TROUBLE CHECK CHART
OUTBOARD WILL NOT START
| OBSERVATION | POSSIBLE CAUSE | PROCEDURE |
|---|---|---|
| Outboard does not turn over | Battery switch not ON | Check battery switch operation |
| Discharged battery | Check battery, recharge or replace | |
| Battery cables and connections | Clean and tighten connections. Check for voltage drop in starter circuit. | |
| Faulty connection or ground, damaged electrical harness | Check all grounds, connections and wiring | |
| Fuse (10 A) | Check wiring, then replace faulty fuse | |
| Wiring harness | Check for 12 V at terminal “B” of key switch | |
| Key switch | Check key switch operation | |
| Starter solenoid | Check wiring and test solenoid | |
| Starter or bendix/drive gears | Check starter, inspect bendix/drive gears | |
| Seized powerhead or gearcase Check and repair as needed | ||
| Outboard turns slowly | Discharged battery | Check battery, recharge or replace |
| Battery cables and connections | Clean and tighten connections. Check voltage drop in starter circuit. | |
| Powerhead hydro-locked | Check cylinders for water | |
| Partially seized powerhead or gearcase | Check and repair as needed | |
| Starter or bendix/drive gears | Check starter, inspect bendix/drive gears |
| OBSERVATION | POSSIBLE CAUSE | PROCEDURE |
|---|---|---|
| Outboard turns over | Stop circuit grounded | Check wiring and emergency stop switch. Check the safety lanyard is installed and stop circuit is not grounded. |
| In gear–Tiller models | Make sure outboard is in neutral | |
| No Fuel | Check for fuel in fuel tank | |
| Water in fuel | Check fuel filter, sample fuel from fuel return manifold. | |
| Contaminated or poor fuel quality | Check or replace fuel supply | |
| Fuel supply restricted | Check primer, anti-siphon valve, and fuel pick-up. Use primer to fill vapor separator with fuel. | |
| Air in fuel system | Check for air in fuel supply manifold, refer to FUEL SYSTEM (vapor separator venting and fuel supply) | |
| Low or no fuel pressure to injectors | Check fuel manifold pressure, refer to FUEL SYSTEM | |
| Incorrect, fouled, or worn spark plugs | Replace spark plugs | |
| Fuel injectors not working | Check voltage at injectors | |
| Excessive fuel or oil, engine flooded | Check for leaking injectors, leaking fuel or oil lift pump, or leaking vapor separator vent, refer to FUEL SYSTEM | |
| Low or no 55 V alternator output | Check voltage on 55 V circuit, refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| Capacitor or 55 V circuit wiring | Check capacitor and 55 V circuits, refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| Ignition | Check ignition, refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| CPS input to EMM, no sync | Check RPM reading while cranking | |
| No ignition system control signal from EMM to ignition coils | Check cranking RPM (300 minimum), refer to SYSTEM ANALYSIS | |
| Low or no compression | Check compression | |
| Water in engine | Check condition of spark plugs and cylinders | |
| Internal powerhead damage | Check and repair as needed | |
| Leaking cylinder/crankcase, intake manifold, or reed valves | Check and repair as needed | |
| EMM program, timing, or operation | Check EMM program and timing; check injector information (by location and serial number) | |
| Neutral switch, tiller models | Check neutral switch operation |
OUTBOARD HARD TO START
| OBSERVATION | POSSIBLE CAUSE | PROCEDURE |
|---|---|---|
| Outboard eventually starts, may or may not run properly once started | Weak battery | Check battery, recharge or replace |
| Battery cables and connections | Clean and tighten connections, check voltage drop on high amperage circuit | |
| Starter or bendix/drive gears | Check starter, inspect bendix/drive gears | |
| Water in fuel system | Check water separator/fuel filter, sample fuel from fuel return manifold test port | |
| Contaminated or poor fuel quality | Check or replace fuel supply | |
| Air in fuel system | Check for air in fuel supply manifold, refer to FUEL SYSTEM (vapor separator venting and fuel supply) | |
| Incorrect, fouled, or worn spark plugs | Replace spark plugs | |
| Low fuel pressure | Check pressure, refer to FUEL SYSTEM | |
| Fuel supply restricted | Check primer bulb, anti-siphon valve, and fuel pick-up, check for fuel system air leaks | |
| Low or no alternator output (55 V) | Check voltage on 55 V circuit, refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| Capacitor or 55 V circuit wiring | Check capacitor and 55 V circuit (white/red), refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| Restricted or leaking fuel injector(s) | Check injectors, refer to FUEL SYSTEM | |
| Weak or erratic ignition operation |
Check ignition, refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| Crankshaft Position Sensor (CPS) | Check CPS air gap and EMM LED indicators | |
| Excessive fuel or oil, engine flooding | Check for leaking injectors, leaking fuel or oil lift pump, or leaking vapor separator vent. Refer to SYSTEM ANALYSIS. | |
| EMM program, timing, or operation | Check EMM program and timing; check injector coefficients; and monitor injector circuits and ignition primary outputs | |
| Internal powerhead damage | Check and repair as needed | |
| Leaking cylinder/crankcase, intake manifold, or reed valves | Check and repair as needed |
OUTBOARD WILL NOT SHUT OFF
| OBSERVATION | POSSIBLE CAUSE | PROCEDURE |
|---|---|---|
| Outboard starts and runs, normal performance while running |
Key switch or wire harness ground | Check key switch and ground to key switch, refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION |
| Stop circuit wiring | Check EMM LED indicators. Check wire harness (black/yellow) and key/stop switch(s). | |
| EMM failure | Check EMM LED indicators and eliminate stop circuit as possible cause. Stop wire (black/yellow) has 4.0 VDC from EMM with key on or outboard running. |
OUTBOARD STARTS AND STALLS
| OBSERVATION | POSSIBLE CAUSE | PROCEDURE |
|---|---|---|
| Outboard may not run for more than a few seconds | Faulty wiring, connections, or grounds | Check all grounds, connections, and wiring |
| Incorrect, fouled, or worn spark plugs | Replace spark plugs | |
| Low or no alternator output (55 V) | Check voltage on 55 V circuits, refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| Capacitor or 55 V circuit wiring | Check capacitor and 55 V circuit, refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| Contaminated or poor fuel quality | Check or replace fuel supply | |
| Low fuel pressure | Check pressure, refer to FUEL SYSTEM | |
| Air in fuel system | Check for air in fuel supply manifold, refer to FUEL SYSTEM (vapor separator venting and fuel supply) | |
| Fuel supply restricted | Check primer bulb, anti-siphon valve, and fuel pick-up, check for fuel system air leaks | |
| Injector electrical circuit or control function | Check voltage at injectors, refer to SYSTEM ANALYSIS | |
| Restricted or leaking fuel injector(s) | Check injectors, refer to FUEL SYSTEM | |
| EMM program, timing, or operation | Check EMM program and timing; check injector coefficients; and monitor injector control wires and ignition primary outputs | |
| Weak or erratic ignition output | Check ignition, refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| Internal powerhead damage | Check and repair as needed |
OUTBOARD STARTS, LOW MAXIMUM RPM
| OBSERVATION | POSSIBLE CAUSE | PROCEDURE |
|---|---|---|
| SystemCheck light | Outboard is in S.A.F.E. | Check Service Codes and SystemCheck warning |
| Setup or rigging change |
Incorrect propeller | Refer to specifications, check recommended WOT RPM; water test and install correct pitch propeller |
| Incorrect outboard mounting height | Refer to installation guidelines | |
| Performance of outboard at lower speeds appears normal |
Incorrect, fouled, or worn spark plugs | Replace spark plugs |
| Contaminated or poor quality fuel | Check or replace fuel supply | |
| Fuel supply restricted | Check primer bulb, anti-siphon valve, and fuel pick-up, check for fuel system air leaks | |
| Low alternator output (55 V) | Check voltage on 55 V circuits, refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| Weak or erratic ignition operation |
Check ignition, refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| Fuel injector electrical circuit or control function |
Check voltage at injectors, refer to SYSTEM ANALYSIS | |
| Restricted or leaking fuel injectors | Check injectors, refer to FUEL SYSTEM | |
| Low fuel pressure | Check circulation pump operation, refer to FUEL SYSTEM | |
| EMM programming, timing, or operation | Check EMM program and timing; check injector coefficients; and monitor injector circuits and ignition primary outputs | |
| Restricted engine exhaust | Check and repair as needed |
EXCESSIVE SMOKING
| OBSERVATION | POSSIBLE CAUSE | PROCEDURE |
|---|---|---|
| May coincide with increased oil consumption (normal if occurs after winterization) |
Contaminated or poor fuel quality | Check or replace fuel supply |
| Excessive fuel or oil consumption | Check fuel system for fuel supply air leaks or leaking fuel injectors | |
| Outboard in break-in mode | Use diagnostics program to check | |
| Outboard mounted too low | Check installation height of outboard | |
| Vapor separator vent | Check vapor separator assembly for proper venting/float valve operation | |
| Faulty/leaking fuel injector(s) | Check injectors, refer to FUEL SYSTEM | |
| Damaged fuel lift pump | Check for internal leaks |
OUTBOARD SURGES, RUNS ROUGH
| OBSERVATION | POSSIBLE CAUSE | PROCEDURE |
|---|---|---|
| 1200 RPM and above | S.A.F.E. | Access EMM fault codes |
| May be erratic or inconsistent | Incorrect, fouled, or worn spark plugs | Replace spark plugs |
| Water in fuel system | Check water separator/fuel filter, sample fuel from fuel return manifold test port | |
| Contaminated or poor fuel quality | Check and replace fuel supply | |
| Low or erratic fuel pressure | Check pressure, refer to FUEL SYSTEM | |
| Air in fuel system | Check for air in fuel supply manifold, refer to FUEL SYSTEM (vapor separator venting and fuel supply) | |
| Fuel supply restricted | Check primer bulb, anti-siphon valve, and fuel pick-up, check for fuel system air leaks | |
| Restricted or leaking fuel injector(s) | Check injectors, refer to FUEL SYSTEM | |
| Faulty wiring, connections, grounds, or CPS air gap | Check all grounds, connections, and wiring. Check CPS air gap. | |
| Low alternator output (55 V) | Check voltage on 55 V circuit, refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| EMM program, timing, or operation | Check EMM program and timing; check injector coefficients; and monitor injector circuits and ignition primary outputs | |
| Weak or erratic ignition operation |
Check ignition, refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| Capacitor or 55 V circuit wiring | Check capacitor and 55 V circuit (white/red), refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION | |
| Restricted engine exhaust | Check and repair as needed | |
| Audible noise | Internal powerhead damage | Check and repair as needed |
| Damaged gearcase | Inspect gearcase and lubricate |
Hose Routing and Water Flow Diagram 40 – 65 E-TEC Inline 2 Cylinder
Hose Routing and Water Flow Diagram 75-90 HP EVINRUDE ETEC
MWS Instrument Wiring Harness
I-Command Keyswitch/TNT Wiring Harness
Lanyard Switch / Emergency Stop Circuits
MWS Key Switch and Neutral Safety Switch
MWS DASHBOARD
Evinrude E-TEC
EMM LED Diagnostic Indicators
