Service Manual 5009001_15-30 HP - AA-AE Oiling System [Oil Component Servicing]

To prevent accidental starting while servicing, twist and remove spark plug leads.

Oil distribution hoses are different lengths. DO NOT alter the length of any hoses. Oil Distribution Hose Length:

• Cylinder – 20 in. (508 mm)
• Crankcase – 10.5 in. (267 mm)

Removal

Release the hose by depressing the outer ring of the hose retaining mechanism.

1. Retainer mechanism
2. Hose support

Once hose is removed from the manifold, make sure hose support is in the end of the hose.

1. Hose support

Installation

Cut Replacement Oil Hose, P/N 778708, to the correct length. Insert hose support in manifold end of hose.

IMPORTANT: DO NOT insert distribution hoses into manifold without a hose support.

Be sure the hose is fully inserted into manifold. Insertion depth is 5/8 in. (16 mm). Visually inspect for hose supports.

Oil distribution hoses have specific locations and routing. DO NOT alter the location of any hoses.

The oil distribution manifold includes a built-in hose retainer. Route oil distribution hoses up through the retainer.

Install crankcase oil distribution hoses to the forward oil manifold ports.

Install cylinder #1 oil hose to the inner (closest to powerhead) oil manifold port.

Install cylinder #2 oil hose to the outer (furthest from powerhead) oil manifold port.

Loop the cylinder block oil distribution hose over the crankcase oil distribution hose and install to the rear oil manifold port.

Install cylinder #1 oil distribution hose to the inboard (closest to powerhead) oil manifold port.

Install cylinder #2 oil distribution hose to the out board (furthest from powerhead) oil manifold port.

1. Hose retainer
2. Oil distribution manifold
3. Crankcase oil supply hose
4. Cylinder block oil supply hose

1. Hose retainer
2. Oil distribution manifold
3. #1 Cylinder
4. #2 Cylinder
5. Crankcase
6. Cylinder block

Refer to OIL SUPPLY DIAGRAMS on p. 145.

Removal

Disconnect the battery cables at the battery.

Disconnect the electrical connector to the oil injection pump.

Disconnect the electrical connector to the low oil switch.

1. Oil pump connector
2. Low oil switch

IMPORTANT: Note oil distribution hose routings before proceeding with disassembly.

Remove oil distribution hoses from the manifold.

Remove oil tank retaining screw.

1. Screw

Installation

Align grommets with pins on powerhead. Install oil tank assembly on powerhead. Clean mounting screw and apply Nut Lock to threads. Install screws and tighten to a torque of 30 to 42 in. lbs. (3.5 to 5 N•m).

1. Grommets
2. Pins

Install protective sleeves and route oil distribution hoses from the oil distribution manifold to the crankcase and cylinder block oil delivery fittings. Refer to OIL SUPPLY DIAGRAMS on p. 145. Secure oil hoses to crankcase and cylinder block fittings with tie straps. On rope start models, install J-clamp to retain two crankcase oil supply hoses.

1. Tie strap
2. Clamp

Run outboard and check for leaks. Use Evinrude Diagnostics software to activate “Oil Prime.” Check oil flow through oil distribution hoses. Check oil system operation and routing of oil system hoses.

Repair any oil leaks and kinked or misrouted hoses. Install engine covers.

Removal

Remove oil distribution hoses from oil manifold. Refer to Oil Distribution Hoses on p. 156.

Remove oil from oil tank.

Remove oil tank. Refer to Oil Tank Assembly on p. 157. Remove retaining screw from oil pump assembly. Twist and pull up on oil pump to remove from tank.

1. Screw

Installation

IMPORTANT: Refer to table below for correct o-ring selection.

1. Oil tank part number location

Apply a drop of outboard lubricant to new oil pump o-ring(s). Install o-ring(s) on oil pump flange. Installation is the reverse of removal.

1. O-rings

Install oil pump retainer screw. Tighten securely.

IMPORTANT: Turn self-tapping screws counter clock-wise to start the threads and clockwise to tighten. Failure to follow this procedure can dam age the threads of the oil tank.