Service Manual 40-90 HP.E-TEC Maintenance [Lubrication]

Inspect condition of water intake screens. Clean or replace as needed.

Confirm function of overboard water pressure indicator.

1. Water intake screen

2. Overboard indicator

• Check Engine Monitor function.

• Check operation or visually inspect thermostats and pressure relief valve. Clean or replace as needed.

• Check that all water passages, hoses, and fit tings for both the EMM and the vapor separator flow water freely.

• Replace water pump.

Steering System

Failure to regrease as recommended could result in steering system corrosion. Corrosion can affect steering effort, making operator control difficult.

Grease the stainless steel output end of the steering cable with Triple-Guard grease.

Use an appropriate cleaning solvent to remove corrosion and dirt from output end of cable prior to coating it with grease. Make sure wiper nut is installed and not damaged.

1. Steering cable

2. Wiper nut

Lubricate the tiller handle grease fittings with Triple-Guard grease.

1. Tiller handle fittings – Standard handle

1. Tiller handle fittings – Long handle

Lubricate the swivel bracket with Triple-Guard grease.

Apply grease until the grease begins to flow from the upper or lower swivel bracket areas.

Coat the pivot points of the trailering bracket with Triple-Guard grease.

2-Cylinder models

1. Grease fitting

2. Tilt support

3-Cylinder models

1. Grease fitting

2. Pivot points

3. Lower swivel bracket area

Lubricate the tilt tube grease fittings with Triple-Guard grease.

1. Tilt tube fittings

Disconnect the battery cables at the battery.

Remove clips and washers from throttle and shift lever pins. Carefully, remove casing guides from pins.

IMPORTANT: DO NOT disturb cable trunnion adjustments.

Shift remote control into FULL THROTTLE/ REVERSE position to fully extend the plastic casing guides.

Apply Triple-Guard grease to:

• Cable attachment pins of both the throttle and shift levers

• Inner casings of both the throttle and shift cables.

1. Attachment pins, throttle and shift cables

2. Inner casings, throttle and shift cables

Shift the remote control to the NEUTRAL/IDLE position.

Install control cables.

Check proper throttle and shift function.

Debris from the water can become lodged around propeller shaft. Frequent inspection can minimize potential gearcase damage.

When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and disconnect the battery cables at the battery.

Remove propeller. Refer to Propeller Hardware Installation on p. 70.

Inspect bushing and blade surfaces. Replace damaged or worn propellers.

Clean propeller shaft. Inspect propeller shaft seals. Replace damaged or worn seals.

Apply Triple-Guard grease to entire length of propeller shaft prior to installing propeller.

Reinstall propeller hardware and propeller.

Draining

Gearcase lubricant may be under pressure and/or hot. If plug is removed from a recently operated outboard, take precautions to avoid injury

IMPORTANT: Always check the fill level of the gearcase lubricant at the upper plug before removing the lower, drain/fill plug. A tie strap can be used to check lubricant level.

1. Tie strap

Remove the lubricant level plug, then the lubricant drain/fill plug, and drain the lube from the gear case into a container.

1. Lubricant level plug

2. Lubricant drain/fill plug

Inspection

Inspect the lube and the magnets on the plugs for metal chips. The presence of metal fuzz can indicate normal wear of the gears, bearings, or shafts within the gearcase. Metal chips can indicate extensive internal damage.

Inspect the lubricant for water contamination. Water can make the lubricant milky in appearance. However, normal aeration can also cause the same appearance.

To check for water contamination, put lubricant into a glass container. Allow the oil to settle for a minimum of one hour to determine if there is an abnormal amount of water in the oil. Some gear case lubricants are designed to mix with a small

amount of water from normal water vapor condensation within the gearcase.

Refer to GEARCASE LEAK TEST on p. 331.

Overheated lubricant will have a black color and burned odor.

Internal gearcase inspection is recommended when lubricant is contaminated or shows signs of failure.

Filling

Refer to the INSPECTION AND MAINTENANCE SCHEDULE on p. 80 for service frequency and recommended lubricants.

Secure the gearcase in a vertical position.

Remove the lubricant level plug and the lubricant drain/fill plug. Slowly fill the gearcase with gearcase lube through the drain/fill hole until it appears at the oil level hole. Filling the gearcase too quickly can cause air pockets and the gearcase may not fill completely. Clean plug seal area and install the lubricant level plug and new seal, then the lubricant drain/fill plug and new seal. Tighten them to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Lubricant level plug

2. Lubricant drain/fill plug

IMPORTANT: The recommended gear lubricants are formulated for marine applications. Do not use automotive gear lubricants, engine oils, or any other oil or grease.

Trim and Tilt

Correct fluid level must be maintained to ensure operation of the impact protection built into the unit.

Check reservoir fluid level at least every three years or 300 operating hours.

• 75–90 HP: System capacity is approximately 21 fl. oz. (620 ml).

• 40–60 HP: System capacity is approximately 15.2 fl. oz. (450 ml).

• Tilt the outboard and engage the tilt support.

1. Tilt support bracket, 75-90 HP

002279

1. Tilt support bracket, 40-60 HP

• Remove filler cap and check fluid level.

• Single Ram System–Add Evinrude/Johnson Biodegradable TNT Fluid, as needed, to bring level to the bottom of the fill plug threads.

Single Ram System, 79 - 90 HP

1. Filler cap

Single Ram System, 40 - 60 HP

1. Filler cap

Install the filler cap and tighten to a torque of 45 to 55 in. lbs. (5 to 6 N·m).

• Disengage tilt support.

• Cycle the unit at least five complete cycles to purge all air from the system. When cycling the unit, hold the trim switch ON an additional 5 to 10 seconds after the unit reaches the end of its travel before activating the switch in the opposite direction.