0325275 EVINRUDE GASKET,Thermostat cover

Table 1
Diagnostic Codes Table
Code and Description Conditions which Generate this Code System Response
545-5 Ether Start Relay open/short to +batt The Electronic Control Module (ECM) detects an open circuit and/or a short to the +Battery at the output to the ether start relay. The code is logged.
Ether injection is disabled.
545-6 Ether Start Relay short to ground The ECM detects a short circuit to ground at the output to the ether start relay.
The ECM has been powered for at least two seconds. When the engine is in auto mode, the engine uses an ether injection system to improve starting in cold temperatures. The duration of the ether cycle is based on the engine coolant temperature. The ECM, which controls the ether injection system, uses the engine coolant temperature sensor to detect engine temperature. The ECM determines if ether should be injected by monitoring actual engine rpm and the engine temperature. The ECM will activate the ether start relay if the engine coolant temperature is below a set temperature and the engine rpm is below a certain level. The ether injection system becomes enabled at 10 °C (50 °F). The ether injection system will run for a minimum of 10 seconds up to a maximum of 130 seconds at −40 °C (−40 °F). The automatic ether injection system is disabled whenever engine rpm exceeds 1900 rpm or the engine coolant temperature exceeds 10 °C (50 °F).The ether injection system can also be operated in manual mode. The ether injection system is switched into manual mode whenever the starting aid switch is depressed. Ether is injected in manual mode if the starting aid switch is depressed and the coolant temperature is below the maximum limit. The manual mode will allow ether to be injected for a maximum of 130 seconds when the switch is toggled. Manual mode allows ether to be injected whenever the coolant temperature is less than 10 °C (50 °F) and engine rpm is greater than 50 rpm.Note: The ether function will be disabled if the ether control parameter is disabled.
Illustration 1 g01213342
Typical schematic
Illustration 2 g01213344
P1 ECM connector
(P1-5) Digital return
(P1-20) Ether aid switch (SAS)
Illustration 3 g01213347
P2 ECM connector
(P2-10) Ether start relay (SAR)
Illustration 4 g01234146
Location of ECM connectors
Illustration 5 g01213349
Customer connector
(Terminal 9) Digital return
(Terminal 22) Ether start relay (SAR)
(Terminal 38) Ether aid switch (SAS)
Personal injury or death can result from using ether.Failure to follow these instructions could result in an explosion and/or fire and possible personal injury.When using starting fluid, follow the manufacturer's instructions carefully. Use ether sparingly and spray it only while cranking the engine. Also, do not store starting fluid containers in the cab.
The ether canister must be removed prior to activating this test.
Do not perform this procedure within 15 M (50 ft) of an open flame.
Do not allow the ether injection system to be on for more than two minutes. Damage to the ether solenoid may occur.
Test Step 1. Inspect Electrical Connectors and Wiring
Turn the main disconnect to the OFF position.
Thoroughly inspect the J1/P1 ECM connector and the J2/P2 ECM connector. Inspect all of the connectors that are associated with the circuit. Refer to Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque. Refer to Troubleshooting, "Inspecting Electrical Connectors" for details.
Check the harness and wiring for abrasion and for pinch points from the sensors back to the ECM. Expected Result:All connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The harness and connectors appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem with the connectors and/or wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Ether Canister
Remove the ether canister from the ether solenoid. Determine if the canister contains any ether. Ether can not be injected if the canister is empty. Expected Result:The ether canister is not empty.Results:
OK - The ether canister is not empty. Proceed to Test Step 3.
Not OK - The ether canister is empty.Repair: Replace the empty ether canister with a new eth