5007793 EVINRUDE 2009 40-65 HP Parts Catalog (Paper)

1. Fuel consumption records must be available before the high fuel consumption complaint can be verified. If symptoms indicate low power, then the low power test should be conducted first, because it could be the cause of the fuel consumption problem. This Primary Engine Test for High Fuel Consumption is the same as the Primary Engine Test for Low Power.2. Visually inspect the fuel system from the fuel tank to the fuel injection lines to see if there are any indications of fuel leaks. Tighten any loose connections found and, if necessary, replace lines that can not be repaired.3. Check the crankcase oil level and the coolant level of the radiator. Start the engine and get to normal operating temperature. A slightly lower rpm (15 rpm below low limit) should be expected for the engine in vehicle than the rpm shown in the Fuel Setting And Related Information Fiche. This is caused by the parasitic loads of the engine accessories involved.4. With the engine running, the throttle must have enough travel for the governor control lever to break over (go past the normal governor stop for high idle position) a small amount when the throttle pedal is fully depressed. If full travel is not available, disconnect throttle linkage from governor lever. With throttle linkage disconnected, full travel of governor lever will indicate linkage problems, and the linkage will have to be adjusted. Limited travel of the governor lever will indicate a problem within the governor.5. Only a mechanic with the correct training should change the set point (balance point) adjustment. The procedure is given in this Service Manual under the subject Governor Adjustments.6. If high idle rpm can not be made correct with the high idle adjustment screw, there is a problem inside the governor. Disassemble the governor and check for damaged parts or wrong parts installed in the governor. Some common problems are worn bushings, worn spring seat, or a broken or wrong governor spring.7. Before 8T0500 Circuit Tester is installed, be sure to test the light for correct operation. Test ligh must come on when the clip of the wire is placed against the probe of the light (replace batteries or bulb if light does not come on). If light comes on and stays on when attached to governor, the insulation is bad or installed wrong in torque spring group or brass terminal. This must be corrected before test is performed.8. With the continuity light installed, quickly push accelerator pedal all the way to the floor. If the fuel control shaft and governor function properly, the continuity light will come on during this free acceleration until high idle is maintained.If the light comes on, this is an indication that the mechanical movement of the governor and fuel injection pump parts operate properly. The fuel setting should now be checked. If the light does not come on during free acceleration, check for a problem inside the governor.9. Install 5P4203 Field Service Tool Group, and check the fuel setting dimension. Compare the results with the dimensions given in the Fuel Setting and Related Information Fiche. If the fuel setting is correct, the vehicle will now have to be tested on a chassis dynamometer to determine the cause for high fuel consumption.If the fuel setting is not correct, adjust to the setting given in the Fuel Setting and Related Information Fiche. Only a mechanic with the correct training should adjust the fuel setting. The procedure to check and adjust the fuel setting is in this Service Manual under the subject Fuel Setting.10. If the test light still does not come on, this means that the fuel control shaft is not moving due to a problem inside the governor or a problem inside fuel injection pump housing. The governor should be checked for worn parts. The fuel injection pump housing should be checked for a worn fuel control shaft or its bore, or a fuel injection pump installed with sleeve not engaged with the lever on the fuel control shaft. The problem must be found and corrected.