BRP E225DHXSEM, E225DPLSEB, E225DPXSEB, E225DCXSEB, E225DPZSEB Service Manual
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BRP US Inc.
Technical Publications
250 Sea Horse Drive
Waukegan, Illinois 60085 United States
† AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II
are registered trademarks of Tyco International, Ltd.
† Amphenol is a registered trademark of The Amphenol Corporation.
† Champion is a registered trademark of Federal-Mogul Corporation.
† Deutsch is a registered trademark of The Deutsch Company.
† Dexron is a registered trademark of The General Motors Corporation.
† Fluke is a registered trademark of The Fluke Corporation
† GE is a registered trademark of The General Electric Company.
† GM is a registered trademark of The General Motors Corporation.
† Locquic and Loctite are registered trademarks of The Henkel Group.
† Lubriplate is a registered trademark of Fiske Brothers Refining Company.
† NMEA is a registered trademark of the National Marine Electronics Association.
† Oetiker is a registered trademark of Hans Oetiker AG Maschinen.
† Packard is a registered trademark of Delphi Automotive Systems.
† Permatex is a registered trademark of Permatex.
† STP is a registered trademark of STP Products Company.
† Snap-on is a registered trademark of Snap-on Technologies, Inc.
The following trademarks are the property of BRP US Inc. or its affiliates:
Evinrude
Johnson
Evinrude
®
®
®
E-TEC
®
Nut Lock™
Screw Lock™
Ultra Lock™
FasTrak™ Gel-Seal II™
S.A.F.E.™ Moly Lube™
SystemCheck™
Triple-Guard
®
Grease
I-Command™ DPL™ Lubricant
Evinrude
Evinrude
Evinrude
®
/ Johnson ® XD30™ Outboard Oil 2+4 ® Fuel Conditioner
®
/ Johnson ® XD50™ Outboard Oil
®
/ Johnson ® XD100™ Outboard Oil
Carbon Guard™
HPF XR™ Gearcase Lubricant
Twist Grip™
Printed in the United States.
© 2008 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
TABLE
OF
CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 INSTALLATION AND PREDELIVERY . . . . . . . . . . . . . . 27
3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 ENGINE COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . 89
5 ENGINE MANAGEMENT MODULE (EMM) . . . . . . . . . . 93
6 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . 125
8 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
9 OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
10 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
11 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
12 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
13 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
GEARCASE – STANDARD ROTATION . . . . . . . . . . . . 295
GEARCASE – COUNTER ROTATION . . . . . . . . . . . . . 317
14 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I–1
TROUBLE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . T–1
DIAGRAMS
EMM SERVICE CODE CHART
2
INTRODUCTION
INTRODUCTION
CONTENTS
ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ENGINE EMISSIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
MANUFACTURER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
DEALER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OWNER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
EPA EMISSION REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
IDENTIFYING MODEL AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3
SAFETY INFORMATION
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This manual is written for qualified, factory-trained
technicians who are already familiar with the use
of Evinrude
ual is not a substitute for work experience. It is an
organized guide for reference, repair, and maintenance of the outboard(s).
This manual uses the following signal words identifying important safety messages.
®
/Johnson® Special Tools. This man-
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.
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 manual may be translated into other languages. In the event of any discrepancy, the English version shall prevail.
To reduce the risk of personal injury, safety warnings are provided at appropriate times throughout
the manual.
DO NOT make 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.
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 notices mean:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
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 manual, YOU ALONE must
decide if your actions might injure people or damage the outboard.
DANGER
Contact with a rotating propeller is likely to result in serious injury or death. Assure the
engine and prop area is clear of people and objects before starting engine or operating boat.
Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and
the propeller can continue to turn even after the engine is off. Remove propeller before servicing and when running the outboard on a flushing device.
DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to
accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled,
can cause serious brain damage or death.
WARNING
Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172
kPa).
The motor cover and flywheel cover are machinery guards. Use caution when conducting
tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and
clothing away from rotating parts.
During service, the outboard may drop unexpectedly. Avoid personal injury; always support
the outboard’s weight with a suitable hoist or the tilt support bracket during service.
To prevent accidental starting while servicing, disconnect the battery cables at the battery.
Twist and remove all spark plug leads.
The electrical system presents a serious shock hazard. DO NOT handle prima ry or secondary
ignition components while outboard is running or flywheel is turning.
Gasoline is extremely flammable and highly explosive under certain conditions. Use caution
when working on any part of the fuel system.
Protect against hazardous fuel spray. Before starting any fuel system service, carefully
relieve fuel system pressure.
Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular
phones in the vicinity of a fuel leak or while fueling.
Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and
causing an explosion.
Always work in a well ventilated area.
Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak.
Definite resistance to tightening must be felt when reusing a locking fastener. If replacement
is indicated, use only authorized replacement or equivalent.
INTRODUCTION
ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL
Units of Measurement List of Abbreviations
A Amperes
amp-hr Ampere hour
fl. oz. fluid ounce
ft. lbs. foot pounds
HP horsepower
in. inch
in. Hg inches of mercury
in. lbs. inch pounds
kPa kilopascals
ml milliliter
mm millimeter
N·m Newton meter
P/N part number
psi pounds per square inch
RPM revolutions per minute
°C degrees Celsius
°F degrees Fahrenheit
ms milliseconds
µs microseconds
Ω Ohms
VVolts
VAC Volts Alternating Current
VDC Volts Direct Current
ABYC American Boat & Yacht Council
ATDC after top dead center
AT air temperature sensor
BPS barometric pressure sensor
BTDC before top dead center
CCA cold cranking amps
CPS crankshaft position sensor
EMM Engine Management Module
ICOMIA International Council of Marine
Industry Associations
MCA marine cranking amps
MWS modular wiring system
NMEA National Marine Electronics Assoc.
NTC negative temperature coefficient
PTC positive temperature coefficient
ROM read only memory
S.A.F.E.™ speed adjusting failsafe electronics
SAC start assist circuit
SAE Society of Automotive Engineers
SYNC synchronization
TDC top dead center
TPS throttle position sensor
WOT wide open throttle
WTS water temperature sensor
6
INTRODUCTION
ENGINE EMISSIONS INFORMATION
ENGINE EMISSIONS
INFORMATION
Maintenance, replacement, or repair of the
emission control devices and systems may be
performed by any marine SI (spark ignition)
engine repair establishment or individual.
Manufacturer’s Responsibility
Beginning with 1999 model year outboards, manufacturers of marine outboards must determine
the exhaust emission levels for each outboard
horsepower family and certify these outboards
with the United States of America Environmental
Protection Agency (EPA). An emissions control
information label, showing emission levels and
outboard specifications, must be placed on each
outboard at the time of manufacture.
Dealer’s Responsibility
When performing service on all 1999 and more
recent Evinrude/Johnson outboards that carry an
emissions control information label, adjustments
must be kept within published factory specifications.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the outboard in any
manner that would alter the horsepower or allow
emission levels to exceed their predetermined
factory specifications.
Exceptions include manufacturer’s prescribed
changes, such as altitude adjustments, for example.
Owner’s Responsibility
The owner/operator is required to have outboard
maintenance performed to maintain emission levels within prescribed certification standards.
The owner/operator is not to, and should not allow
anyone to, modify the outboard in any manner
that would alter the horsepower or allow emissions levels to exceed their predetermined factory
specifications.
Tampering with the fuel system to change horsepower or modify emission levels beyond factory
settings or specifications will void the product warranty.
EPA Emission Regulations
All new 1999 and more recent Evinrude/Johnson
outboards are certified to the EPA as conforming
to the requirements of the regulations for the control of air pollution from new watercraft marine
spark ignition outboards. This certification is contingent on certain adjustments being set to factory
standards. For this reason, the factory procedure
for servicing the product must be strictly followed
and, whenever practical, returned to the original
intent of the design. The responsibilities listed
above are general and in no way a complete listing of the rules and regulations pertaining to the
EPA requirements on exhaust emissions for
marine products. For more detailed information on
this subject, you may contact the following locations:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
501 3rd St. NW
Washington, DC 20001
EPA INTERNET WEB SITE:
www.epa.gov
7
INTRODUCTION
MODEL DESIGNATION
MODEL DESIGNATION
PREFIX
STYLE:
J = Johnson
E = Evinrude
HORSEPOWER
LENGTH:
= 15” Std.
L = 20” Long
Y = 22.5” Special
X = 25” X-long
Z = 30” XX-long
MODEL RUN
or SUFFIX
B E 200 DP X SE E
DESIGN FEATURES:
AP = Advanced Propulsion
B = Blue Paint
C = Counter Rotation
D = Evinrude E-TEC™
E = Electric Start w/Remote Steering
F = Direct-Injection
G = Graphite Paint
H = High Output
J = Jet Drive
M = Military
P = Power Trim and Tilt
R = Rope Start w/Tiller Steering
S = Saltwater Edition
T = Tiller Steering
TE = Tiller Electric
V = White Paint
W = Commercial Model
MODEL YR:
I= 1
N= 2
T= 3
R= 4
O= 5
D= 6
U= 7
C= 8
E= 9
S= 0
Ex: SE = 2009
8
INTRODUCTION
MODELS COVERED IN THIS MANUAL
MODELS COVERED IN
THIS MANUAL
This manual covers service information on all
200.1 and 210 cubic inch, 90° V Evinrude E-TEC
models.
Model Shaft Color G earcase
E200DHLSEB 3.3 L 20” BL .54 L2
E200HSLSEA 3.3 L 20” WH .54 L2
E200HVLSEC 3.3 L 20” WH .54 M2
E200DHXSEA 3.3 L 25” WH .54 M2
E200HCXSEA 3.3 L 25” WH .54 M2 CR
E225DPLSEB 3.3 L 20” BL .54 M2
E225DHLSEB 3.3 L 20” BL .58 L2
E225HSLSEC 3.3 L 20” WH .58 L2
E225DHXSEM 3.3 L 25” BL .58 L2
E225DPXSEB 3.3 L 25” WH .54 M2
E225DCXSEB 3.3 L 25” WH .54 M2 CR
E225DPZSEB 3.3 L 30” WH .54 M2
E225DCZSEB 3.3 L 30” WH .54 M2 CR
E250DPLSEB 3.3 L 20” BL .54 M2
E250DPXSEB 3.3 L 25” WH .54 M2
E250DCXSEB 3.3 L 25” WH .54 M2 CR
E250DPZSEB 3.3 L 30” WH .54 M2
E250DCZSEB 3.3 L 30” WH .54 M2 CR
E250HSLSES 3.4 L 20” WH .58 L2
E250HSLSEF 3.4 L 20” WH .58 L2
E250DHLSEC 3.4 L 20” BL .58 L2
E250DHLSEF 3.4 L 20” BL .58 L2
E250DHXSEC 3.4 L 25” BL .58 L2
E250DHXSEF 3.4 L 25” BL .58 L2
E250HGLSES 3.4 L 20” SM .58 L2
E250HGLSEF 3.4 L 20” SM .58 L2
E250HGXSES 3.4 L 25” SM .58 L2
E250HGXSEF 3.4 L 25” SM .58 L2
E300DSLSES 3.4 L 20” WH .54 M2
E300DSLSEF 3.4 L 20” WH .54 M2
E300DPXSEC 3.4 L 25” WH .54 M2
E300DPXSEF 3.4 L 25” WH .54 M2
E300DPZSEC 3.4 L 30” WH .54 M2
E300DPZSEF 3.4 L 30” WH .54 M2
E300DCXSEC 3.4 L 25” WH .54 M2 CR
E300DCXSEF 3.4 L 25” WH .54 M2 CR
E300DCZSEC 3.4 L 30” WH .54 M2 CR
E300DCZSEF 3.4 L 30” WH .54 M2 CR
Identifying Model and Serial Numbers
Outboard model and serial numbers are located
on the swivel bracket and on the powerhead.
®
1
1. Model and serial number 000449
1
1. Serial number 006828
9
INTRODUCTION
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
HP 200 225 250
Full Throttle
Operating Range
200 HP
Power
Idle RPM in Gear 500 ± 50
Test Propeller
Weight
(may vary depending
on model)
Lubrication
ENGINE
Minimum (High) Fuel Pressure
Minimum Fuel Lift Pump Pressure
FUEL
Maximum Fuel Inlet Vacuum 4 in. Hg. (13.5 kPa)
Engine Type 90° V 6-Cylinder Loop-Charged
Displacement
Bore 3.854 in (97.89 mm)
Stroke 2.858 in. (72.60 mm)
Standard Bore
Top Crankshaft Journal 1.6199 to 1.6204 in. (41.15 to 41.16 mm)
Center Crankshaft Journals 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Bottom Crankshaft Journal 1.5747 to 1.5752 in. (40.0 to 40.01 mm)
Rod Crankpin 1.4995 to 1.5000 in. (38.09 to 38.106 mm)
Piston Ring End Gap, Both 0.022 to 0.028 in. (0.57 to 0.72 mm)
Fuel/Oil Ratio EMM Controlled
Starting Enrichment EMM Controlled
Preferred Fuel Regular unleaded gasoline
Acceptable Fuel See Fuel Requirements on p. 58 for additional information.
@ IDLE RPM – 500 ± 50
@ IDLE RPM – 500 ± 50
Minimum Octane 87 AKI (R+M)/2 or 90 RON
Additives
(149 kw)
@ 5150 RPM
Standard Rotation Models: P/N 436080 or P/N 396277
Counter Rotation Models: P/N 436081 or P/N 398674
3.8535 to 3.8545 in. (97.87 to 97.90 mm)
To bore oversize, add piston oversize dimension to standard bore
2+4
Use of other additives may result in engine damage.
See Fuel Requirements on p. 58 for additional information.
4500–5800 RPM
225 HP
(168 kw)
@ 5150 RPM
20 in. (L) Models: 503 lbs. (228 kg)
25 in. (X) Models: 524 lbs. (238 kg)
30 in. (Z) Models: 530 lbs. (240 kg)
Evinrude/Johnson XD100 Oil
Refer to Oil Requirements on p. 59
200.1 cu. in. (3279 cm
22 to 28 psi (152 to 193 kPa)
3 psi (21 kPa)
®
Fuel Conditioner, Fuel System Cleaner
250 HP (187 kw)
3
)
@ 5150 RPM
10
Minimum Battery
Requirements
Alternator Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation
Tachometer Setting 6 pulse (12 pole)
ELECTRICAL
Charging Isolator Integral, Terminal on Engine Harness
Engine Fuse P/N 967545 – 10 A
Thermostat 143°F (62°C)
Maximum Temperature 190°F (88°C)
INTRODUCTION
SERVICE SPECIFICATIONS
HP 200 225 250
675 CCA (845 MCA); or
750 CCA (940 MCA) below 32°F (0°C)
(Use a 107 amp-hr battery for extreme applications.)
COOLING
Crankshaft Position Sensor Air Gap Fixed
IGNITION
GEARCASE
Water pressure 11 psi minimum @ 5000 RPM
Type Capacitor Discharge
Firing Order 1-2-3-4-5-6
Ignition Features EMM Controlled
RPM Limit 6050
Spark Plug
Gear Ratio
Lubricant HPF XR Gearcase Lubricant
Capacity
Shift Rod Height
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD
Lubrication
Refer to Emission Control Information Label
†
Champion
“L2” Type Gearcase – 200 HP: 14:26 (.538) (1.86:1)
“L2” Type Gearcase – 225 HP: 14:24 (.583) (1.71:1)
“M2” Type – Counter Rotation: 35.8 fl. oz. (1060 ml)
20 in. (L) Models: 21 29/32 (556.25 mm) ± one-half turn
25 in. (X) Models: 26 29/32 (683.25 mm) ± one-half turn
30 in. (Z) Models: 31 29/32 (810.25 mm) ± one-half turn
QC8WEP @ 0.028 ± 0.003 in. (0.71 mm)
“M2” Type Gearca se: 13:24 (.542) (1.85:1)
Refer to GEARCASE TYPES on p. 285
“M2” Type Gearcase: 38.9 fl. oz. (1150 ml)
“L2” Type Gearcase: 32.5 fl. oz. (960 ml)
Refer to GEARCASE TYPES on p. 285
Power Trim/Tilt & Power Steering Fluid or
GM Dexron
†
II Automatic Transmission Fluid
Fluid Capacity 21 fl. oz. (622 ml)
Trim Range 0° to 21°
Tilt Range 22° to 75°
Tilt UP Stall Pressure 1500 psi (10342 kPa)
POWER TRIM/TILT
Tilt IN Stall Pressure 800 psi (5516 kPa)
11
INTRODUCTION
SERVICE SPECIFICATIONS
HP 250 H 300
Full Throttle
Operating Range
Power
Idle RPM in Gear 500 ± 50
Test Propeller
Weight
(may vary depending
on model)
Lubrication
ENGINE
Minimum (High) Fuel Pressure
Minimum Fuel Lift Pump Pressure
FUEL
Maximum Fuel Inlet Vacuum 4 in. Hg. (13.5 kPa)
Engine Type 90° V 6-Cylinder Loop-Charged
Displacement 210.0 cu. in. (3441 cc)
Bore 3.854 in (97.89 mm)
Stroke 3.000 in. (76.20 mm)
Standard Bore
Top Crankshaft Journal 1.6199 to 1.6204 in. (41.15 to 41.16 mm)
Center Crankshaft Journals 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Bottom Crankshaft Journal 1.5747 to 1.5752 in. (40.0 to 40.01 mm)
Rod Crankpin 1.4995 to 1.5000 in. (38.09 to 38.106 mm)
Piston Ring End Gap, Both 0.022 to 0.028 in. (0.57 to 0.72 mm)
Fuel/Oil Ratio EMM Controlled
Starting Enrichment EMM Controlled
Preferred Fuel Regular unleaded gasoline
Acceptable Fuel See Fuel Requirements on p. 58 for additional information.
@ IDLE RPM – 500 ± 50
@ IDLE RPM – 500 ± 50
Minimum Octane 87 AKI (R+M)/2 or 90 RON
Additives
4500–6000 RPM 5000–6000 RPM
250 HP
(187 kw)
@ 5250 RPM
Standard Rotation Models: P/N 436080 or P/N 396277
Counter Rotation Models: P/N 436081 or P/N 398674
20 in. (L) Models: 507 lbs. (230 kg)
25 in. (X) Models: 528 lbs. (239 kg)
30 in. (Z) Models: 534 lbs. (242 kg)
Evinrude/Johnson XD100 Oil
Refer to Oil Requirements on p. 59
3.8535 to 3.8545 in. (97.87 to 97.90 mm)
To bore oversize, add piston oversize dimension to standard bore
22 to 28 psi (152 to 193 kPa)
3 psi (21 kPa)
®
Fuel Conditioner, Fuel System Cleaner
2+4
Use of other additives may result in engine damage.
See Fuel Requirements on p. 58 for additional information.
300 HP
(234 kw)
@ 5500 RPM
12
Minimum Battery
Requirements
Alternator Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation
Tachometer Setting 6 pulse (12 pole)
ELECTRICAL
Charging Isolator Integral, Terminal on Engine Harness
Engine Fuses P/N 967545 – 10 A
Thermostat 143°F (62°C)
Maximum Temperature 190°F (88°C)
INTRODUCTION
SERVICE SPECIFICATIONS
HP 250 H 300
675 CCA (845 MCA); or
750 CCA (940 MCA) below 32°F (0°C)
(Use a 107 amp-hr battery for extreme applications.)
COOLING
Crankshaft Position Sensor Air Gap Fixed
IGNITION
GEARCASE
Water pressure 11 psi minimum @ 5000 RPM
Type Capacitor Discharge
Firing Order 1-2-3-4-5-6
Ignition Features EMM Controlled
RPM Limit 6050
Spark Plug
Gear Ratio
Lubricant HPF XR Gearcase Lubricant
Capacity
Shift Rod Height
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD
Lubrication
Refer to Emission Control Information Label
†
Champion
“M2” Type – Counter Rotation: 35.8 fl. oz. (1060 ml)
20 in. (L) Models: 21 29/32 (556.25 mm) ± one-half turn
25 in. (X) Models: 26 29/32 (683.25 mm) ± one-half turn
30 in. (Z) Models: 31 29/32 (810.25 mm) ± one-half turn
QC8WEP @ 0.028 ± 0.003 in. (0.71 mm)
“M2” Type Gearca se: 13:24 (.542) (1.85:1)
“L2” Type Gearcase: 14:24 (.583) (1.71:1)
Refer to GEARCASE TYPES on p. 285
“M2” Type Gearcase: 38.9 fl. oz. (1150 ml)
“L2” Type Gearcase: 32.5 fl. oz. (960 ml)
Refer to GEARCASE TYPES on p. 285
Power Trim/Tilt & Power Steering Fluid or
GM Dexron
†
II Automatic Transmission Fluid
Fluid Capacity 21 fl. oz. (622 ml)
Trim Range 0° to 21°
Tilt Range 22° to 75°
Tilt UP Stall Pressure 1500 psi (10342 kPa)
POWER TRIM/TILT
Tilt IN Stall Pressure 800 psi (5516 kPa)
13
INTRODUCTION
STANDARD TORQUE SPECIFICATIONS
STANDARD TORQUE
SPECIFICATIONS
Size In. Lbs. Ft. Lbs. N·m
No. 6 7–10 0.58–0.83 0.8–1.1
No. 8 15–22 1.25–1.83 1.7–2.5
No. 10 24–36 2–3 2.7–4.0
No. 12 36–48 3–4 4.0–5.4
1/4 in. 60–84 5–7 7-9.5
5/16 in. 120–144 10–12 13.5–16.5
3/8 in. 216–240 18–20 24.5–27
7/16 in. 336–384 28–32 38–43.5
IMPORTANT: These values apply only when
a specific torque for a specific fastener is not
listed in the appropriate section. When tightening two or more screws on the same part, DO
NOT tighten screws completely, one at a time.
WARNING
PRODUCT REFERENCE AND ILLUSTRATIONS
BRP US Inc. reserves the right to make changes
at any time, without notice, in specifications and
models and also to discontinue models. The right
is also reserved to change any specifications or
parts, at any time, without incurring any obligation
to equip same on models manufactured prior to
date of such change. Specifications used are
based on the latest product information available
at the time of publication.
The continuing accuracy of this manual cannot be
guaranteed.
All photographs and illustrations used in this manual may not depict actual models or equipment,
but are intended as representative views for reference only.
Certain features or systems discussed in this
manual might not be found on all models in all
marketing areas.
All service technicians must be familiar with nautical orientation. This manual often identifies parts
and procedures using these terms.
Torque wrench tightening specifications
must be strictly adhered to. 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.
Nautical Orientation 006411
14
SPECIAL TOOLS
SPECIAL TOOLS
TABLE OF CONTENTS
DIAGNOSTIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
UNIVERSAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
ELECTRICAL / IGNITION TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
FUEL /OIL SYSTEM TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
POWERHEAD TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
GEARCASE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
TRIM AND TILT TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
SHOP AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
1
15
SPECIAL TOOLS
DIAGNOSTIC TOOLS
DIAGNOSTIC TOOLS
Diagnostic Software P/N 765011 765011 Bootstrap tool P/N 586551 002276 Interface cable P/N 437955 45583
UNIVERSAL TOOLS
Universal Puller Set P/N 378103 32885
Slide hammer P/N 391008 CO1577
Small puller jaws P/N 432131 23150
Lifting eye P/N 321537 23701
Slide hammer P/N 432128 15345
Large puller jaws P/N 432129 23148
Lifting ring assembly P/N 396748 000669
Flywheel holder P/N 771311 42938
Bearing puller jaws P/N 432130 23149
16
SPECIAL TOOLS
UNIVERSAL TOOLS
1
Slide hammer adapter P/N 390898 15356
Tilt tube nut wrench P/N 342680 46879
Temperature gun P/N 772018 45240
Puller Bridge – 432127 23146
Tilt tube service kit P/N 434523 33249
Fresh water flusher P/N 500542 50110
Syringe P/N 346936 50243
†
pincers, P/N 787145
Oetiker
001081
17
SPECIAL TOOLS
ELECTRICAL / IGNITION TOOLS
ELECTRICAL / IGNITION TOOLS
Digital multimeter
Ohms resolution 0.01
Purchase through local supplier
Crimping pliers P/N 322696 30387
DRC7265
Peak reading voltmeter
P/N 507972
Stator Test Adapter P/N 5006211 004222
49799
Test probe kit P/N 342677 45241
Tachometer/timing light P/N 507980 49789
18
Connector tool P/N 342667 42004
†
connector tools
AMP
Primary Lock Tool P/N 777077
Secondary Lock Tool P/N 777078
Release Tool P/N 351413
Lock Installer P/N 777079
002277
FUEL /OIL SYSTEM TOOLS
SPECIAL TOOLS
FUEL /OIL SYSTEM TOOLS
1
Fuel pressure gauge (60 PSI)
P/N 5007100
90° fitting, P/N 353322
005339
Fuel pressure gauge (15 PSI)
P/N 5006397
90° fitting, P/N 353322
POWERHEAD TOOLS
Cylinder bore gauge P/N 771310 45303
Rod cap alignment fixture
P/N 396749
004560
21596
Injector test fitting kit
P/N 5005844
Torquing socket P/N 346187 50242
002465
Piston stop tool P/N 342679
Replacement tip P/N 5006098
46543
Guide rods
P/N 383175
000828
Crankshaft bearing and sleeve
installer P/N 338649
21953C
19
SPECIAL TOOLS
GEARCASE TOOLS
1 2
Wrist pin pressing tool
P/N 396747
23668
1. Wrist pin retaining ring driver
2. Wrist pin cone P/N 331913
GEARCASE TOOLS
P/N 396747
DR1641
Seal installation tool P/N 325453 23651
Universal Driveshaft Shimming Tool
P/N 5005925
1. Lower Driveshaft Shimming Bolt
(S2 gearcase) P/N352878
Gearcase filler
P/N 501882
1
002601
49790
Universal Pinion Bearing Remover
and installer kit P/N 5005927
Gearcase pressure tester
P/N 507977 (Stevens P/N S-34)
Gearcase vacuum tester
P/N 507982 (Stevens P/N V-34)
002805
49794
Universal shift rod height gauge
P/N 389997
Pressing fixture P/N 354059 006782
32872
20
SPECIAL TOOLS
GEARCASE TOOLS
1
Prop shaft bearing housing
installers P/N 354058 (L2)
P/N 354057 (M2)
Gearcase Alignment Gauge Kit
P/N 5006349
006783
004315
Prop shaft bearing housing
remover/puller P/N 354060
Gauging Head, “M2” Type
Gearcases, P/N 5007749
006784
006822
Prop shaft bearing housing
alignment pins P/N 354140
Gauging Head, “L2” Type
Gearcases, P/N 5007750
006788
006823
Backing plate P/N 325867 23621
Driveshaft socket P/N 311875 23261
Bearing Installation Tool
P/N 339778
Driveshaft Puller P/N 390706 32884
32519
Spanner wrench P/N 432400 15358
Prop shaft bearing installer
P/N 432401
15355
21
SPECIAL TOOLS
GEARCASE TOOLS
Slide hammer adapter P/N 432398 15356
Driveshaft seal protector
P/N 318674
23692
1 2
1. Pinion nut holder P/N 334455
2. Wrench retainer P/N 341438
40371
Lower Driveshaft Puller P/N 342681 47257
Pinion nut starting tool P/N 342216 40372
Prop shaft bearing installer
P/N 339750
Prop shaft housing seal installer
P/N 336311
32880
32973
Seal installation tool P/N 330268 32924
Seal installation tool P/N 354056 006824
22
TRIM AND TILT TOOLS
SPECIAL TOOLS
TRIM AND TILT TOOLS
1
Gauge and collar assembly
P/N 983975
Hydraulic cylinder rod holder
P/N 983213
33023
23665
Trim/tilt service kit P/N 390010 33013
Tilt cylinder end cap remover
P/N 352932, for single-piston
tilt systems
005340
Tilt cylinder seal protector
P/N 326005
Spanner wrench P/N 912084 32213
23694
2 1
1. Trim/tilt service kit P/N 434524
2. Replacement o-ring kit for
adapter tips P/N 434729
27340
Tilt cylinder end cap remover
P/N 326485, for three-piston
tilt systems
33741
12
1. Trim cylinder end cap
remover/installer P/N 436710
2. Replacement tip for 436710
33742A
23
SPECIAL TOOLS
SHOP AIDS
SHOP AIDS
Cleaning Solvent P/N 771087
“6 in 1” Multi-Purpose Lubricant P/N 777192
Oil - XD100™ P/N 764357
D.P.L. Spray P/N 777183
Oil - XD50™ P/N 764354
Anti-Corrosion Spray P/N 777193
Oil - XD30™ P/N 764349
HPF XR™ Gear Lube P/N 778749
HPF PRO Gearcase Lube P/N 778755
Engine Tuner P/N 777185
24
Silicone spray P/N 775630
Moly Lube P/N 175356
SPECIAL TOOLS
SHOP AIDS
1
Storage Fogging Oil
P/N 777186
Lubriplate† 777 P/N 317619
Power Trim/Tilt and Power Steering Fluid
P/N 775612
Black Neoprene Dip P/N 909570
Electrical Grease P/N 503243
2 + 4™ Fuel conditioner P/N 775613
Triple-Guard® Grease P/N 508298
Needle Bearing Grease, P/N 378642
Starter Bendix Lube P/N 337016
Biodegradeable TNT Fluid
P/N 763439
Gel-Seal and Gasket Remover P/N 771050
†
Permatex
No. 2, P/N 910032
25
SPECIAL TOOLS
SHOP AIDS
RTV Silicone Sealant P/N 263753
Fuel System Cleaner P/N 763681
Gel·Seal II P/N 327361
Gasket Sealing Compound P/N 508235
Pipe Sealant with Teflon P/N 910048
Locquic Primer P/N 772032
Thermal Joint Compound P/N 322170
Instant Bonding Adhesive P/N 509955
1 2 3
1. Screw Lock P/N 500417
2. Nut Lock P/N 500421
3. Ultra Lock P/N 500423
†
Purple 222 equivalent
(Loctite
(Loctite Blue 242 Equivalent)
(Loctite Red 271 Equivalent)
Carbon Guard™ P/N 775629
26
Adhesive 847 P/N 776964
INSTALLATION AND PREDELIVERY
INSTALLATION AND PREDELIVERY
TABLE OF CONTENTS
BOAT RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
REMOTE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
BATTERY SWITCHES AND MULTIPLE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
AUXILIARY BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
FUEL SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
OILING SYSTEM SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
CABLE AND HOSE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
OUTBOARD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
HULL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
TRANSOM MEASURING AND DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
LIFTING THE OUTBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
STEERING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
OUTBOARD MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
OUTBOARD RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
CABLE, HOSE, AND WIRE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CONTROL CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
ELECTRICAL HARNESS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
WATER PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
CANBUS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
FUEL AND OIL PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
FUEL SYSTEM PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
OIL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
OIL INJECTION RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
BREAK-IN OILING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
OIL SUPPLY PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
BEFORE START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
RUNNING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
ENGINE MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
EMERGENCY STOP / KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
START-IN-GEAR PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
TACHOMETER PULSE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
WATER PUMP OVERBOARD INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PROPELLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
PROPELLER SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
PROPELLER HARDWARE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
FINAL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
TILT LIMIT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
TRIM SENDING UNIT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
TRIM TAB ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
DUAL-OUTBOARD ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
2
27
INSTALLATION AND PREDELIVERY
BOAT RIGGING
BOAT RIGGING
Remote Controls
Control Selection
WARNING
The remote control used must have startin-gear prevention. This feature can prevent injuries resulting from unexpected
boat movement when the outboard starts.
Remote control styles and applications are
described in the Evinrude/Johnson Genuine Parts
and Accessories Catalog. Plan the installation of
all remote controls carefully. Read the outboard's
Operator's Guide and the remote control's installation instructions prior to installation.
The remote control and wiring harness used must
have the following features:
• Start-in-gear prevention
• Emergency stop / key switch
• Shift stroke must measure 1.125 to 1.330 in.
(28.6 to 33.8 mm) between NEUTRAL and
FORWARD
• Throttle stroke must PUSH for open
• All wiring must be compatible with Modular Wir-
ing System (MWS) components
• Dual-outboard controls require separate key
switches with a single emergency stop switch.
Dual-outboard key switches with emergency stop
switch
DRC40118
WARNING
Always install and recommend use of an
emergency stop/key switch. Doing so will
reduce the risk of personal injury or death
should the operator fall away from the controls or out of the boat.
Engine Monitoring System
IMPORTANT: Outboards with remote controls
must be equipped with an I-Command system, a
SystemCheck gauge, or an equivalent engine
monitor. Operating the outboard without an
engine monitor will void the warranty for failures
related to monitored functions.
3
1. Emergency stop clip
2. Safety lanyard
3. Key switch with emergency stop feature
28
Refer to ENGINE MONITORING SYSTEM on
p. 101.
002817
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