BOMBARDIER
BOMBARDIER RECREAT/ONAL PRODUCTS
Bombardier Motor Corporation of America
Technical PubIications
250 Sea Horse Drive
Waukegan , Illinois 60085 United States
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Evinrude @
Evinrude @
Evinrude @/ Johnson @ Formu/a
Evinrude @/ Johnson @ Formu/a
Evinrude @/ Johnson @ Formu/a
Evinrude @/ Johnson @Genuine Parts
Extreme Pressure Grease
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-
AII rights reserved Bombardier Motor Corporation of America its affiliates. 1
SAFETY INFORMATION
Before working part of the outboard, read the SAFETY section at the end of this manual.
This manual is written for qualified, factory-trained technicians who already familiar with the use of Bombardier Special Tools. This manual is not substitute for work experience . It is organized guide for reference , repair, and maintenance of the outboard(s) .
This manual uses the following signal words identifying important safety messages.
DANGER
Indicates imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
WARNING
Indicates potentially hazardous situation which, if not avoided, CAN result in severe injury or death .
CAUTION
Indicates potentially hazardous situation which, if not avoided, result in minor or moderate personal injury or property damage. It also used to alert against unsafe practices.
IMPORTANT: Identifies information that will help prevent damage to machinery and appears next to information that controls correct assembIy and operation of the product.
These safety alert signal words
It is understood that this manual translated into other languages. the event of disthe English version shall prevail .
reduce the risk of personal injury, safety review is provided at the beginning of each section
00 NOT do repairs until you have read the instructions and checked the pictures relating to the repairs.
careful, and never rush guess service cedure Human is caused factors : carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol use , to few . Oamage to boat and outboard 1ixed in short period 01 time, but injury death has lasting effect
When replacement parts required, use Evinrude @/Johnson @ Genuine Parts parts with equivalent characteristics, including type, strength and material Using substandard parts could result in injury product malfunction.
Torque wrench tightening specifications must strictly followed. Replace locking fastener (locknut patch screw) if its locking feature becomes weak . Oefinite resistance to turning must felt when reusing locking fastener If replacement is specified or required because the locking fastener has weak , use authorized Evinrude/Johnson Genuine Parts
If you use procedures service tools that not recommended in this manual , YOU ALONE must decide i1 your actions might injure people damage the outboard.
practices. If shop protect your-
ALERT! YOUR 8AFETY 18 INVOLVEO!
TABLE OF CONTENTS INTRODUCTION •••••••••.•.•••••••....•..•••••.••.•..••.•••.••••..••.••.••••.••.•... !> SPECIAL TOOLS AND SERVICE SPECIFICATIONS ..•.••.•. 1!> INSTALLATION AND PREDELIVERY ................................. 33 !>9 79 MAINTENANCE ELECTRICAL .................................................................... ....................................................................... IGNITION ............................................................................ MANUAL STARTER ........................................................... ................................................................... FUEL SYSTEM OILING SYSTEM POWERHEAD MIDSECTION GEARCASE TRIM AND TIL ................................................................ .................................................................... ...................................................................... ........................................................................ .................................................................. ............................................................................. 111 137 147 181 191 21!> 233 2!>9 S-1 SAFETY INDEX ......................................................................... Index-1 3
INTRODUCTION TABLE OF CONTENTS INTRODUCTION TABLE OF CONTENTS ARRANGEMENT OF THIS MANUAL ........................................•........... 6 MODELS COVERED IN THIS MANUAL 6 IDENTIFYING MODEL AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6 MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 MODEL LIST ....................................................................... 7 TYPICAL PAGE - 8 TYPICAL PAGE - 9 TYPICAL PAGE - 10 TYPICAL PAGE -D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11 ABBREVIATIONS USED IN THIS MANUAL .................•............................ 12 UNITS OF MEASUREMENT • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • .• 12 LIST OF ABBREVIATIONS •..••••••••••••••••.••••••••••••••••••••••••••••••••••••••• 12 PRODUCT REFERENCE AND ILLUSTRATIONS ...................................•...... 13 SYMBOLS ........................................................................ 13 ELECTRICAL • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •• 13 VALUES ••••.•.••••••••••••••••••••••••.••••••••••••••••••••••••••••••••••••.•• 14 5
ARRANGEMENT OF THIS MANUAL
This manual is divided into 15 major sections:
12.
WIRING DIAGRAMS
MODELS COVERED IN THIS MANUAL
This manual covers information for Johnson 2-cylinder, 45 cubic inch, (2S), 40 and 50 horsepower models.
IDENTIFYING MODEL AND SERIAL NUMBERS
Outboard model and serial numbers located the swivel bracket and the powerhead . "
OF THIS MANUAL
INTRODUCTION ARRANGEMENT
INTRODUCTION
SPECIAL TOOLS AND SERVICE SPECS 2. INSTALLATION AND PREDELIVERY
MAINTENANCE 4. ELECTRICAL 5. IGNITION 6. FUEL SYSTEM
OILING SYSTEM
POWERHEAD
MIDSECTION
GEARCASE
TRIM
1.
3.
7.
8.
9.
10.
11.
AND TILT
MANUAL STARTER
SAFETY
13.
001026 40/50 PL Model Powerhead 1 Seria ! 001027 1 001029
MODEL DESIGNATION
STYLE:
J = Johnson
LENGTH:
=15" Std. = Evinrude
L = 20 " Long \ I = 22 5 " Special
HORSEPOWER = 25 " X-Iong + /'
Z = 30 " XX-Iong
DESIGN FEATURES:
= Counter Rotation
= Evinrude
= Electric Start w/Remote Steering
F = Oirect Injection
G= Graphite Johnson / Evinrude
J = Jet
= Military
= Power Trim and Tilt
R = Rope Start Steering
S = Special Styling (paint color)
= Tiller Steering
W = Commercial Model
V = White Johnson / Evinrude
MODEL LIST
J40RSRS
J40RLSRS
J40PLSRS
J40MLSRC
J50PLSRS
YR: I = 1 N=2 = 3 R=4 0=5 0=6 U=7 =9 S = SR = 2004
INTRODUCTION MODEL DESIGNATION
J 50
t
L SR __ ___ J __
Number Start Shaft
Model
15 "
20 "
Electric 20 "
20 "
Electric 20 "
Steer Tiller Tiller Remote Tiller Remote MODEL RUN or SUFFIX 7
MODEL
TYPICAL PAGEGEARCASE SERVICE
,St=RVICE CHAR m
600 V4 20 /N. MODELS
lIalic subheading above Servic e Charl indic ale s pe rlaining mod els.
Subseclion lill e indicales beginning 01 Ih e subseclion.
Tr/p/e-Guard Grease
Gsskel Sesling Adhes/ve Sea/anl Mo/yLube Red U/lra Lock Nul Lock Sea Lube Bear/ng Lubr/canl
allenlion 10 lorque specificalions Some unils as in Ibs Us e appropriale lorqu e.
INTRODUCTION
TYPICAL PAGE -
24·36 'n /b s (2 7 - 4 ' 120· 74 4111 /' (13 6. 1 ($ 3 G lG- 28 Ft fbs I I I I 1 26·18FI (35·38 @- 100 11 0 Ft ( 136 '49 35 40 Fr Jb s U so GO.1'rc e th fO.cls m" s t (Jfld dry \ I / • j F 60·84 , ,, Ib s (6 8·9 5 Bold leller indicale s liquid prod uCllo appl ie d 10 surface
tl ..... 60 84 111 /b s. (ti 8· 9 5 Exploded view 01 Servic e Charl ass is l s in id enlifying
18 20 Ft Tighlening l orque fa sl ener (lA 1 '! l '. !! J) \ n , I 328 ( 12 2·14 9 Indi ca le s li sl co rr es ponding 10 ap pl icabIe lell e r in ex plod ed view 01 Ih e Se rvi ce Charl 1 '. "\1\, /)!
parls and posilions
D F G
Hose, and Wire Rou
Route all hoses, cabIes , and wiring sleeve conduit into the and the
Refer to the lollowing diagram to ensure positioning 01 rigging components in
INSTALLATIO.N AND PREDELIVERY
water pressure gauge is to used , install the water pressure hose litting in the cylinder bIock Use Pipe Sealant with (P/N 910048) the threads of the hose fitting Reler to installation instructions supplied with gauge
Route the water pressure hose with oil tank sending unit Route hose along cabIes toward the back 01 the powerhead Use tie straps to lasten in place
I1I temperature gauge is to used, route sending unit wire with hose water pressure gauge. Follow the path 01 cabIes adequate length 10 reach cylinder head Reler 10 installation instructions supplied with gauge
PAGES ec tion Title
TYPICAL
Fu e / supp/y hose 2. Oi/ hos e 3 Oi/ supp/y hose 4. Ba/tery cabIes 5 Ma in wire harn ess (MWS) 6 Thrott1e 7 Shift Oi/ tank sending unit h arn ess 9 Water press ure hose 10 Access ory charge wire Model specific illustrations designated with image caption s 000084 outboard main wire to m wire harness 1 Se a / INTRODUCTION TYPICAL PAGE -
1.
OUTBOARD RIGGING PROCEDURE
press ure fitting /oca tion : s tarboard side 0 1cy /in de rlc rankcas e asse mbIy. thro tt1e
47
9
TYPICAL PAGE -
POWERHEAD INSTALLATION
IMPORiANT: The molor mounl , wa sher, a nd screw as assembIy disassembIe.
Installation
Place mounl assembIies in posilion, wilh flals lacing away Irom each olher
proc edure concerning p a rticular m od el
Title indicates th e matex procedure specific to inner V4 Mod e ls is fini she d. Fro m thi s
Apply Extreme Pressure Grease 10 all sides 01 relainer and inslall belween mounls
Apply Nut Lock 10 relainer screw, inslall Ihe screw, and lorque 10 151020 ft Ibs (201027 N·m)
concerned ensure sealing, clean and Iree 01 oil , grease , and loreign matter
Ihe driveshaft splines wilh Lube apply lubricanl 10 end 01 driveshaft
INTRODUCTION TYPICAL
PAGE -
39820
23079
23497
TYPICAL PAGE -D
Two pulse hoses connecl Ihe pump 10 pulse lillings Ihe 01 Ihe cy lind er/ crankcase
• V4 Models - cylinders 1 and 3
• V6 Models - cy lind ers 1 and 4
tor-Manifold
lor-manilold dislribules Ihe oil supoil lift pump pressure-sensing swilch monilors oil inj eclio n pressure.
Oi I In jector-Ma nifold
Cross ref e rence s
• 40 V oil injeclor direc l rea de rs 10
• Oil dislribulion manilold r ela l ed lopic s
• Oil pressure swilch
• Pres s ur e regulalor (oil relurn ho se)
• Oil dislribulion hoses
• Oil 10 luel check valve
1
OILING SYSTEM COMPONENTS
Oil Pressure Switch
Th e oil pressure swilCh is localed in Ihe injeclor-manilold and reacls 10 changes in oil manilold pressure The supplies and monilors eleclricurrenl 10 Ihe swilch.
componenls numbered 10
The swilch opens correspond 10 oil manilold pressures : image
53 psi (365 kPa) (nominal) 10 close
43 psi (296 kPa) (nominal) 10 reopen
Refer 10 011 Pressure Switch 1est 224
Service Code faully eleclrical circuil an inoperalive pressure swilch aclivales service code 38 oil sensor feedback lack of oil pressure) and Ihe
Aclivales Ihe System Check "NO OIL" lighl l
I1 Slores service code Seclion labs a llow for Iniliales S L.O W. quicker reference when Ihumbing Service Code 39 Ihrough manual
If oil pressure is delecled during slartup, Ihe iniliales an oil injeclor "reco very mode " 10 pressurize Ihe syslem 1I inadequale oil pressure is still delecled after Ihe recovery mode is pleled, Ihe
Aclivales Ihe System Check "NO OIL " lighl Slores service code Iniliales S L O W.
TYPICAL 1 Oil injec /or 2. Oil dis /ribLl/io n manifold Oil dis /rib ulio n hoses 4. Oil /o c l Jeck valve 0007 22 INTRODUCTION TYPICAL
PAGE -D
209 11
ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL
Units 01 Measurement
List 01 Abbreviations
Amperes American Boat & Yacht Council
amp-hr hour after top dead center
fl.oz. fluid ounce
ft.lbs foot pounds
ATS air sensor
BPS barometric sensor
HP horsepower before top dead center
in. inch cold cranking amps
in. Hg inches of mercury
CPS crankshaft position sensor
in.lbs. inch pounds direct injection
kPa kilopascals
ECU electronic control unit
milliliter engine management module
millimeter
ICOMIA International Council of Marine
N·m Newton meter Industry Associations
P/N number marine cranking amps
psi pounds square inch
MWS modular wiring system revolutions minute
NTC negative coefficient degrees Celsius power distribution
°F degrees Fahrenheit positive temperature coefficient
ms milliseconds read only
IJs microseconds
.Q Ohms
V Volts
VAC Volts Alternating Current
S.A.F.E. speed adjusting failsafe electronics
SAC assist circuit
SAE Society of Automotive Engineers
SYNC synchronization
VDC Volts Direct top dead center
TPS position sensor
WOT wide throttle
WTS water sensor
INTRODUCTION
PRODUCT REFERENCE AND ILLUSTRATIONS
Bombardier Motor Corporation of America reserves the right to make changes at time, without notice, in specifications and models and also to discontinue models. The right is also reserved to change specifications parts, at time, without incurring obIigation to equip same models manufactured prior to date of such change. Specifications used based the latest product information availabIe at the time of pubIication.
The continuing accuracy of this manual cannot guaranteed.
AII photographs and illustrations used in this ual not depict actual models equipment, but intended as representative views for referonly.
Certain features systems discussed in this manual might not found all models in all areas.
AII service technicians must familiar with nautical orientation. This manual often identifies parts and procedures using these terms.
FORWARD
Nautical Orientation
SYMBOLS
Throughout this service manual, symbols used to interpret electrical troubIeshooting results to assign values in drawings.
Electrical
When "00" shows the meter face, continuity, very high resistance, is indicated. The symbol is referred to as infinity.
When "V" follows value the meter face, the procedure is measuring voltage.
INTRODUCTION PRODUCT REFERENCE AND ILLUSTRATIONS
13
follows value the meter face, the is Q is the symfor ohm , the of for resis-
Values precedes value the meter face , it shows must less equal to, the value
Q) CQ
precedes value the meter face, the must greater equal to, the value
Q) CQ
INTRODUCTION SYM80LS
DR4205
DR 42 06
DR4207
SPECIAL TOOLS AND SERVICE SPECIFICATIONS TA8LE OF CONTENTS
SERVICE SPECIFICATIONS TABLE OF CONTENTS SPECIAL TOOLS ....................................................................................................................................... 17 ELECTRICAL IIGNITION 17 FUEL 18 GEARCASE ........................................................................................................................................... 19 POWERHEAD 20 STARTER 21 UNIVERSAL 22 SHOP AIDS 24 TECHNICAL DAT 27 STANDARD TORQUE SPECIFICATIONS ................................................................................................ 29 FUEL REQUIREMENTS ............................................................................................................................. 30 MINIMUM OCTANE ................................................................................................................................. 30 ADDITIVES 30 OIL REQUIREMENTS 31 ENGINE LUBRICANT 31 PROPELLER SELECTION ........................................................................................................................ 31 PROCEDURE 32 NEW ENGINE PREDELIVERY CHECKS 32 15
SPECIAL TOOLS AND