Service Manual 40-65 HP E-TEC Oiling System [Oiling System Tests]

IMPORTANT: Always perform visual inspections to identify oiling system leaks. Make sure the oil tank is filled and oil supply is not contaminated.

Oil Injection Pump Static Test

IMPORTANT: Static tests are performed with the outboard not running.

Use Evinrude Diagnostics software to activate the Oil Injector test. This test starts the EMM control function for the oil injection pump.

The EMM controls the pump by providing ground through pin 23 (blue wire) of the J1-B connector and pin 2 (blue wire) of the oil tank connector.

Static Tests Screen

1. Oil injector test button

IMPORTANT: This test is operating the pump with 12 V battery power on the system voltage (55 V) circuit. The oil injection pump will not activate on 12 V.

Use an inductive timing light to monitor current flow through the ground circuit (blue wire) at the oil tank connector (pin 2).

If the light flashes, the EMM and oil injection circuits are not at fault.

Refer to Oil Injection Pump Voltage Test on p. 183.

Check voltage at pin 1 (white/red wire) of oil tank electrical connector.

Acceptable voltage readings:

• Key switch ON: slightly less than 12 V
• Outboard running: 55 V Results:
• If voltage is not within range, refer to Oil Injection Pump Circuit Resistance Test on p. 184.
• No voltage reading, refer to System Voltage Test on p. 110.

Monitor the voltage on the oil injector circuit at pin 2 (blue wire) of oil tank connector with out board running at 1500 RPM.

Use an appropriate test probe and a digital multi meter calibrated to a scale that reads 55 V (DC). Connect positive meter lead to pin 2 and negative meter lead to ground.

1. Oil injection pump connector (pin 2)

Voltage reading should be approximately 55 V, and drop approximately 5 V as EMM actuates oil injection pump.

IMPORTANT: The complete oil injection pump electrical circuit includes EMM alternator output, the engine wire harness, the injection pump winding and connectors, and the oil injector control circuit of the EMM. Check continuity of all wiring and connections.

Disconnect the battery cables at the battery.

Use an appropriate test probe to make a connection to pin 1 of the oil injection pump connector.

Calibrate a digital multimeter to the LOW OHMS scale and measure the resistance between pin 23 of the EMM J1-B connector and pin 1 of the oil injection pump connector.

Oil Injection Pump Circuit Resistance 22 Ω

1. Oil injection pump connector (pin 1)

Results:

• An infinite reading (∞) indicates an open circuit. Isolate the faulty wiring, connection, or injection pump winding. Repair faulty wiring or replace faulty pump.
• For a higher than expected reading, test resistance of the injection pump. If injection pump resistance reading is approximately 22 Ω, injection pump winding is good. Isolate faulty component. Repair faulty wiring or replace faulty component and retest.

Remove oil distribution hose from fitting at oil distribution manifold. Do not lose the brass hose sup port.

1. Oil distribution hose
2. Hose support

Temporarily install a length of oil hose.

Start the outboard and observe oil flow:

• Oil flows from hose, compare to oil flow at other distribution fittings
• If one or more fittings fail to flow oil, replace the oil injection pump assembly.

Reinstall hose into manifold.

IMPORTANT: Make sure hose support is in hose and hose is fully inserted into manifold. Refer to Oil Distribution Hoses on p. 186.

Make sure the oil injection fittings of the cylinder and crankcase assembly allow fluid to move.

Remove oil distribution hose from oil distribution manifold.

Use a Syringe, P/N 346936, filled with isopropyl alcohol to force fluid through hose and fitting.

1. Syringe

Remove the oil from the oil tank.

Turn the key switch ON. The dash mounted Engine Monitor system should show a LOW OIL warning.

Once the warning has been confirmed, refill the oil tank and start the outboard. The LOW OIL warning should stop after the oil pump cycles 3 times.