Service Manual 5008740_200-300 HP 90 ° V System Analysis [Diagnostic Procedures]

Inspect wiring and electric al connections. Disassemble a nd clean all corrode d connections. Replace damaged wiring, connectors, o r terminals. Repair any shorted electrical circuits.

• Refer to ELECTRICAL HARNESS CONNECTIONS on p. 91.
• Refer to WIRING DIAGRAM at the back of this manual.
• Refer to CONNECTOR SERVICING on p. 122

004183

1. Main engine harness ground
2. Ground stud (battery

Inspect spark plugs for wear, oil fowling, or dam age. A rich or lean running condition or evidence of internal engine damage could be identified b y the appearance of the spark plugs.

Check the fuse an d the emergency stop switch lanyard.

Before running the out board, use Evinrude Diagnostics software to review historical information saved in the EMM.

Check the Active Faults and Occurred Faults screens for current service codes. Correct any
problems and clear the codes before further troubleshooting. Refer to Occurred Service
Codes (Faults) on p. 65.

The occurred fault screen displays detailed information about the operating conditions of the engine at the time the code was set.

008128

Occurred Faults Review Screen

1. Detailed information

Review information about how the outboard has been operated using the Profiles screens.

008587

RPM Profile

• Check the RPM Profile for long period s of low speed operation or periods of over-revving rpm.

• Check the Engine Temperature Profile for evidence of cold running or overheating.

008588
Engine Temperature Profile

• The Last Two Minutes pro file reports engine run-time value s during the last two minutes of operation above 15 00 rpm. Information is collected once persecond. The ne west record is first on the list. As each new record is added, the oldest record is removed.

008589

Last Two Minutes Profile

The Engine Identity Report provides a snap-shot of current engine and sensor
conditions. From the Identity screen, press the Print button. Next, press Printer
to print, or PDF File to save the report.

008590

Engine Identity Report

Run the outboard to confirm actual symptoms before performing any unnecessary procedures. Inspection should include the following:

• Make sure the outboard can be cranked easily, with no mechanical binding.
• Check the EMM LED Indicators for system status information. Refer to EMM LED INDICATORS on p. 78.

Outboard will not crank, starter does not operate:

• Check condition of battery and cables (ma in battery switch and cables). Make sure battery cables are not reversed.
• Confirm that switched B+ is present at “A” terminal (purple wire) o f starter solenoid with key switch in the ON position.
• Refer to ELECTRIC START TESTS on p. 101. Repair starter or start circuit as needed.

Outboard cranks, will not start:

• Check emergency stop switch and lanyard
• Check the EMM LED Indicators for system status information. Refer to EMM LED INDICATORS on p. 78.

• Use the Evinrude Diagnostics software Occurred Faults screen to check for current
service codes. If there are multiple occurred sensor codes, inspect all 5 V sensor
circuits for broken or grounded wiring.
• Perform a Static Igntion test using Evinrude Diagnostics software and an inductive
timing light. Refer to Static Ignition Test on p. 82.
• If ignition test indicates steady spark, refer to FUEL DELIVERY TESTS on p. 85.

Outboard runs, low on power, misfires:

• Check the EMM LED Indicators for system status information. Refer to EMM LED INDICATORS on p. 78.
• Use the Evinrude Diagnostics software Monitor
screen to check system (55 V) and TPS voltages. System volt age should b e steady , a nd
TPS voltage should be between 0.2 and 4.85 V

IMPORTANT: Use a digital multimeter to check voltage on external circuits only when necessary .All EMM output currents are DC current

• Use the diagnostics software Dynamic Tests to isolate a faulty cylinder.
See DYNAMIC TESTS on p. 77.
• Use an inductive timing light to check ignition
and fuel injector circuits. Refer to Running Ignition Tests on p. 83 and Running
Fuel System Tests on p. 86.
• Use the diagnostics software Fuel Control Adjustment test to help identify a
cylinder that may be too rich or too lea n. Refer to Fuel Control Adjustment on p. 77.
• Use an inductive amp meter to monitor injector circuit current. Compare
readings of all circuits to identify possible failure.
• Check fuel quality and that fuel is present at injectors.
• Use the diagnostics software Logging function to record engine data as a problem is occurring.

008574
Logging Screen

• AFTER all the above inspections, if the cause of a running quality problem still cannot be identified, perform a compression test to check for internal powerhead damage.

IMPORTANT: Remove a cylinder head or disassemble the engine only as a last resort.