POWERHEAD REPLACEMENT KIT INSTALLATION INSTRUCTIONS

Transcription

1 APPLICATION POWERHEAD REPLACEMENT KIT INSTALLATION INSTRUCTIONS Use this instruction sheet when installing powerhead replacement kits on Evinrude E-TEC 60 V outboards, 5 00 Hp. DO NOT install on any other models. SAFETY INFORMATION For safety reasons, this kit should be installed by an authorized Evinrude /Johnson dealer. This instruction sheet is not a substitute for work experience. Additional helpful information may be found in other service literature for your engine. This instruction sheet uses the following signal words identifying important safety messages. DANGER Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING Indicates a potentially hazardous situation which, if not avoided, CAN result in severe injury or death. CAUTION Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate personal injury or property damage. It also may be used to alert against unsafe practices. IMPORTANT: Identifies information that will help prevent damage to machinery and appears next to information that controls correct assembly and operation of the product. These safety alert signal words mean: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so to protect yourself, as well as the people around you. It is understood that this instruction sheet may be translated into other languages. In the event of any discrepancy, the English version shall prevail. DO NOT do any repairs until you have read the instructions and checked the pictures relating to the repairs. Be careful, and never rush or guess a service procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol use, to name a few. Damage to a boat and outboard can be fixed in a short period of time, but injury or death has a lasting effect. When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Using substandard parts could result in injury or product malfunction. Torque wrench tightening specifications must be strictly followed. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts. If you use procedures or service tools that are not recommended in this instruction sheet, YOU ALONE must decide if your actions might injure people or damage the outboard. Printed in the United States. 006 BRP US Inc. All rights reserved. TM, Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates. *353030* DSS0677I of 8

2 POWERHEAD REPLACEMENT KIT (Evinrude E-TEC 60 V 5 00 HP) P/N Name of Part Qty P/N Name of Part Qty - POWERHEAD ASSEMBLY CLAMP, 4.0 mm -muffler grommets GASKET, C/C to exhaust housing - V TIE STRAP, Overboard indicator hose GASKET, C/C to exhaust housing - V6 to vapor separator of 8

3 REQUIRED TOOLS IMPORTANT: Alignment Pin Kit, P/N , must be used when installing a powerhead on any Evinrude E-TEC 60 V model outboard. Remove lower engine cover screws and port and starboard covers.. Lower cover screws Alignment pin tools Remove flywheel cover and rear shroud. REMOVAL WARNING Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Service Manual. To prevent accidental starting while servicing, disconnect the battery cables at the battery. Disconnect the power trim/tilt switch connector Remove air temperature sensor from air silencer. Remove the air silencer of 8

4 Remove screw and washer from shift rod lever to release the lower shift rod. V4 MODELS Disconnect electrical harness from exhaust valve actuator. It is not necessary to remove actuator from exhaust housing.. Shift rod screw Disconnect power trim connectors.. Actuator connector ALL MODELS Disconnect water overflow hose from vapor separator. Remove clamps and muffler assembly from rear of powerhead.. Tilt limit switch connector. Sending unit connector Overflow indicator hose. Muffler clamps Remove the four small powerhead screws, seven large powerhead screws, and the upper mount screws. 3. Tilt relay connector Large powerhead screws. Small powerhead screws 3. Upper mount screws of 8

5 Install Lifting Tool, P/N 3467, on crankshaft. Tighten mounting screw securely using an Allen /4 in. hexagonal wrench. Attach suitable chain hoist to lifting tool. INSTALLATION Apply Permatex No. to both sides of a new base gasket around the exhaust ports only. Install gasket on adapter. To ensure proper sealing, mating surfaces must be clean With weight of powerhead supported by hoist, use a suitable tool to carefully separate the powerhead from exhaust housing. IMPORTANT: Do not damage the powerhead adapter mating surfaces when separating. Remove the powerhead.. Permatex No IMPORTANT: V4 and V6 base gaskets are NOT interchangeable. Be sure to use the correct part. Coat the driveshaft splines with Moly Lube. Do not apply lubricant to end of driveshaft. Use Lifting Tool, P/N 3467, and hoist to slowly lower powerhead onto exhaust housing. If necessary, rotate flywheel in a clockwise direction to align crankshaft and driveshaft splines of 8

6 Install pins from Alignment Pin Kit, P/N , as shown. Tighten pins until fully seated. Torque the large powerhead screws through 4 to 0 to ft. lbs (7 to 30 N m). Remove Alignment Pins and torque screws 5 through 7 to 0 to ft. lbs (7 to 30 N m). Torque the four small powerhead screws to 60 to 84 in. lbs. (7 to 9.5 N m). Torque upper mount screws to 0 to 30 ft. lbs. (49 to 76 N m). Confirm that screw heads are tight against steering arm. C D Alignment Pin here A 5 B Alignment Pin here 7 Large screw torque sequence, 7 Small screw torque sequence, A D Apply Triple-Guard grease to the threads, and Gasket Sealing Compound to the shank of the powerhead screws. Apply Triple-Guard grease to upper mount screw threads. With alignment pins in place, loosely install remaining powerhead screws and upper mount screws. IMPORTANT: Retorque powerhead mounting screws after outboard has been run at full operating temperature. Position the shift rod in the shift rod lever. Install the retaining screw and washer. Torque screw to 60 to 84 in. lbs. (7 to 9.5 N m) Shift rod screw IMPORTANT: Confirm that gearcase shifts solidly into both forward and reverse and that propeller shaft spins freely in neutral.. Large powerhead screws. Small powerhead screws 3. Upper mount screws 4. Alignment pin tool of 8

7 V4 MODELS Apply Electrical Grease to exhaust valve actuator electrical connector and install on actuator. Install air silencer and air temperature sensor. IMPORTANT: Leave enough slack in harness so that lower cover will not pull it away from actuator Install rear shroud and flywheel cover.. Actuator connector ALL MODELS Connect the power trim connectors Install the lower engine covers and tighten the screws.. Tilt limit switch connector. Sending unit connector Lower cover screws Tilt relay connector of 8

8 Connect trim/tilt switch connector IMPORTANT: Perform the following procedures before returning outboard to service. Refer to Service Manual: Use the Evinrude Diagnostics Software program to make sure powerhead break-in has been started. Prime fuel system. Prime oiling system. Check timing pointer and engine timing. Calibrate throttle position sensor (TPS). 8 of 8