2012 Evinrude 40/50/60/65/75/90 HP Service Manual

Printed in the United States. © 2011 BRP US Inc. All rights reserved. TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates. BRP US Inc. Technical Publications P.O. Box 597 Sturtevant, Wisconsin 53177 United States www.evinrude.com or www.johnson.com † AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II are registered trademarks of Tyco International, Ltd. † Amphenol is a registered trademark of The Amphenol Corporation. † BEP is a registered trademark of Actuant Corporation. † Champion is a registered trademark of Federal-Mogul Corporation. † Deutsch is a registered trademark of The Deutsch Company. † Dexron is a registered trademark of The General Motors Corporation. † Fluke is a registered trademark of The Fluke Corporation † GE is a registered trademark of The General Electric Company. † GM is a registered trademark of The General Motors Corporation. † Locquic and Loctite are registered trademarks of The Henkel Group. † Lubriplate is a registered trademark of Fiske Brothers Refining Company. † NMEA is a registered trademark of the National Marine Electronics Association. † Oetiker is a registered trademark of Hans Oetiker AG Maschinen. † Packard is a registered trademark of Delphi Automotive Systems. † Permatex is a registered trademark of Permatex. † STP is a registered trademark of STP Products Company. † Snap-on is a registered trademark of Snap-on Technologies, Inc. The following trademarks are the property of BRP US Inc. or its affiliates: Evinrude ® Twist Grip™ Johnson ® Nut Lock™ Evinrude ® E-TEC ® Screw Lock™ FasTrak™ Ultra Lock™ S.A.F.E.™ Moly Lube™ SystemCheck™ Triple-Guard ® Grease I-Command™ DPL™ Lubricant Evinrude ® ICON™ 2+4 ® Fuel Conditioner Evinrude ® / Johnson ® XD30™ Outboard Oil Carbon Guard™ Evinrude ® / Johnson ® XD50™ Outboard Oil HPF XR™ Gearcase Lubricant Evinrude ® / Johnson ® XD100™ Outboard Oil HPF PRO™ Gearcase Lubricant Gel-Seal II™

2 SERVICE MANUAL CONTENTS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 1 REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 2 ROUTINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3 ENGINE COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . 49 4 ENGINE MANAGEMENT MODULE (EMM) . . . . . . . . . . 53 5 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 6 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . . 87 7 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 8 OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 9 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 10 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 11 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 12 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 GEARCASE SERVICE, 40 – 65 HP MODELS . . . . . . . 296 GEARCASE SERVICE, 75 – 90 HP MODELS . . . . . . . 318 13 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 14 MANUAL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–1 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I–1 TROUBLE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . T–1 DIAGRAMS IMPORTANT: For complete outboard rigging and control installation information, refer to the Predeliv- ery and Installation Guide included with the service manual set. All special tools referenced in this manual can be found in the Special Tools Guide, P/N 5008526.

REFERENCE INFORMATION 3 1 REFERENCE INFORMATION TABLE OF CONTENTS SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 EMISSION-RELATED INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 MANUFACTURER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DEALER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 OWNER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 EPA EMISSION REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

REFERENCE INFORMATION SAFETY NOTICE SAFETY NOTICE Before working on any part of the outboard, read the SAFETY section at the end of this manual. This pu blication is written fo r qualified, facto ry- trained technicia ns who ar e alrea dy familiar with the use of Evinrude/Johnson Special Tools. The included in formation is not a substitu te for wo rk experience. It is an organized guide for reference, repair, and/or maintenance. The following symbols and/or signal words may be used in this document: Indicates an instruction which, if not followed, could severely damage engine components or other property. These safety alert signal words mean: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! IMPORTANT: Identifies information that controls correct assembly and operation of the product. DO NOT perform any work unt il yo u have read and understood these instructions completely. Torque wre nch tig htening specifications must strictly be adhered to. Should removal of any locking fastener (lock tabs, locknuts, or p atch screws) be requ ired, a lways replace with a new one. When repla cement p arts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and mate rial. Use of subst andard p arts could result in injury or product malfunction. Always wear EYE PROTECTION AND APPRO- PRIATE GLOVES when using power tools. Unless othe rwise spe cified, engine must be OFF when performing this work. Always be aware of p arts that can move, such as flywheels, propellers, etc. Some components may be HOT. Always wait for engine to cool down before performing work. If you use procedures or service tools that are not recommended in th is manual, YOU ALONE must decide if your actions might injure peo ple or dam- age the outboard. This document ma y be tra nslated into othe r la n- guages. In the event of any discrepancy, the Eng- lish version shall prevail. A DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. A WARNING Indicates a hazardous situation which, if not avoided, could result in death or seri- ous injury A CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or mod- erate personal injury. NOTICE

REFERENCE INFORMATION SAFETY NOTICE 1 A DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off. Remove propeller before ser- vicing and when running the outboard on a flushing device. DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death. A WARNING Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa). The motor cover and flywheel cover are machinery guards. Use caution when conducting tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and clothing away from rotating parts. During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service. To prevent accidental starting while servicing, disconnect the battery cables at the battery. Twist and remove all spark plug leads. The electrical system presents a serious shock hazard. DO NOT handle primary or secondary ignition components while outboard is running or flywheel is turning. Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system. Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling. Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and causing an explosion. Always work in a well ventilated area. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to tightening must be felt when reusing a locking fastener. If replacement is indicated, use only authorized replacement or equivalent.

6 REFERENCE INFORMATION ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Units of Measurement List of Abbreviations A Amperes amp-hr Ampere hour fl. oz. fluid ounce ft. lbs. foot pounds HP horsepower in. inch in. Hg inches of mercury in. lbs. inch pounds kPa kilopascals ml milliliter mm millimeter N·m Newton meter P/N part number psi pounds per square inch RPM revolutions per minute °C degrees Celsius °F degrees Fahrenheit ms milliseconds µs microseconds Ω Ohms V Volts VAC Volts Alternating Current VDC Volts Direct Current ABYC American Boat & Yacht Council ATDC after top dead center AT air temperature sensor BPS barometric pressure sensor BTDC before top dead center CCA cold cranking amps CFR Code of Federal Regulations CPS crankshaft position sensor EMM Engine Management Module EPA Environmental Protection Agency ICOMIA International Council of Marine Industry Associations ID Inside dimension MCA marine cranking amps MWS modular wiring system NMEA National Marine Electronics Assoc. ROM read only memory S.A.F.E. speed adjusting failsafe electronics SAC start assist circuit SAE Society of Automotive Engineers SYNC synchronization TDC top dead center TPS throttle position sensor USCG United States Coast Guard WOT wide open throttle WTS water temperature sensor

7 REFERENCE INFORMATION EMISSION-RELATED INSTALLATION INSTRUCTIONS 1 EMISSION-RELATED INSTALLATION INSTRUCTIONS Failing to follow these instructions when installing a certified engine in a vessel violates federal law (40 CFR 1068.105 (b)), subject to fines or other penalties as described in the Clean Air Act. Maintenance, replacement, or rep air of the emis- sion control de vices and systems ma y be per- formed by any ma rine SI (sp ark ig nition) engine repair establishment or individual. Manufacturer’s Responsibility Beginning with 1 999 model year o utboards, man- ufacturers o f ma rine outboards must de termine the exha ust emissio n levels for each outbo ard horsepower family and certif y the se o utboards with the Unite d States of America Environmental Protection Age ncy (EP A). An emissions control information labe l, showing emission leve ls a nd outboard specifications, mu st be placed o n each outboard at the time of manufacture. Dealer’s Responsibility When pe rforming service on all 1 999 a nd more recent Evinrude/Johnson outboa rds tha t carry an emissions control information la bel, adjustments must be kept with in pub lished factory specifica- tions. Replacement or repair of any emission rela ted component must b e exe cuted in a manne r that maintains emission levels within the prescrib ed certification standards. Dealers are not to mo dify the outbo ard in an y manner th at wo uld alter the horsepower or allow emission levels to excee d their predete rmined factory specifications. Exceptions include manu facturer’s prescrib ed changes, such as altitude ad justments, for exa m- ple. Owner’s Responsibility The owner/operator is required to have outboa rd maintenance performed to maintain emission lev- els within prescribed certification standards. The owner/operator is not to, and should not allow anyone to, modify the outboard in any manner that wo uld a lter th e horsepower or a llow e mis- sions levels to exceed their predetermined factory specifications. Tampering with the fuel system to change horse- power or mo dify emission levels beyond fa ctory settings or specifications will void the product war- ranty. EPA Emission Regulations All new 19 99 an d more recent Evinrude/Johnson outboards are certified to the EPA as confo rming to the requirements of the regulations for the con- trol of air pollutio n from new watercraf t marine spark ignition outboards. This certification is con- tingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followe d and, whe never pra ctical, ret urned to the original intent of the design. The responsibilities liste d above are gen eral and in no way a comple te list- ing of the r ules and reg ulations pert aining to th e EPA re quirements on e xhaust emissions for marine products. For more detailed information on this subject, you may cont act th e fo llowing loca- tions: VIA U.S. POSTAL SERVICE: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 401 M St. NW Washington, DC 20460 VIA EXPRESS or COURIER MAIL: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 501 3rd St. NW Washington, DC 20001 EPA INTERNET WEB SITE: www.epa.gov

8 REFERENCE INFORMATION MODEL DESIGNATION MODEL DESIGNATION Model and serial numbers are located on the swivel bracket and on the powerhead. B E 200 DP X IN E STYLE: J = Johnson E = Evinrude HORSEPOWER LENGTH: = 15” Std. L = 20” Long Y = 22.5” Special X = 25” X-long Z = 30” XX-long MODEL YR: I= 1 N = 2 T = 3 R = 4 O = 5 D = 6 U = 7 C = 8 E = 9 S = 0 Ex: IN = 2012 MODEL RUN or SUFFIX DESIGN FEATURES: B = Blue Paint C = Counter Rotation D = Evinrude E-TEC ® E = Electric Start w/Remote Steering F = Direct-Injection G = Graphite Paint H = High Output J = Jet Drive M = Military P = Power Trim and Tilt R = Rope Start w/Tiller Steering S = Saltwater Approved T = Tiller Steering TE = Tiller Electric V = White Paint W = Commercial Model PREFIX: B = Bodensee model D = ICON model 1. Model and serial number 002224 1 1. Serial number 002225 1