2008 Evinrude E-TEC 55MFE Technical Manual
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- 2008 Evinrude E TEC 55MFE
Certified Service and Repair manual of the highest original quality with hundreds of high-quality images, diagrams and detailed description for service, repair and maintenance procedures.
This manual covers service information on all 2-cylinder, 52.7 cubic inch, Evinrude E-TEC MFE 55 models.
Manual is searchable and deeply indexed for easy access to information.
| Model Number | Start | Shaft | Drive |
| E55MRL*** | Rope | 20-inch | Propeller |
| E55MJRL*** | Rope | 20-inch | Jet Pump |
Manual chapters:
- INTRODUCTION
- SERVICE TOOLS and SHOP AIDS
- INSTALLATION AND PREDELIVERY
- OPERATION
- MAINTENANCE
- ENGINE COVER SERVICE
- ENGINE MANAGEMENT MODULE (EMM)
- SYSTEM ANALYSIS
- ELECTRICAL AND IGNITION
- FUEL SYSTEM
- OILING SYSTEM
- COOLING SYSTEM
- POWERHEAD
- MIDSECTION
- GEARCASE
- MANUAL STARTER
- TROUBLE CHECK CHART
- SERVICE PARTS
- INDEX
- DIAGRAMS
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Full list of manual chapters:
INTRODUCTION
MODEL DESIGNATION
MODELS COVERED IN THIS MANUAL
Identifying Model and Serial Numbers
SERVICE SPECIFICATIONS
ABBREVIATIONS USED IN THIS MANUAL
Units of Measurement
List of Abbreviations
STANDARD TORQUE SPECIFICATIONS
PRODUCT REFERENCES
NOTES
Technician's Notes
Related Documents
SERVICE TOOLS and SHOP AIDS
DIAGNOSTIC TOOLS
UNIVERSAL TOOLS
ELECTRICAL / IGNITION TOOLS
FUEL /OIL SYSTEM TOOLS
POWERHEAD TOOLS
GEARCASE TOOLS
MANUAL STARTER TOOLS
SHOP AIDS
NOTES
Technician's Notes
Related Documents
INSTALLATION AND PREDELIVERY
BOAT RIGGING
Battery Installation
Battery Switches and Multiple Batteries
Battery and Switch Wiring Diagrams
Fuel System Requirements
OUTBOARD INSTALLATION
Hull Preparation
Transom Measuring and Drilling
Drilling Diagram
Lifting the Outboard
Outboard Mounting
Tiller Handle Attachment
FUEL AND OIL PRIMING
Fuel Requirements
Fuel System Priming
Oil Requirements
Oil Injection Rate
Break-In Oiling
Oil Supply Priming
BEFORE START-UP
Gearcase Lubricant
Oil Level
RUNNING CHECKS
Fuel System
Emergency Stop Switch
Control Operation
Start-In-Gear Prevention
Water Pump Overboard Indicator
Operating Temperature
Idle Speed
Break-In
PROPELLERS
Propeller Selection
Propeller Hardware Installation
FINAL ADJUSTMENTS
Trim Tab Adjustment
NOTES
Technician's Notes
Related Documents
OPERATION
STARTING THE ENGINE
Fuel Requirements
Oil Requirements
Fuel Selector Switch
Starting Procedure
Stopping the Engine
SHIFTING AND SPEED CONTROL
Speed Control
MANUAL TILT
Tilt UP
Tilt DOWN
Tilt Support
Trailering
MOTOR ANGLE ADJUSTMENT
DE-WATER PROCEDURE
Post-Submersion Servicing
Prolonged Submersion
SPECIAL OPERATING CONDITIONS
Sea Water
Weedy Water
Freezing Weather
MAINTENANCE
INSPECTION AND MAINTENANCE SCHEDULE
ANTI-CORROSION PROTECTION
Sacrificial Anodes
Testing Procedure - Continuity
Metallic Component Protection
Exterior Finishes
COOLING SYSTEM
Flushing
Water Intake Screens
Additional Maintenance
LUBRICATION
Swivel Bracket and Trailering Bracket
Tilt Tube
Throttle and Shift Linkage
Propeller Shaft
Gearcase Lubricant
FUEL AND OIL SYSTEMS
Fuel Filter
Oil Reservoir
Hoses and Connections
Air Silencer
SPARK PLUGS
Removal
Indexing
STORAGE
Fuel System Treatment (gasoline only)
Internal Engine Treatment
Additional Recommendations
PRE-SEASON SERVICE
Outboard Mounting Bolts
Gearcase Lubricant
Operational Checks
SUBMERGED ENGINES
Engine Dropped Overboard (Not Running)
Engine Dropped Overboard (Running)
Engine Dropped Overboard (In Salt Water)
Prolonged Submersion (Fresh or Salt Water)
ENGINE COVER SERVICE
UPPER COVER SERVICE
Latch Hook Installation
Tilt Assist Strap
LOWER COVER SERVICE
Lower Cover Removal
Lower Cover Installation
Latch Handle Installation
Fuel Selector Switch Installation
De-Water Valve Service
ENGINE MANAGEMENT MODULE (EMM)
DESCRIPTION
EMM Functions
EMM Connections
LED Indicators
EMM INPUTS AND OUTPUTS DIAGRAM
INTERNAL SENSORS
EMM Temperature Sensor
55 V Circuit Sensor
12 V Circuit Sensor
Barometric Pressure Sensor
EXTERNAL SENSORS
Air Temperature Sensor
Engine Temperature Sensor
Low Oil Switch
Throttle Position Sensor
Crankshaft Position Sensor
Neutral Switch
INTERNAL EMM FUNCTIONS
ROM Verification
Idle Controller
RPM Limiter
Neutral RPM Limiter
Exhaust Water Valve Activation
Engine Monitor and Warning Systems
Fault Code Creation and Storage
ENGINE MONITORING SYSTEM
System Self-Test
Service Mode
Engine Running
S.A.F.E. WARNING SYSTEM
Activation
Recovery
DIAGNOSTIC SOFTWARE FUNCTIONS
Communication
Static Information
Dynamic Information
Stored Service Codes (Faults)
Hard Faults
Persistent Faults
Static Tests
Dynamic Tests
Oil Control Settings
Tiller/Remote Programming
Ignition Timing
TPS Calibration
Idle Speed Control
Fuel Control Adjustment
Fuel Injector Servicing
Reports
Software Replacement
EMM Transfer
EMM Replacement
EMM SERVICING
Removal
Installation
SYSTEM ANALYSIS
DIAGNOSTIC PROCEDURES
Visual Inspections
Operational Inspections
Troubleshooting
DYNAMIC TESTS
Cylinder Drop Tests
Fuel Control Adjustment
Inductive Amp Meter Test
EMM LED INDICATORS
Key ON
Starting
Running
IGNITION OUTPUT TESTS
Ignition System Requirements
Wiring Inspection
Crankshaft Position Sensor (CPS) Test
System Voltage Test
Static Ignition Test
Running Ignition Tests
Ignition Control Circuit Tests
Ignition Coil Tests
Capacitor Test
FUEL DELIVERY TESTS
Fuel Pump Static Test
Fuel Injector Static Test
Running Fuel System Tests
EXHAUST WATER VALVE
Exhaust Water Valve Static Test
Exhaust Water Valve Dynamic Test
ELECTRICAL AND IGNITION
SERVICE CHART
ELECTRICAL HARNESS CONNECTIONS
Engine Harness to Stator Connector
EMM J1-A Connector
EMM J1-B Connector
EMM J2 Connector
GROUND CIRCUITS
EMM Ground Tests
Additional Ground Tests
FUSE
SENSOR TESTS
Crankshaft Position Sensor (CPS) Test
Throttle Position Sensor (TPS) Test
Engine Temperature Sensor Test
Air Temperature Sensor (AT) Test
STATOR TESTS
Stator Resistance Tests
Stator Voltage Output Test
CHARGING SYSTEM TESTS
12 V Charging Circuit
55 V Alternator Circuit
ELECTRIC START CIRCUIT
Start Circuit Diagram
Start Circuit Operation
ELECTRIC START TESTS
Starter Solenoid Test
No Load Current Draw Test
EXHAUST WATER VALVE TEST
SystemCheck CIRCUIT TESTS
Gauge Self-Test Check
CHECK ENGINE Circuit Test
WATER TEMP/ HOT Circuit Test
LOW OIL Circuit Test
NO OIL Circuit Test
TACHOMETER CIRCUIT TESTS
FLYWHEEL AND STATOR SERVICING
Flywheel Removal
Stator Service
Flywheel Installation
TIMING ADJUSTMENTS
Timing Pointer
Timing Verification
TPS Calibration
ELECTRIC STARTER SERVICING
Starter Removal
Starter Disassembly
Starter Cleaning and Inspection
Starter Assembly
Starter Installation
CONNECTOR SERVICING
DEUTSCH Connectors
AMP Connectors
Packard † Connectors
FUEL SYSTEM
SERVICE CHART
FUEL SYSTEM HOSE ROUTING
FUEL SYSTEM CIRCUIT DIAGRAM
COMPONENTS
Fuel Lift Pump
Fuel Filter
Vapor Separator
Fuel Circulation Pump
Fuel Manifolds
Fuel Injectors
FUEL SYSTEM TESTS
Fuel System Pressure Test
Pressure Regulator Test
Vapor Separator Vent Check
Fuel Injector Pressure Test
Fuel Injector Resistance Test
Circulation Pump Resistance Test
Lift Pump Pressure Test
Lift Pump Vacuum Test
Lift Pump Diaphragm Test
Anti-Siphon Valve Test
FUEL COMPONENT SERVICING
Relieving Fuel System Pressure
Fuel Filter Service
Fuel Lift Pump Service
Vapor Separator Service
Fuel Manifold Service
Fuel Injector Service
Intake Manifold Service
OILING SYSTEM
SERVICE CHART
OIL SUPPLY DIAGRAMS
OIL RECIRCULATION DIAGRAM
OILING SYSTEM CIRCUIT DIAGRAM
COMPONENTS
Oil Tank Assembly
Oil Injection Pump
Electrical Circuit (55 V)
LOW OIL Warning
NO OIL Warning
Cylinder and Crankcase
Oil Recirculation System
OIL CONTROL SETTINGS
Oil Priming
Oiling Rates
Break-in Oiling
OILING SYSTEM TESTS
Oil Injection Pump Static Test
Oil Injection Pump Voltage Test
Oil Injection Pump Circuit Resistance Test
Oil Injection Pump Function Test
Oil Injection Fittings Flow Test
LOW OIL Sending Unit Test
OIL COMPONENT SERVICING
Oil Distribution Hoses
Oil Tank Assembly
NOTES
Technician's Notes
Related Documents
COOLING SYSTEM
HOSE ROUTING AND WATER FLOW DIAGRAM
COMPONENTS
Water Pump and Intakes
Exhaust Housing
Pressure Relief Valve
Thermostat
Block Venting
Water Pressure Connection
OPERATION
Cylinder Block / Cylinder Head Cooling
EMM and Vapor Separator Cooling
ENGINE TEMPERATURE CHECK
Software Method
Pyrometer Method
Idle Operating Temperature Troubleshooting (Below Range)
THERMOSTAT SERVICING
Disassembly
Inspection
Assembly
PRESSURE RELIEF VALVE SERVICING
Disassembly
Inspection
Assembly
NOTES
Technician's Notes
Related Documents
POWERHEAD
SERVICE CHART
POWERHEAD REMOVAL
POWERHEAD DISASSEMBLY
General
Throttle Linkage Removal
Shift Linkage Removal
Crankcase Disassembly
Cylinder Head Removal
Connecting Rods and Pistons
Crankshaft Removal
CYLINDER BLOCK CLEANING
POWERHEAD INSPECTION
Cylinder Head
Crankshaft
Cylinder Bore
Pistons
Piston Rings
Bearings
POWERHEAD ASSEMBLY
Crankshaft Assembly
Pistons and Connecting Rods
Cylinder Head Installation
Crankshaft and Connecting Rod Installation
Crankcase Assembly
Shift Linkage Installation
Throttle Linkage Installation
Final Powerhead Assembly
POWERHEAD INSTALLATION
Powerhead Mounting
Shift Linkage Adjustment
POWERHEAD VIEWS
Port Short Block
Starboard Short Block
Port Dressed Powerhead
Starboard Dressed Powerhead
Front
Rear
Top
MIDSECTION
SERVICE CHART
EXHAUST HOUSING SERVICE
Exhaust Housing Removal
Exhaust Water Valve
Exhaust Relief Cavity
Exhaust Housing Installation
STERN BRACKET SERVICE
Clamp Screw
Stern Bracket Disassembly
Stern Bracket Assembly
Tilt Assist Cylinder
TILLER HANDLE SERVICE
Removal
Disassembly
Inspection
Assembly
Installation
Throttle Cable Adjustment
MIDSECTION AND TILLER ADJUSTMENTS
Steering Friction Adjustment
Throttle Friction Adjustment
GEARCASE
SERVICE CHART
PROPELLER SERVICE, MRL MODELS
Inspection
IMPELLER SERVICE, MJRL MODELS
Inspection
Removal
Installation
GEARCASE LEAK TEST
GEARCASE REMOVAL AND INSTALLATION
Gearcase Removal
Gearcase Installation
WATER PUMP SERVICE
Disassembly
Inspection
Assembly
SHIFT ROD ADJUSTMENT
GEARCASE DISASSEMBLY
Pre-Disassembly Inspection
Propeller Shaft Bearing Housing Removal
Pinion Gear and Driveshaft Removal
Shift Housing, Gear and Propeller Shaft Removal
INTERNAL GEARCASE SERVICE
Pinion Bearing Removal
Pinion Bearing Installation
Shift Housing Disassembly
Shift Housing Assembly
Driveshaft Bearing Housing Service
Propeller Shaft Bearing Housing Service
DRIVESHAFT SHIMMING
GEARCASE ASSEMBLY
Shift Housing, Gear, and Propeller Shaft Installation
Shift Rod Housing Installation
Pinion Gear and Driveshaft Installation
Propeller Shaft Bearing Housing and Gear Installation
NOTES
Technician's Notes
Related Documents
MANUAL STARTER
SERVICE CHART
RECOIL STARTER REMOVAL
RECOIL STARTER DISASSEMBLY
RECOIL STARTER CLEANING AND INSPECTION
RECOIL STARTER ASSEMBLY
RECOIL STARTER INSTALLATION
NOTES
Technician's Notes
Related Documents
TROUBLE CHECK CHART
OUTBOARD WILL NOT START
OUTBOARD WILL NOT START
OUTBOARD HARD TO START
OUTBOARD WILL NOT SHUT OFF
OUTBOARD STARTS AND STALLS
OUTBOARD STARTS, LOW MAXIMUM RPM
EXCESSIVE SMOKING
OUTBOARD SURGES, RUNS ROUGH
SERVICE PARTS
INDEX
NOTES
Technician's Notes
Related Documents
DIAGRAMS
