Service Manual 5007211_Evinrude E-TEC 75-90 HP Add Ons

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added 4 de setembro de 2020 às 21:23 updated 21 de dezembro de 2020 às 17:08

BRP Marine

Sections:

OUTBOARD WILL NOT START
OUTBOARD HARD TO START
OUTBOARD WILL NOT SHUT OFF
OUTBOARD STARTS AND STALLS
OUTBOARD STARTS, LOW MAXIMUM RPM

EXCESSIVE SMOKING
OUTBOARD SURGES, RUNS ROUGH
Hose Routing and Water Flow Diagram
EVINRUDE EMM SERVICE CODE CHART

OUTBOARD WILL NOT START

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
Outboard turns over	In gear–Tiller models	Make sure outboard is in neutral
Outboard turns over	No Fue	Check for fuel in fuel tank
Outboard turns over	Water in fuel	Check fuel filter, sample fuel from fuel return manifold
Outboard turns over	Contaminated or poor fuel quality	Check or replace fuel supply
Outboard turns over	Fuel supply restricted	Check primer, anti-siphon valve, and fuel pick-up. User primer to fill vapor separator with fuel.
Outboard turns over	Air in fuel system	Check for air in fuel supply manifold, refer to FUEL SYSTEM on p.155 (vapor separator venting and fuel supply)
Outboard turns over	Low or no fuel pressure to injectors	Check fuel manifold pressure, refer to FUEL SYSTEM on p.155
Outboard turns over	Incorrect, fouled, or worn spark plugs	Replace spark plugs
Outboard turns over	Fuel injectors not working	Check voltage at injectors
Outboard turns over	Excessive fuel or oil, engine flooded	Check for leaking injectors, leaking fuel or oil lift pump, or leaking vapor separator vent, refer to SYSTEM ANALYSIS on p. 103
Outboard turns over	Low or no 55 V alternator output	Check voltage on 55 V circuit, refer to SYSTEM ANALYSIS on p. 103 and ELECTRICAL AND IGNITION on p. 123
Outboard turns over	Capacitor or 55 V circuit wiring	Check capacitor and 55 V circuits, refer to SYSTEM ANALYSIS on p. 103 and ELECTRICAL AND IGNITION on p. 123
Outboard turns over	Ignition	Check ignition, refer to SYSTEM ANALYSIS on p. 103 and ELECTRICAL AND IGNITION on p.123
Outboard turns over	CPS input to EMM, no sync	Check RPM reading while cranking
Outboard turns over	No ignition system primary voltage output from EMM to ignition coils	Check cranking RPM (300 minimum), refer to SYSTEM ANALYSIS on p. 103
Outboard turns over	Low or no compression	Check compression
Outboard turns over	Water in engine	Check condition of spark plugs and cylinders
Outboard turns over	Internal powerhead damage	Check and repair as needed
Outboard turns over	Leaking cylinder/crankcase, intake manifold, or reed valves	Check and repair as needed
Outboard turns over	EMM program, timing, or operation	Check EMM program and timing; check injector information (by location and serial number)
Outboard turns over	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
Outboard eventually starts, may or may not run properly once started	Battery cables and connections	Clean and tighten connections, check voltage drop on high amperage circuit
Outboard eventually starts, may or may not run properly once started	Starter or bendix/drive gears	Check starter, inspect bendix/drive gears
Outboard eventually starts, may or may not run properly once started	Water in fuel system	Check water separator/fuel filter, sample fuel from fuel return manifold test port
Outboard eventually starts, may or may not run properly once started	Contaminated or poor fuel quality	Check or replace fuel supply
Outboard eventually starts, may or may not run properly once started	Air in fuel system	Check for air in fuel supply manifold, refer to FUEL SYSTEM on p. 155 (vapor separator venting and fuel supply)
Outboard eventually starts, may or may not run properly once started	Incorrect, fouled, or worn spark plugs	Replace spark plugs
Outboard eventually starts, may or may not run properly once started	Low fuel pressure	Check pressure, refer to FUEL SYSTEM on p. 155
Outboard eventually starts, may or may not run properly once started	Fuel supply restricted	Check primer bulb, anti-siphon valve, and fuel pick-up, check for fuel system air leaks
Outboard eventually starts, may or may not run properly once started	Low or no alternator output (55 V)	Check voltage on 55 V circuit, refer to SYSTEM ANALYSIS ON P. 103 and ELECTRICAL AND IGNITION on p. 123
Outboard eventually starts, may or may not run properly once started	Capacitor or 55 V circuit wiring	Check capacitor and 55 V circuit (white/red), refer to SYSTEM ANALYSIS on p. 103 and ELECTRICAL AND IGNITION on p.123
Outboard eventually starts, may or may not run properly once started	Restricted or leaking fuel injector(s)	Check injectors, refer to FUEL SYSTEM on p. 155
Outboard eventually starts, may or may not run properly once started	Weak or erratic ignition operation	Check ignition, refer toSYSTEM ANALYSIS on p.103 and ELECTRICAL AND IGNITION on p.123
Outboard eventually starts, may or may not run properly once started	Crankshaft Position Sensor (CPS)	Check CPS air gap and EMM LED indicators
Outboard eventually starts, may or may not run properly once started	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 on p.103
Outboard eventually starts, may or may not run properly once started	EMM program, timing, or operation	Check EMM program and timing; check injector coefficients; and monitor injector circuits and ignition primary outputs
Outboard eventually starts, may or may not run properly once started	Internal powerhead damage	Check and repair as needed
Outboard eventually starts, may or may not run properly once started	Low compression	Check compression
Outboard eventually starts, may or may not run properly once started	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 on p. 103 and ELECTRICAL AND IGNITION on p. 123
Outboard starts and runs,normal performance while running	Stop circuit wiring	Check EMM LED indicators. Check wire harness (black/yellow) and key/stop switch(s)
Outboard starts and runs,normal performance while running	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
Outboard may not run for more than a few seconds	Incorrect, fouled, or worn spark plugs	Replace spark plugs
Outboard may not run for more than a few seconds	Low or no alternator output (55 V)	Check voltage on 55 V circuits, refer to SYSTEM ANALYSIS on p. 103 and ELECTRICAL AND IGNITION on p. 123
Outboard may not run for more than a few seconds	Capacitor or 55 V circuit wiring	Check capacitor and 55 V circuit, refer to SYSTEM ANALYSIS on p. 103 and ELECTRICAL AND IGNITION on p. 123
Outboard may not run for more than a few seconds	Contaminated or poor fuel quality	Check or replace fuel supply
Outboard may not run for more than a few seconds	Low fuel pressure	Check pressure, refer to FUEL SYSTEM on p. 155
Outboard may not run for more than a few seconds	Air in fuel system	Check for air in fuel supply manifold, refer to FUEL SYSTEM on p. 155 (vapor separator venting and fuel supply)
Outboard may not run for more than a few seconds	Fuel supply restricted	Check primer bulb, anti-siphon valve, and fuel pick-up, check for fuel system air leaks
Outboard may not run for more than a few seconds	Injector electrical circuit or control function	Check voltage at injectors, refer to SYSTEM ANALYSIS on p. 103
Outboard may not run for more than a few seconds	Restricted or leaking fuel Injector(s)	Check injectors, refer to FUEL SYSTEM on p. 155
Outboard may not run for more than a few seconds	EMM program, timing, or operation	Check EMM program and timing; check injector coefficients: and monitor injector control wire and ignition primary outputs
Outboard may not run for more than a few seconds	Weak or erratic ignition output	Check ignition, refer to SYSTEM ANALYSIS on p. 103 and ELECTRICAL AND IGNITION on p.123
Outboard may not run for more than a few seconds	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.	Access EMM service codes and check System Check warning
Setup or rigging change	Incorrect propeller	Refer to specifications, check recommended WOT RPM; water test and install correct pitch propeller
Setup or rigging	Incorrect outboard mounting height	Refer to installation guidelines
Performance of outboard at lower speeds appears normal	Throttle plate opening	Check throttle plate and WOT opening
Performance of outboard at lower speeds appears normal	Incorrect, fouled, or worn spark plugs	Replace spark plugs
Performance of outboard at lower speeds appears normal	Contaminated or poor quality fuel	Check or replace fuel supply
Performance of outboard at lower speeds appears normal	Fuel supply restricted	Check primer bulb, anti-siphon valve, and fuel pick-up,check for fuel system air leaks
Performance of outboard at lower speeds appears normal	Low alternator output (55 V)	Check voltage on 55 V circuits, refer to SYSTEM ANALYSIS on p. 103 and ELECTRICAL AND IGNITION on p. 123
Performance of outboard at lower speeds appears normal	Weak or erratic ignition operation	Check ignition, refer to SYSTEM ANALYSIS on p. 103 and ELECTRICAL AND IGNITION on p. 123
Performance of outboard at lower speeds appears normal	Fuel injector electrical circuit or control function	Check voltage at injectors, refer to SYSTEM ANALYSIS on p. 103
Performance of outboard at lower speeds appears normal	Restricted or leaking fuel injectors	Check injectors, refer to FUEL SYSTEM on p. 155
Performance of outboard at lower speeds appears normal	Low fuel pressure	Check circulation pump operation, refer to FUEL SYSTEM on p. 155
Performance of outboard at lower speeds appears normal	EMM programming, timing, or operation	Check EMM program and timing; check injector coefficient; and monitor injector circuits and ignition primary outputs
Performance of outboard at lower speeds appears normal	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	Check or replace fuel supply
May coincide with increased oil consumption (normal if occurs after winterization)	Excessive fuel or oil consumption	Check fuel system for fuel supply air leaks or leaking fuel injectors
May coincide with increased oil consumption (normal if occurs after winterization)	Outboard in break-in mode	Use diagnostic program to confirm
May coincide with increased oil consumption (normal if occurs after winterization)	Outboard mounted too low	Check installation height of outboard
May coincide with increased oil consumption (normal if occurs after winterization)	Vapor separator vent	Check vapor separator assembly for proper venting/float valve operation
May coincide with increased oil consumption (normal if occurs after winterization)	Faulty/leaking fuel injector(s)	Check injectors, refer to FUEL SYSTEM on p. 155
May coincide with increased oil consumption (normal if occurs after winterization)	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
May be erratic or inconsistent	Water in fuel system	Check water separator/fuel filter, sample fuel from fuel return manifold test port
May be erratic or inconsistent	Contaminated or poor fuel quality	Check and replace fuel supply
May be erratic or inconsistent	Low or erratic fuel pressure	Check pressure, refer to FUEL SYSTEM on p. 155
May be erratic or inconsistent	Air in fuel system	Check for air in fuel supply manifold, refer to FUEL SYSTEM on p.155 (vapor separator venting and fuel supply)
May be erratic or inconsistent	Fuel supply restricted	Check primer bulb, anti-siphon valve, and fuel pick-up, check for fuel system air leaks
May be erratic or	Restricted or leaking fuel injector (s)	Check injectors, refer to FUEL SYSTEM on p. 155
May be erratic or inconsistent	Faulty wiring, connections,grounds, or CPS air gap	Check all grounds, connections, and wiring. Check CPS air gap.
May be erratic or inconsistent	Low alternator output (55 V)	Check voltage on 55 V circuit, refer to SYSTEM ANALYSIS on p. 103 and ELECTRICAL AND IGNITION on p. 123
May be erratic or inconsistent	EMM program, timing, or operation	Check EMM program and timing; check injector coefficient; and monitor injector circuits and ignition primary outputs
May be erratic or inconsistent	Weak or erratic ignition operation	Check ignition, refer to SYSTEM ANALYSIS on p. 103 and ELECTRICAL AND IGNITION on p. 123
May be erratic or inconsistent	Capacitor or 55 V circuit wiring	Check capacitor and 55 V circuit (white/red), refer to SYSTEM ANALYSIS on p. 103 and ELECTRICAL AND IGNITION on p. 123
May be erratic or inconsistent	Restricted engine exhaust	Check and repair as needed
May be erratic or inconsistent	Internal powerhead damage	Check and repair as needed
Audible noise	Damaged gearcase	Inspect gearcase and lubricate