller Shaft Bearing Housing and Gear Installation..................343
		Final Assembly and Adjustment..........................................344
TRIM AND TILT..................................................................345
	SERVICE CHART..............................................................346
	SYSTEM DESCRIPTION.........................................................348
		Manual Adjustment......................................................348
		Trailering Bracket And Tilt Support....................................348
	ROUTINE INSPECTIONS........................................................350
		General................................................................350
		Reservoir Fluid........................................................350
		Manual Release Valve...................................................350
		Stern Brackets.........................................................350
	TROUBLESHOOTING............................................................350
	ELECTRICAL CIRCUIT TESTS...................................................351
		Relay Testing..........................................................351
		Trim and Tilt Motor Current Draw Tests.................................351
		Trim and Tilt Motor No Load Test.......................................352
		Trim Gauge Test........................................................353
		Trim Sender Test.......................................................353
	TRIM AND TILT REPLACEMENT..................................................354
		Removal................................................................354
		Installation...........................................................356
	TRIM AND TILT SERVICE......................................................358
		Disassembly............................................................358
		Assembly...............................................................360
	NOTES......................................................................362
		Technician’s Notes.....................................................362
		Related Documents......................................................362
MANUAL STARTER.................................................................363
	SERVICE CHART..............................................................364
	RECOIL STARTER REMOVAL.....................................................365
	RECOIL STARTER DISASSEMBLY.................................................365
	RECOIL STARTER CLEANING AND INSPECTION.....................................367
	RECOIL STARTER ASSEMBLY....................................................367
	RECOIL STARTER INSTALLATION................................................371
	NOTES......................................................................372
		Technician’s Notes.....................................................372
		Related Documents......................................................372
SAFETY.........................................................................373
	TABLE OF CONTENTS..........................................................373
	MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM......................375
		Outboard Shift Systems and Safety......................................376
		Outboard Speed Control System and Safety...............................377
		Outboard Steering Control System and Safety............................378
		Outboard Fuel, Electrical System, and Safety...........................380
		Outboard Mounting System and Safety....................................383
		If weakened, parts could fail later on the water, when not expected....384
		Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety........385
		Outboard Emergency Stop System and Safety..............................386
		Summing up.............................................................388
	MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM......................389
		Handling Outboards.....................................................389
		Handling Lead/Acid Batteries...........................................393
		Gasoline – Handle With Care!...........................................394
		Hazardous Products.....................................................395
		Safety Awareness Test..................................................396
INDEX..........................................................................397
TROUBLE CHECK CHART............................................................405
	OUTBOARD WILL NOT START....................................................405
	OUTBOARD WILL NOT START....................................................406
	OUTBOARD HARD TO START.....................................................407
	OUTBOARD WILL NOT SHUT OFF.................................................408
	OUTBOARD STARTS AND STALLS.................................................408
	OUTBOARD STARTS, LOW MAXIMUM RPM...........................................409
	EXCESSIVE SMOKING..........................................................409
	OUTBOARD SURGES, RUNS ROUGH................................................410

INDEX DETAILS:

Johnson Evinrude 40hp 50hp 60hp 65hp 75hp 90hp E TEC Outboard Shop Manual 2012 – 2015

A
Abbreviations 6
Accessories
Battery Cable, P/N 584348 64
XD100 Outboard Oil Decal, P/N 352369
164
Adjustments
Control Cable 19, 276, 286
Shift Linkage 220
Shift Rod 11, 13, 300, 323
Steering Friction 27
Throttle Friction 27
Tilt Limit Switch 28
Timing Pointer 113
TPS Calibration 114
Trim Sending Unit 29, 30
Trim Tab 31
Air Silencer 43
Air Temperature Sensor
Connections 92
Description 57
Resistance Test 96
Alternator Circuit Test 99
AMP Connector Servicing 117
Anodes
Anti-Corrosion 44
Continuity Check 44
Gearcase 301, 324
Propeller Shaft Bearing Housing 310, 335
Stern Bracket 252, 254, 257
B
Batteries
Charging System Tests 98
Connections 24
Maintenance 24
Requirements 11, 13
Storage 46
Bearing
Connecting Rod 209
Crankshaft 198, 199, 203, 204
Driveshaft 309, 334
Pinion Gear 305, 329
Propeller Shaft 310, 335, 336
Wrist Pin 197, 205
Break-In
EMM Programming 165, 220
Gearcase 298, 317, 320, 342
Oiling 165
Procedure 67
C
Capacitor Test 83
Clamp Screw 258
Connecting Rods
Installation on Crankshaft 209
Installation on Piston 205
Orientation 205, 209
Removal from Crankshaft 196
Removal from Piston 197
TIghtening 209
Control Cable
Adjustments 19
Installation 19
Cooling System
Adapter Housing 177
Components 176
Cylinder Block Venting 178
EMM and Vapor Separator Cooling 179
Engine Temperature Check 180
Exhaust Housing 176
Flushing 35
Hose Routing and Water Flow 174
Operating Temperatures 11, 13, 34
Operation 179
Pressure Relief Valve 177, 183
Running on a hose 36
Thermostat 11, 13, 177
Thermostats 177, 182
Vapor Separator 133
Water Intake Screens 34, 305, 328, 338
Water Pump 176, 298, 320
Water Supply Tube 176, 248, 249
Corrosion
I–2
INDEX
Anodes 44, 252, 254, 257, 301, 310, 324, 335
Cylinder walls 200
Long Term Storage 45
Metal components 44
Steering Cable 37
Cover Service 50
Crankcase
Assembly 211
Disassembly 195
Crankshaft
Assembly 203, 208
Disassembly 197
Inspection 201
Crankshaft Position Sensor
Description 59
Operation Test 80
Resistance Test 95
Cylinder Bore
Honing 200
Inspection 201
Cylinder Head
Inspection 201
Installation 207
Removal 196
D
Deutsch Connector Servicing 116
Diagnostic Procedures
Dynamic Tests 76
Fuel Delivery Tests 84
Ignition Tests 79
LED Indicators 77
Strategy 74
Diagnostic Software
Break-In Programming 165
Communication With Outboard 63
Crankshaft Position Sensor 80
Cylinder Drop Tests 76
Diagnostic Procedures Overview 74
Fuel Injector Programming 68, 146
Fuel Injector Tests 84
Fuel Pump Test 84
I-Command settings 23
Idle Speed Control 68
Oil Injector Test 167
Oil Priming 170
Oiling Rate 66, 164
Reports 69
Sensor Monitoring 95
Service Codes 65
Static Ignition Test 81
Timing Verification 67, 114
TPS Calibration 68, 114
Driveshaft
Installation 314, 340
Removal 303, 325
Service 327
Shimming 312, 337
Driveshaft Bearing Housing 309, 334
Dual-Outboard
Alignment 32
I-Command settings 23
E
Electrical Circuits
EMM Pin Locations 92
Fuse 94
Ground Circuits 94
Key Switch 102
Start Circuit 100
SystemCheck 107
Electrical Connectors
AMP Connectors 117
Deutsch Connectors 116
Packard Connectors 119
Electrical Harness
Connections 20, 21
Emergency Stop Switch
Operation Check 33
Test 105
Emissions Information 7
EMM
12 V Circuit Sensor 56
Connections 54, 55, 92
Diagnostics 63, 74
Functions 54, 60
LED Indicators 77
Sensors 56, 57
Service Codes 65
Servicing 70
Software Replacement 69
Timing Verification 114
I–3
INDEX
TPS Calibration 114
Transfer 70
Engine Monitor
Description 61
Low Oil Warning 58, 162, 168
No Oil Warning 162
Operation Check 33
Engine Temperature Check 180
Engine Temperature Sensor
Description 57
Resistance Test 96
Exhaust Housing
Assembly 249
Cleaning and Inspection 249
Installation 245, 247
Removal 243, 246
Exhaust Water Valve
Service 244
Tests 86, 106
Exterior Finish Protection 44
F
Flushing, Cooling System 35
Flywheel
Installation 111
Removal 110
Fuel Injectors
Crush Ring Replacement 146
Electrical Circuits 128
EMM Programming 146, 147
Installation 147
Removal 146
Tests 138, 139
Fuel System
Additives 10, 12, 131
Components 132
Filter 132, 143
Fuel Circulation Pump 84, 134, 139
Fuel Filter 43
Fuel Lift Pump 132, 139, 141, 143
Fuel Manifolds 145
Fuel Requirements 131
Hose Routing 126
Injector Servicing 68
Intake Manifold 149
Minimum Octane 10, 12, 131
Pressure Tests 137
Priming 136
Relieving Pressure 142
Requirements 130
Troubleshooting 76, 84, 137
Vapor Separator 132, 144
Fuse 94
G
Gearcase
Assembly 313, 338
Disassembly 301, 324
Inspection 301, 324
Installation 297, 319
Leak Test 295
Lubricant 11, 13, 39
Removal 296, 318
Grommet 18, 19
H
Honing 200
Hoses
Grommet 18
Inspection 43
Oil Distribution 169
Oil Recirculation System 163
Routing, Cooling System 174
Routing, Fuel System 126
I
I-Command
Outboard connections 21
System settings 23
Water Pressure Gauge 23
Idle Speed 10, 60, 68
Ignition
Control Circuit Tests 83
Electrical Circuits 90, 91
Ignition Coil Servicing 112
Ignition Coil Tests 83
Required Systems 79
Running Tests 82
Static Ignition Test 81
Timing 67
Information Display Systems
Tachometer Setting 33
I–4
INDEX
Intake Manifold
Assembly 150
Disassembly 150
Inspection 150
Installation 151
Removal 149
K
Key Switch
Operation Check 33
Start Circuit 102
L
LED Indicators 77
Lower Cover
Installation 51
Removal 50
Lubrication
Engine Oil 10, 12, 160
Gearcase 11, 13, 39
Power Trim 11, 13
Propeller Shaft 39
Swivel Bracket 38
Throttle and Shift Linkage 38
Tiller handle 37
Tilt Tube 38
Trailering Bracket 38
Trim and Tilt 41
M
Maintenance Schedule 16
Manual Starter
Assembly 365
Installation 369
Rope Replacement 368
Manual Tilt
Assembly 268
Disassembly 265
Models
Included Models 9
Model Designation 8
Serial Number Location 8
Motor Mounts
Lower Mount Servicing 243, 245, 246, 247
Upper Mount Servicing 215, 243, 245, 251,
253, 258
Muffler
Installation 219
Removal 192
Servicing 244
N
New Engines
Outboard Rigging Procedure 17
O
Oetiker Clamp Servicing 25
Oil Injector
Electrical Circuit (55 V) 161
Electrical Tests 166
Functional Test 168
Oiling Rate 66, 164
Oiling System
Components 160
Electrical Circuits 159
Engine Lubricant 10, 12, 160
Low Oil Switch 58
New Engine Set-Up 160
Oil Distribution 156
Oil Distribution Hoses 156, 169
Oil Filters 43
Oil Recirculation 163
Oil Tank 160, 169
Oiling Rate 66, 164
Priming 165
Servicing 169
Tests 166
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
P
Packard Connector Servicing 119
Pinion Gear
Bearing Installation 305, 329
Bearing Removal 305, 329
Installation 314, 340
Removal 303, 325
I–5
INDEX
Piston Rings
End Gap 202, 206
Installation 206
Removal 197
Pistons
Assembly 205
Inspection 202
Installation 206
Removal 196
Powerhead
Assembly 203
Cleaning 200
Cylinder Compression Testing 190
Disassembly 193
Inspection 201
Installation 216
Removal 190
Predelivery Checks 33
Pre-Season Service 46
Pressure Relief Valve
Assembly 184
Disassembly 183
Inspection 184
Priming
Fuel System 136
Propeller
Inspection 293
Installation 294
Selection 293
Propeller Shaft
Installation 313, 338
Lubrication 39
Removal 304, 328
Propeller Shaft Bearing Housing
Disassembly 310, 335
Installation 316, 341
Removal 302, 325
R
Relays
Trim and Tilt 106, 349
Remote Controls
Cable Adjustment 19
Rigging
Outboard 17
Rope Replacement 368
RPM Limit 11, 13, 59, 60
S
S.A.F.E.
Description 62
Low Oil 58
No Oil 162
Temperature 56, 57
Safety 1
Sensor Tests 95
Sensors
Air Temperature Sensor 57, 96
Barometric Pressure Sensor 57
Crankshaft Position Sensor 59, 80, 95
EMM 56
Engine Temperature Sensor 57, 96, 182
Throttle Position Sensor 59, 95
Service Charts
Electrical and Ignition 88
Fuel System 122
Gearcase 290
Manual Starter 362
Midsection 234
Oiling System 154
Shift Cable Adjustment, Tiller 286
Shift Housing
Assembly 307, 332
Installation 313, 338
Removal 304, 328
Shift Linkage
Adjustment 220
Installation 212
Lubrication 38
Removal 194
Shift Rod
Housing Installation 339
Shift Rod Adjustment 11, 13, 300, 323
Shimming, Driveshaft 312, 337
Shutdown 62
No Oil 162
Spark Plugs
Gap 11, 42
Indexing 42
Maintenance Schedule 16
Recommendation 11, 13, 42
Removal 42
I–6
INDEX
Replacement 42
Service 42
Specifications 10
Starter
Assembly 365
Circuit Description 100
Current Draw Test 103
Installation 115, 369
Removal 115
Rope Replacement 368
Solenoid Test 102
Voltage Drop Test 103
Start-In-Gear Protection 33
Stator
Resistance Test 97
Service 111
Voltage Output Test 97
Steering Handle
Assembly 273, 281
Disassembly 272, 278
Inspection 273, 281
Installation 275, 285
Removal 271, 277
Steering System
Lubrication 37
Steering Arm and Shaft 251, 253, 257, 259
Steering Friction 27, 259
Steering Torque 31
Stern Bracket
Assembly 252, 256, 261
Disassembly 251, 253, 258
Manual Tilt 265
Removal 252, 260
Stop Circuit 105
Storage 45
Submerged Engines 47
Swivel Bracket
Installation 257
Lubrication 38
Manual Tilt 265
Removal 254
SystemCheck
Circuits 107
LOW OIL Warning Signal 162
NO OIL Warning Signal 162
Outboard connections 20
Tests 107, 108, 109
Winterization Procedure 45
T
Tachometer
Pulse Setting 33
Technical Data 10
Temperature
Operating 34, 180
Operation below freezing 160
Sensors 57
Temperature Sender
Service 182
Thermostat
Assembly 183
Description 177
Disassembly 182
Inspection 183
Temperature 11, 13
Throttle Cable Adjustment, Tiller 276, 287
Throttle Linkage
Installation 213
Lubrication 38
Removal 194
Throttle Position Sensor
Description 59
Resistance Test 95
Tiller Adjustments
Steering Friction Adjustment 27
Tiller handle
Lubrication 37
Tilt Limit Switch
Adjustment 30
Cam Installation 241, 242
Tilt Support 346
Tilt Tube
Installation 242, 253
Lubrication 38
Removal 241, 252
Timing Adjustments
Timing Verification 114
TPS Calibration 114
Timing Pointer Adjustment 113
Tools
Accessory Power Cable Kit, P/N 5008092
63
I–7
INDEX
Backing Plate, P/N 325867 304, 326
Ball Socket Installer tool, P/N 342225 276,
287
Ball Socket Remover tool, P/N 342226 149,
271, 277
Battery Cable, P/N 584348 64
Bearing Installation Tool, P/N 326562 311,
336
Bearing Installation Tool, P/N 339750 336
Bearing Puller, P/N 432130 310
Bootstrap Tool, P/N 586551 69
Collar, P/N 328363 312
Collar, P/N 341440 337
Connector Service Tool, P/N 342667 116
Crankshaft Bearing/Sleeve Installer, P/N
338647 203
Crimp Tool, AMP 117
Crimping Pliers, P/N 322696 116
Diagnostic Interface Cable, P/N 437955 63
Diagnostic Power Supply, P/N 587005 63,
80
Driveshaft Holding Socket, P/N 311875
325, 341
Driveshaft Holding Socket, P/N 334995
303, 316
Driveshaft Puller, P/N 390706 326
Driveshaft Seal Protector, P/N 312403 312,
313, 315
Driveshaft Seal Protector, P/N 318674 337,
338, 340
Driveshaft Shimming Tool, P/N 5005925
312, 337
Electrical Test Probe Kit, P/N 342677 99
Flywheel Holder, P/N 771311 111
Fuel Pressure Gauge, P/N 5006397 139
Fuel Pressure Gauge, P/N 5007100 137,
142
Gauging Head, P/N 352879 328
Gearcase Alignment Gauge Kit, P/N
5006349 328
Gearcase Filler, P/N 501882 40
Gearcase Pressure Tester, P/N 507977
295
Gearcase Vacuum Tester, P/N 507982 295
Guide Pins, P/N 383175 317
Injector Test Fitting Kit, P/N 5005844 138
Key Switch Assembly, P/N 176408 64
Large Puller Jaws, P/N 432129 199, 309,
310, 334, 335
Lifting Fixture, P/N 396748 191, 192, 216,
218
Lower Driveshaft Puller, P/N 342681 326
Oetiker Pincers, P/N 787145 26
Peak Reading Voltmeter, P/N 507972 98
Pinion Bearing Remover and Installer, P/N
5005927 305
Pinion Bearing Remover/Installer, P/N
5005927 305, 329
Pinion Nut Holder, P/N 334455 325, 341
Pinion Nut Starting Tool, P/N 320675 315
Pinion Nut Starting Tool, P/N 342216 340
Piston Stop Tool, P/N 342679 113
Primary Lock Tool, P/N 777077 117
Puller Bridge, P/N 432127 309, 310, 334,
335
Puller, P/N 387206 304
Retaining Ring Pliers, P/N 331045 302, 316
Rod Cap Alignment Fixture, P/N 396749
209
Seal Installation Tool, P/N 326551 311, 336
Seal Installation Tool, P/N 330268 334
Seal Installation Tool, P/N 336311 336
Seal Installer, P/N 342665 309
Secondary Lock Installer, P/N 777079 117
Secondary Lock Tool, P/N 777078 117
Shim Gauge Bar, P/N 328366 312
Shim Gauge Bar, P/N 328367 337
Slide Hammer Adapter, P/N 340624 352
Slide Hammer Adaptor Kit, P/N 390898 146
Slide Hammer, P/N 391008 146, 203, 326,
352
Slide Hammer, P/N 432128 199, 242
Small Puller Jaws, P/N 432131 335
Starter Rope Threading Tool, P/N 378774
368
Starter Winder/Installer Kit, P/N 392093
365
Stator Test Adaptor, P/N 5005799 97, 98
Syringe, P/N 346936 168
Temperature Gun, P/N 772018 180, 181
Terminal Release Tool, P/N 351413 118
Thermal Joint Compound, P/N 322170 181
I–8
INDEX
Tilt Tube Service Kit, P/N 434523 241
Torquing Socket, P/N 331638 196, 210
Twist-Grip Remover, P/N 390767 272, 279
Universal Puller Set, P/N 378103 111, 302,
325
Universal Shift Rod Height Gauge, P/N
389997 300, 323
Wrench Retainer, P/N 341438 325, 341
Wrist Pin Bearing Tool, P/N 336660 205
Wrist Pin Cone, P/N 318600, 206
Wrist Pin Pressing Tool, P/N 326356 197
Wrist Pin Retaining Ring Driver, P/N
318599 206
Torque Charts
see Service Charts
TPS Calibration 114
Trailering Bracket 346
Lubrication 38
Trim and Tilt
Assembly 358
Disassembly 356
Electrical Circuit Tests 106
Inspection 348
Installation 354
Lubrication 41
Removal 352
Reservoir Fluid 11, 348
Troubleshooting 348, 349
Trim Gauge Test 351
Trim Sender
Adjustment 29, 30
Test 351
Trim Tab
Adjustment 31
Installation 297
Removal 296, 318
Troubleshooting
Charging System Tests 98
Cylinder Drop Tests 76
Diagnostic Procedures 74
Fuel Control Adjustment 76
Fuel System 84, 137
Ignition 79, 82
Oiling System 166
Sensors 95
Stator Resistance Test 97
Strategy 75
Trim and Tilt 348, 349
U
Upper Mount Servicing 215
V
Vapor Separator
Description 132
Installation 144
Removal 144
Voltage Drop Test 103
W
Water Intake Screens 34, 305, 328, 338
Inspection 34
Water Pressure Gauge 23
Water Pump
Assembly 299, 321
Description 176
Disassembly 298, 320
Inspection 298, 320
Water Tube 248, 249
Winterizing 45
Wrist Pin
Bearing 197
Installation 205
Removal 19

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.