Service Manual 40-90 HP.E-TEC Powerhead [Powerhead Removal]

Start and run outboard until it achieves operating temperature, then shut OFF.

Disconnect crankshaft position sensor (CPS) connector. Remove all spark plugs.
Advance throttle linkage to WOT.
Install compression tester’s hose attachment into spark plug hole (14 mm threads).
While cranking outboard with starter, note maximum pressure reading on gauge. Repeat procedure for each cylinder.

If engine shows a variation greater than 15 psi
(100 kPa) between cylinders, check for:
• damaged cylinder head
• damaged pistons
• broken or stuck piston rings
• scored cylinder walls
Return throttle to idle position and reconnect CPS connector. Replace spark plugs. Refer to Spark Plug Indexing on p. 90.

2-Cylinder Models

Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 183.
To prevent accidental starting while servicing, twist and remove spark plug leads.

Remove lower motor covers. Lower Cover Removal on p. 96.
Disconnect power trim connectors and exhaust water valve electrical connector (60, 65).

1. Connectors

Disconnect cooling water hoses from exhaust housing.

1. Overboard indicator hose
2. Drain hose

Remove pin and washer from shift rod lever to release the lower shift rod.

1. Shift rod screw

ROPE START MODELS
Remove throttle cable and tiller shift rod

1. Cable anchor
2. Anchor screw
3. Cable retainer
4. Shift rod retainer

Remove the recoil starter housing and starter ratchet. Refer to RECOIL STARTER REMOVAL on p. 399.

1. Starter housing screws (3)

ALL MODELS
Install Lifting Fixture, P/N 396748, on flywheel and seat the three screws completely.

Be sure to use only the 1 1/8 in. (short) screws, P/N 398067, included with the tool to avoid damage to electronic components under the flywheel.

1. Lifting fixture
2. 1 1/8 in. screws

Fasten appropriate chain hook to eye of tool and support weight of powerhead with hoist.
Loosen the screws holding the exhaust water valve to the exhaust housing.
Move water valve aside and remove the eight exhaust housing to powerhead screws.

1. Powerhead screws

IMPORTANT: Do not damage the powerhead or exhaust housing mating surfaces.

3-Cylinder Models

Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure.
Refer to Relieving Fuel System Pressure on p. 142.
To prevent accidental starting while servicing, twist and remove spark plug leads.

Remove lower motor covers. Lower Cover
Removal on p. 96.
Disconnect power trim connectors.

Remove pin and washer from shift rod lever to release the lower shift rod.

1. Shift rod pin

Remove six retaining screws and exhaust relief muffler.

Install Lifting Fixture, P/N 396748, on flywheel and seat the three screws completely.

Be sure to use only the 1 1/8 in. (short) screws, P/N 398067, included with the tool to avoid damage to electronic components under the flywheel.

1. Lifting fixture
2. 1 1/8 in. screws

Fasten appropriate chain hook to eye of tool and support weight of powerhead with hoist.

Remove the small powerhead screw at rear.

1. Rear small powerhead screw

Remove remaining four small powerhead screws,six large powerhead screws, and the upper mount screws.

1. Small powerhead screws
2. Large powerhead screws
3. Upper mount screws

Use a suitable tool to carefully separate the powerhead from exhaust housing.

IMPORTANT: Do not damage the powerhead or exhaust housing mating surfaces.

Systems Removal
To simplify reassembly and wiring installation, layout the various screws and clamps in the order of their proper location.
Remove the electric starter. Refer to Starter Removal on p. 159.
Remove the oil tank. Refer to Oil Tank Assembly on p. 207.
Remove fuel pump assemblies, fuel manifolds, and filter. Refer to FUEL COMPONENT SERVICING on p. 183.
Remove EMM, then electrical harness assembly.
Label connectors for reassembly locations. Refer to EMM SERVICING on p. 116.

Remove flywheel and stator. Refer to FLYWHEEL AND STATOR SERVICING on p. 154.
Remove ignition coils and fuel injectors. Refer to Fuel Injector Service on p. 187.
IMPORTANT: Mark injectors for cylinder location before removal. All injectors must be installed in their original location. Improper injector installation can result in powerhead failure.
Remove all oil distribution and recirculation hoses.
Remove throttle linkage. Refer to Throttle Linkage Removal on p. 232.
Remove shift linkage. Refer to Shift Linkage Removal on p. 232.
Remove the throttle body and reed plate assemblies. Refer to Intake Manifold Service on p. 189.
Remove pressure valve assembly. Refer to PRESSURE RELIEF VALVE SERVICING on
p. 221.