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EVINRUDE E-TEC 115 HP 2011
BRP EVINRUDE E-TEC 115 HP 2011 User Manual
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Table of Contents
S M Ervice Anual Contents
4
Table of Contents
4
Table of Contents
5
Safety Notice
6
Abbreviations Used in this Manual
8
Units of Measurement
8
List of Abbreviations
8
Emission-Related Installation Instructions
9
Manufacturer's Responsibility
9
Dealer's Responsibility
9
Owner's Responsibility
9
Epa Emission Regulations
9
Model Designation
10
Models Covered in this Manual
11
Service Specifications
12
Standard Torque Specifications
14
Product Reference and Illustrations
14
Routine Service
15
Inspection and Maintenance Schedule
16
Lifting the Outboard
17
Outboard Rigging Connections
17
Control Cable Installation
19
Battery Cable Connections
21
Systemcheck Harness Connections
21
I-Command Network Connections
22
Icon Network Connections
24
Water Pressure Gauge
25
Battery and Battery Connections
26
Oetiker Clamp Servicing
27
Adjustments
29
Tilt Limit Switch Adjustment
29
Trim Sending Unit Adjustment
30
Trim Tab Adjustment
31
Dual-Outboard Alignment
32
Operational Checks
33
Cooling System
34
Engine Flushing
34
Running the Outboard Using a Hose and Flushing Adapter
35
Lubrication
36
Steering System
36
Tilt Tube
36
Propeller Shaft
37
Swivel Bracket and Trailering Bracket
37
Throttle and Shift Linkage
37
Gearcase Lubricant
38
Trim and Tilt
39
Indexing
40
Spark Plugs
40
Fuel and Oil Systems
41
Fuel Filter
41
Air Silencer
42
Hoses and Connections
42
Oil Filters and Oil Reservoir
42
Cleaning
43
Exhaust Pressure Fitting
43
Operation Test
43
Anti-Corrosion Protection
44
Storage
45
Pre-Season Service
47
Submerged Engines
48
Engine Cover Service
49
Latch Hook Installation
50
Upper Cover Cap Replacement
50
Upper Cover Service
50
Lower Cover Installation
51
Lower Cover Removal
51
Lower Cover Service
51
Latch Handle Installation
52
Trim Switch Installation
52
Engine Management Module (Emm)
53
Description
54
Emm Inputs and Outputs Diagram
55
55 V Circuit Sensor
56
Emm Temperature Sensor
56
Internal Sensors
56
Barometric Pressure Sensor
57
Circuit Sensor
57
Exhaust Pressure Sensor
57
Air Temperature Sensor
58
Engine Temperature Sensor
58
External Sensors
58
Oil Pressure Sensor
59
Throttle Position Sensor
59
Crankshaft Position Sensor
60
Neutral Switch (V4 Models)
60
Engine Monitor and Warning Systems
61
Exhaust Valve (V4 Models)
61
Fault Code Creation and Storage
61
Idle Controller
61
Internal Emm Functions
61
Rom Verification
61
Rpm Limiter
61
Start Assist Circuit (Sac)
61
Engine Monitor System
62
Shutdown Mode
63
Warning System
63
Communication
64
Diagnostic Software Functions
64
Static Information
64
Dynamic Information
65
Hard Faults
65
Persistent Faults
65
Static Tests
65
Stored Service Codes (Faults)
65
Dynamic Tests
66
Oil Control Settings
67
Tiller/Remote Programming
67
Fuel Injector Servicing
68
Ignition Timing
68
Tps Calibration
68
Reports
69
Software Replacement
69
Emm Servicing
70
Emm Transfer
70
System Analysis
73
Diagnostic Procedures
74
Operational Inspections
74
Visual Inspections
74
Troubleshooting
75
Cylinder Drop Tests
76
Dynamic Tests
76
Fuel Control Adjustment
76
Inductive Amp Meter Test
76
Emm Led Indicators
77
Key on
77
Starting
77
Running
78
Ignition Output Tests
79
Required Ignition Systems
79
Wiring Inspection
79
Crankshaft Position Sensor (Cps) Test
80
System Voltage Test
80
Static Ignition Test
81
Running Ignition Tests
82
Capacitor Test
83
Ignition Coil Tests
83
Ignition Control Circuit Tests
83
Fuel Delivery Tests
84
Fuel Injector Static Test
84
Fuel Pump Static Test
84
Running Fuel System Tests
85
Exhaust Valve (V4 Models)
86
Exhaust Valve Static Test
86
Electrical and Ignition
87
Service Chart
88
Ignition System Circuit Diagrams
90
Electrical Harness Connections
92
Fuse
94
Ground Circuits
94
Crankshaft Position Sensor (Cps) Test
95
Sensor Tests
95
Throttle Position Sensor (Tps) Test
95
Air Temperature Sensor (At) Test
96
Engine Temperature Sensor Test
96
Stator Resistance Tests
97
Stator Tests
97
Stator Voltage Output Test
97
12 V Charging Circuit
98
Charging System Tests
98
55 V Alternator Circuit
99
Auxiliary Battery Charge Wire
99
Electric Start Circuit
100
Electric Start Tests
102
Remote Control Switch Tests
104
Tilt/Trim Relay Test
106
Exhaust Valve Relay Tests
107
Systemcheck Circuit Tests
109
Tachometer Circuit Tests
111
Flywheel and Stator Servicing
112
Flywheel Removal
112
Flywheel Installation
113
Stator Service
113
Ignition Coil Installation
115
Ignition Coil Removal
115
Ignition Coil Servicing
115
Timing Adjustments
116
Timing Pointer
116
Timing Verification
117
Electric Starter Servicing
118
Starter Removal
118
Tps Calibration
118
Starter Disassembly
119
Starter Cleaning and Inspection
121
Starter Assembly
122
Connector Servicing
125
Starter Installation
125
Fuel System
131
Service Chart
132
Fuel System Hose Routing
135
Fuel System Circuit Diagram - V4
136
Fuel System Circuit Diagram - V6
137
Fuel Flow Requirements
138
Fuel System Requirements
138
Portable Fuel Tanks
138
Regulations and Guidelines
138
Fuel Requirements
139
Components
140
Fuel Filter
140
Fuel Lift Pump
140
Vapor Separator
140
Fuel Circulation Pump
141
Fuel Injectors
142
Fuel Manifolds
142
Fuel System Priming
143
Priming the Fuel System
143
Vent Line Clamp
143
Fuel System Pressure Test
144
Fuel System Tests
144
Fuel Injector Pressure Test
145
Pressure Regulator Test
145
Vapor Separator Vent Check
145
Circulation Pump Resistance Test
146
Fuel Injector Resistance Test
146
Lift Pump Pressure Test
146
Lift Pump Diaphragm Test
147
Lift Pump Vacuum Test
147
Anti-Siphon Valve Test
148
Fuel Component Servicing
148
Relieving Fuel System Pressure
148
Fuel Filter Service
149
Fuel Lift Pump Service
150
Vapor Separator Service
150
Fuel Manifold Service
151
Fuel Injector Service
152
Intake Manifold Service
155
Oiling System
159
Service Chart
160
Oiling System Circuit Diagram
161
Oil Supply Diagrams - V4
162
Oil Supply Diagrams - V6
164
Oil Recirculation Diagrams - V4
166
Oil Recirculation Diagrams - V6
168
Components
170
Oil System Requirements
170
Oil Tank Assembly
170
Recommended Lubricants
170
Oil Injection Pump
171
Oil Pressure Sensor
171
Rear Oil Manifold
171
Cylinder and Crankcase
172
Electrical Circuit (55 V)
172
Low Oil Warning
172
NO OIL Warning
172
Oil Recirculation System
173
Oil Control Settings
174
Oil Injection Rate
174
Break-In Oiling
175
Oil Supply Priming
175
Oil Injection Pump Static Test
177
Oil Injection Pump Voltage Tests
177
Oiling System Tests
177
Oil Injection Pump Circuit Resistance Test
178
Oil Supply Vacuum Test
179
Low Oil Sending Unit Test
180
Oil Injection Fittings Flow Test
180
Oil Injection Pump Function Test
180
Oil Component Servicing
181
Oil Distribution Hoses
181
Oil Injection Pump
182
Cooling System
185
Hose Routing and Water Flow Diagrams
186
Adapter/Inner Exhaust Housing
188
Components
188
Water Pump and Intakes
188
Water Supply Tube
188
Block Venting
189
Pressure Relief Valve
189
Thermostats
189
Cylinder Block / Cylinder Head Cooling
190
Emm and Vapor Separator Cooling
190
Operation
190
Engine Temperature Check
191
Pyrometer Method
191
Software Method
191
Idle Operating Temperature Troubleshooting (below Range)
192
Disassembly
193
Installation
193
Removal
193
Temperature Sender Servicing
193
Thermostat Servicing
193
Assembly
194
Disassembly
194
Inspection
194
Pressure Relief Valve Servicing
194
Powerhead
195
Service Chart
196
Compression Testing
198
Powerhead Removal
198
Powerhead Disassembly
200
Systems Removal
200
Crankcase Disassembly
201
Shift Linkage Removal
201
Throttle Linkage Removal
201
Connecting Rods and Pistons
202
Cylinder Head Removal
202
Crankshaft Removal
203
Cylinder Block Cleaning
206
Powerhead Inspection
207
Crankshaft Assembly
209
Powerhead Assembly
209
Pistons and Connecting Rods
211
Cylinder Head Installation
213
Crankshaft and Connecting Rods
214
Crankcase Assembly
217
Shift Linkage Installation
218
Final Powerhead Assembly
219
Throttle Linkage Installation
219
Upper Mount Servicing
220
Powerhead Installation
221
Powerhead Views
225
V4 Port - Hose Routings
225
V4 Starboard - Hose Routings
225
V4 Port
226
V4 Starboard
226
V4 Front
227
V4 Rear
228
V4 - V6 Top - Hose Routings
229
V4 - V6 Top
230
V6 Starboard - Hose Routings
231
V6 Port - Hose Routings
232
V6 Starboard
233
V6 Port
234
V6 Front
235
V6 Rear
236
Midsection
237
Service Chart
238
Removal
242
Tilt Tube
242
Installation
243
Exhaust Housing Removal
244
Exhaust Housing Service
244
Lower Mount Service
244
Exhaust Housing Installation
245
Exhaust Housing Disassembly - V4 Models
246
Exhaust Housing Disassembly - V6 Models
246
Cleaning and Inspection
247
Exhaust Housing Assembly - V6 Models
247
Exhaust Housing Assembly - V4 Models
248
Extension Service - V4 Models
250
Installation
250
Removal
250
Stern Bracket
250
Stern Bracket Disassembly
250
Stern Bracket Assembly
253
Exhaust Relief Muffler Assembly
256
Gearcase
257
Service Charts
259
Gearcase Types
265
Propeller Service
267
Gearcase Leak Test
269
Gearcase Removal and Installation
270
Assembly
273
Disassembly
273
Inspection
273
Water Pump Service
273
Shift Rod Adjustment
276
Gearcase - Standard Rotation
277
Gearcase Disassembly
277
Pre-Disassembly Inspection
277
Propeller Shaft Bearing Housing Removal - "S2" and "O" Type
278
Propeller Shaft Bearing Housing Removal - "L2" and "M2" Type
279
Pinion Gear and Driveshaft Removal - "S2" Type
280
Pinion Gear and Driveshaft Removal - "O", "L2", and "M2" Type
283
Driveshaft Service
284
Shift Housing, Gear and Propeller Shaft Removal
285
Water Intake Screens
285
Gearcase Housing Inspection
286
Pinion Bearing Installation
287
Pinion Bearing Removal
287
Shifter, Bearing and Seal Service
287
Shift Housing Disassembly
288
Shift Housing Assembly
290
Driveshaft Bearing Housing Service
292
Propeller Shaft Bearing Housing Service
293
Driveshaft Shimming
295
Gearcase Assembly
297
Shift Housing, Gear, and Propeller Shaft Installation
297
Water Intake Screens
297
Shift Rod Housing Installation
298
Pinion Gear and Driveshaft Installation - "S2" Type
299
Pinion Gear and Driveshaft Installation - "O", "L2", and "M2" Type
303
Propeller Shaft Bearing Housing and Gear Installation - "S2" and "O" Type
304
Propeller Shaft Bearing Housing and Gear Installation - "L2" Type
305
Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
307
Final Assembly and Adjustment
308
Gearcase Disassembly
309
Pre-Disassembly Inspection
309
Propeller Shaft Bearing Housing Removal - "M2" Type
309
Propeller Shaft Bearing Housing Removal - "O" Type
309
Pinion Gear Removal and Driveshaft Servicing
310
Gearcase Housing Inspection
311
Shift Housing, Gear and Propeller Shaft Removal
311
Water Intake Screens
311
Shift Housing Disassembly
312
Shifter, Bearing and Seal Servicing
312
Shift Housing Assembly
313
Pinion Bearing
315
Propeller Shaft Bearing Housing and Forward Gear - "O" Type
315
Propeller Shaft Bearing Housing and Forward Gear - "M2" Type
319
Driveshaft Shimming
322
Gearcase Assembly
323
Shift Housing, Gear, and Propeller Shaft Installation
323
Water Intake Screens
323
Pinion Gear and Driveshaft Installation
324
Propeller Shaft Bearing Housing and Gear Installation - "O" Type
324
Shift Rod Cover
324
Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
325
Final Assembly and Adjustment
326
Trim and Tilt
327
Service Chart
328
System Description
330
Modes of Operation (Three Piston System)
331
General
337
Manual Release Valve
337
Reservoir Fluid
337
Routine Inspections
337
Single Piston System
337
Stern Brackets
337
Troubleshooting
337
Three Piston System
338
Electrical Circuit Tests
341
Relay Testing
341
Trim and Tilt Motor Current Draw Tests
341
Trim and Tilt Motor no Load Test
342
Trim Gauge Test
343
Removal
344
Trim and Tilt Replacement
344
Trim Sender Test
344
Installation
346
Disassembly
347
Servicing-Single Piston System
347
Assembly
348
Disassembly
349
Servicing - Three Piston System
349
Tilt Piston Removal
352
Tilt Piston Assembly
353
Tilt Piston Identification
353
Tilt Rod Assembly
354
Trim Rod Removal
355
Trim Rod Assembly
356
Manifold and Reservoir Installation
357
Trim Rod Installation
358
Motor Installation
359
Tilt Rod Installation
359
Safety
363
Marine Products and the Safety of People Who Use Them
365
Outboard Shift Systems and Safety
366
Outboard Speed Control System and Safety
367
Outboard Steering Control System and Safety
368
Outboard Fuel, Electrical System, and Safety
370
Outboard Mounting System and Safety
373
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
375
Outboard Emergency Stop System and Safety
376
Summing up
378
Handling Outboards
379
Marine Products and the Safety of People Who Fix Them
379
Handling Lead/Acid Batteries
383
Gasoline - Handle with Care
384
Hazardous Products
385
Safety Awareness Test
386
4
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BRP EVINRUDE E-TEC 115 HP 2011 Specifications
General
Brand
BRP
Model
EVINRUDE E-TEC 115 HP 2011
Category
Outboard Motor
Language
English
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