0438617 EVINRUDE GEARCASE ASSY., (Less driveshaft and pump)

Illustration 1 g00899642
Test Step 1. Check for Connector Damage.
Turn the circuit breaker for the engine to the OFF position.
Turn the keyswitch to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and for pinch points.Expected Result:The connectors and wiring should be free of the following problems: damage, corrosion, abrasion and incorrect attachment.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Test the Lamp.
Turn the keyswitch to the OFF position.
Observe the lamp as you turn the keyswitch to the ON position. The engine should be OFF.
Turn the keyswitch to the OFF position.Expected Result:The lamp should illuminate for one second when the keyswitch is turned to the ON position.Results:
OK - The lamp illuminated for one second when the keyswitch was turned to the ON position.Repair: The ECM tests all lamps when the ECM is powered up. If the lamp lights, the circuit is working properly. If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors". Stop.
Not OK - The lamp did not illuminate for one second when the keyswitch is turned to the ON position. Proceed to test step 3.Test Step 3. Check the Circuit for the Lamp.
Turn the keyswitch to the OFF position.
Disconnect ECM connector J1/P1.
Remove wire C485-YL from ECM connector P1-21.
Reconnect ECM connector J1/P1.
Connect a wire jumper between wire C485-YL and the - Battery terminal.
Turn the keyswitch to the ON position. The engine should be OFF.
Observe the Lamp.
Turn the keyswitch to the OFF position.
Remove the wire jumpers and reconnect all connectors.Expected Result:The lamp should illuminate when the keyswitch is turned to the ON position.Results:
OK - The lamp illuminated when the keyswitch was turned to the ON position. Proceed to test step 7.
Not OK - The lamp did not illuminate when the keyswitch was turned to the ON position. Proceed to test step 4.Test Step 4. Check the Voltage at the Lamp.
Turn the keyswitch to the ON position. The engine should be OFF.
Measure the voltage between wire 125-OR on the lamp terminal and the chassis ground.Expected Result:The voltage should be 24 3 VDC on wire 125-OR at the lamp terminal.Results:
OK - The voltage is 24 3 VDC on wire 125-OR at the lamp terminal. Proceed to test step 5.
Not OK - The voltage is not 24 3 VDC on wire 125-OR at the lamp terminal.Repair: Turn the keyswitch to the ON position. Check for voltage between engine ground and the following points: either side of the fuse for the side floodlight, wire 112-PU on the main relay, either side of the main breaker and + Battery. The circuit is okay to the point that voltage is detected. The next component in the circuit is faulty. Repair the component or replace the component. Stop.Test Step 5. Check the Lamp for the High Exhaust Temperature.
Turn the keyswitch to the OFF position.
Connect a wire jumper between wire C485-YL on the lamp terminal and engine ground.
Observe the lamp as you turn the keyswitch to the ON position. The engine should be OFF.
Turn the keyswitch to the OFF position.Expected Result:The lamp should illuminate when the keyswitch is turned to the ON position.Results:
OK - The lamp illuminated when the keyswitch was turned to the ON position. Proceed to test step 6.
Not OK - The lamp did not illuminate when the keyswitch was turned to the ON position.Repair: Replace the lamp. Reset the system and check for diagnostic codes. Stop.Test Step 6. Measure the Resistance of Wire C485-YL.
Turn the keyswitch to the OFF position.
Disconnect ECM connector J1/P1.
Measure the resistance between ECM connector P1-21 and wire C485-YL at the lamp terminal.
Reconnect ECM connector J1/P1.Expected Result:The resistance should be less than 10 Ohms.Results:
OK - The resistance is less than 10 Ohms. Proceed to test step 7.
Not OK - The resistance is greater than 10 Ohms. There is an open circuit or excessive resistance in the harness and/or the connectors. Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 7. Check the ECM.
Turn the keyswitch to the OFF position.
Observe the lamp as you turn the keyswitch to the ON position. The engine should be OFF.
Turn the keyswitch to the OFF position.Expected Result:The lamp should illuminate for one second when the keyswitch is turned to the ON position.Results:
OK - The lamp illuminated for one second when the keyswitch was turned to the ON position.Repair: The ECM tests all lamps when the ECM is powered up. If the lamp lights, the circuit is working properly. If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors". Stop.
Not OK - The ECM is not illuminating the lamp. The wiring and connectors are okay.Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM". Stop.