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™

Page 4

TABLE

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

Page 5

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

Page 6

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.

Page 7

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.

Page 8

INTRODUCTION

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

Page 9

INTRODUCTION

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

Page 10

INTRODUCTION

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

Page 11

INTRODUCTION

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. Model and serial number 000449

1. Serial number 006828

Page 12

INTRODUCTION

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

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)

)

@ 5150 RPM

Page 13

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)

Page 14

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

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

Page 15

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)

Page 16

INTRODUCTION

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

Page 17

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

Page 18

SPECIAL 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

Page 19

SPECIAL TOOLS

UNIVERSAL TOOLS

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

Page 20

SPECIAL 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

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

Page 21

FUEL /OIL SYSTEM TOOLS

SPECIAL TOOLS

FUEL /OIL SYSTEM TOOLS

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

Page 22

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

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

Page 23

SPECIAL TOOLS

GEARCASE TOOLS

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

Page 24

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

Page 25

TRIM AND TILT TOOLS

SPECIAL TOOLS

TRIM AND TILT TOOLS

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

1. Trim cylinder end cap remover/installer P/N 436710

2. Replacement tip for 436710

33742A

Page 26

SPECIAL TOOLS

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

Silicone spray P/N 775630

Moly Lube P/N 175356

Page 27

SPECIAL TOOLS

SHOP AIDS

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

Page 28

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

Adhesive 847 P/N 776964

Page 29

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

Page 30

INSTALLATION AND PREDELIVERY

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.

1. Emergency stop clip

2. Safety lanyard

3. Key switch with emergency stop feature

Refer to ENGINE MONITORING SYSTEM on p. 101.

002817

Page 31

INSTALLATION AND PREDELIVERY

BOAT RIGGING

Control Installation

Plan the installation of remote controls carefully, following all instructions provided with the remote control.

Make sure the following items are checked:

• Correct length, type and quality of control

cables and wiring harnesses

• Proper routing of cables and harnesses

• Slack in front of the outboard for remote control

cables

• Positioning and securing of cables and har-

nesses along their lengths to prevent movement or damage.

Typical transom-mounted outboard installations require a 12 in. (30 cm) cable loop at the front of the outboard when the cables are routed from the side of the splash well.

Battery Installation

Each outboard requires its own starting battery. Select a battery that meets or exceeds the minimum requirements.

Minimum 12 Volt Battery Recommendations

Outboard Model Battery Rating

115–300 HP 675 CCA (845 MCA), or

750 CCA (940 MCA) below 32°F (0°C) 107 amp-hr in extreme applications

Location and Preparation

Proper installation will prevent battery movement while underway.

• Secure all batteries in protected locations.

• Place battery as close to the outboard as possi-

ble.

• Battery location must provide access for peri-

odic maintenance.

• Use battery mounting trays or battery boxes on

all battery installations.

• Connections and terminals must be covered

with an insulator.

• Battery connections must be clean and free

from corrosion.

• Read and understand the safety information

supplied with the battery before installation.

123

1. Surface side-mount remote control

2. Cable support

3. 12 in. (30 cm) cable loop at front of outboard

DR4277

IMPORTANT: Cables of the proper length,

style, and quality that are correctly installed and adjusted will eliminate most control-related operational problems.

WARNING

Keep the battery connections clean, tight, and insulated to prevent their shorting or arcing and causing an explosion. If the battery mounting system does not cover the connections, install protective covers. Check often to see that connections stay clean and tight.

Page 32

INSTALLATION AND PREDELIVERY

BOAT RIGGING

Connections IMPORTANT: Connect the battery positive (+)

cable to the battery positive (+) post FIRST. Connect the battery negative (–) cable to the battery negative (–) post LAST.

Install a starwasher on the threaded battery post. Stack cables from the outboard, then cables from accessories. Finish this connection with a hex nut.

Marine Style Battery Post

1. Starwasher

2. Hex nut

3. Terminal Insulator

DR5103

IMPORTANT: Do not use wing nuts to fasten

ANY battery cables. Wing nuts can loosen and cause electrical system damage not covered under warranty.

Tighten all connections securely. Apply Triple- Guard grease to prevent corrosion.

Battery Cable Requirements

Evinrude outboards are shipped with stranded copper battery cables for typical installations in which the starting battery is positioned close to the transom.

Specialized outboard installations with extended length battery cables require an increased wire size. Refer to the following table.

IMPORTANT: Inadequate battery cables can

affect the performance of an outboard’s high amperage start circuit and the cranking speed of the outboard. DO NOT use aluminum wire cables. Use ONLY AWG stranded copper wire cables.

40–250 HP

1 to 10 Ft. (.3 to 3 m)

11 to 15 Ft.

(3.4 to 4.6 m)

16 to 20 Ft.

(4.9 to 6.1 m)

4 Gauge

2 Gauge

1 Gauge

Battery Switches and Multiple Batteries

A multiple battery setup, including marine battery selector switches, can provide flexibility in single and dual outboard installations.

Refer to Battery and Switch Wiring Diagrams on p. 33 for various battery connection options.

The battery selection function can be used for emergency starting if a primary battery becomes discharged.

The OFF position of the battery selector switch can be used to minimize battery discharge during periods of non-use.

Page 33

INSTALLATION AND PREDELIVERY

BOAT RIGGING

Typical battery functions IMPORTANT: Never connect an external bat-

tery isolator to the stator of an Evinrude E-TEC.

Primary

• Used as starting battery under normal operating

conditions.

• Red (+) cable connected to battery selector

switch.

• Primary battery is charged by connection to

main red (+) outboard battery cable.

Dual outboard installations can utilize the opposing outboard's primary battery as a secondary battery for emergency starting only.

Secondary

• Used as back-up starting battery under abnor-

mal operating conditions.

• Red (+) cable connected to battery selector

switch.

• Secondary battery is charged independently

from primary battery.

Accessory

• Not used as starting battery.

• Isolated from outboard start function.

• No red (+) cable connected to battery selector

switch.

Secondary and accessory batteries are often charged by an isolated battery charging circuit. Refer to Auxiliary Battery Charging on p. 32.

Battery Switch Requirements

Battery switches must meet the following requirements.

• The switch must be approved for marine use.

• The switch should be a “make before break”

design to protect the charging system from a no-load condition.

• Switch amperage rating should be adequate for

the outboard it will be used on.

• Use one battery switch for each outboard

installed.

• Use the appropriate sized wire and terminals for

all connections.

• Use AWG stranded copper wire. Battery Switch Location

• Always locate battery switch as close to the bat-

teries as possible.

• Locate switch so that it cannot be accidently

bumped or switched.

• Refer to the battery switch manufacturer’s

installation instructions for specific information related to the installation of switch.

• Fasten all battery switches to solid surfaces.

• Route wiring as directly as possible.

• Support the battery switch as needed to prevent

abrasion.

• Use appropriate wiring and connectors.

• Seal all connections and terminals with liquid

neoprene or electrical sealer to prevent corrosion.

IMPORTANT: Insulate all battery positive (+)

terminals to prevent shorting.

Page 34

INSTALLATION AND PREDELIVERY

BOAT RIGGING

Battery Switch Operation

• Select the primary battery for normal operation.

• Secondary batteries should only be selected for

emergency starting.

• ALL or BOTH switch position is for emergency

starting only.

Provide operator with the documentation supplied by the battery switch manufacturer. Make sure that the operator is informed of proper battery switch operation.

IMPORTANT: The negative (–) terminals of a

multiple 12-volt battery installation must be connected together.

Auxiliary Battery Charging

Evinrude E-TEC V4–V6 outboards are equipped with isolated battery charging capability. The isolated charge connection must only be used to charge a single 12-volt battery or two 12-volt batteries wired in parallel.

IMPORTANT: Never connect an external bat-

tery isolator to the stator of an Evinrude E-TEC outboard.

Accessory Charge Lead Kit, P/N 5006253, is routed from a connector on the outboard’s electrical panel to the accessory battery.

1 2

1. Starting battery (primary)

2. Accessory battery (secondary)

3. Cable connecting negative (–) battery terminals

DRC7284

1. Accessory battery charge connector 003912

IMPORTANT: The accessory charging kit must

never be connected to any battery of a 24-volt electrical system.

Page 35

Battery and Switch Wiring Diagrams

INSTALLATION AND PREDELIVERY

BOAT RIGGING

ne outboard: Battery disconnec

OFF

PRIMARY

000135rev1

ne outboard: One primary starting

battery; one secondary battery

BOTH

OFF

SECONDARY

PRIMARY

Two outboards: Two starting batteries for each outboard

BOTH

OFF

SECONDARY

Positive (+) Battery cables Negative (–) Battery cables Accessory charge wires, P/N 5006253 50 amp Fuse

SECONDARY

PRIMARY

BOTH

OFF

PRIMARY

000134N

Page 36

INSTALLATION AND PREDELIVERY

BOAT RIGGING

Two outboards: One primary starting battery for each outboard; one isolated accessory battery

PRIMARY

BOTH

OFF

BOTH

OFF

ACCESSORY

PRIMARY

Two outboards: One primary starting battery for each outboard; two isolated accessory batteries

PRIMARY

BOTH

OFF

ACCESSORY

Positive (+) Battery cables Negative (–) Battery cables Accessory charge wire, P/N 5006253 50 AMP Fuse

ACCESSORY

BOTH

OFF

PRIMARY

000086N

Page 37

INSTALLATION AND PREDELIVERY

BOAT RIGGING

Fuel System Requirements

Overview

Boat fuel systems must meet minimum specifications to insure the proper delivery of fuel to the outboard.

The guidelines established by the ABYC and U.S. Coast Guard should always be followed.

• Permanent fuel tanks must be properly vented

outside of the hull.

• Remote fuel tank gas fills must be grounded.

• Permanent fuel tank pickups should have the

correct anti-siphon valve installed to prevent fuel flow if a leak occurs in the fuel distribution system. Refer to ABYC Standard H-24.

Fuel Hose

All fuel hoses must be designated as fuel hose and approved for marine use.

• Use only fuel lines (or copper tubing) that meet

the outboard minimum I.D. requirement.

• “USCG Type A1” fuel hose must be used

between permanent fuel tanks and motor well fittings on inaccessible routings.

• Use “USCG Type B1” for fuel hose routings in

motor well areas.

• Permanently installed fuel hoses should be as

short and horizontal as possible.

• Use corrosion-resistant metal clamps on per-

manently installed fuel hoses.

• Multi-outboard applications require separate

fuel tank pickups and hoses. (A fuel selector switch may be used for “kicker” motors as long as it has enough flow capacity for the larger outboard.)

Fuel System Primer

Outboards require a priming system capable of refilling the fuel system after periods of non-use.

Primer bulbs that meet the outboard's minimum inside diameter fuel line requirements are used on most outboards.

Install the primer bulb in the fuel supply hose as follows:

• The primer bulb should be installed in an acces-

sible location.

• The arrow on the primer bulb must point in the

direction of fuel flow.

• The fuel primer bulb must be positioned in the

fuel supply hose so the primer bulb can be held with the arrow pointing “up” during priming.

1. Arrow indicates direction of fuel flow 000124

An alternative to a primer bulb is a U.S. Coast Guard approved marine primer pump. Electric primer pumps offer the convenience of outboard priming from a dash-mounted momentary switch.

Page 38

INSTALLATION AND PREDELIVERY

BOAT RIGGING

Fuel Filters

Boat-mounted fuel filters and water-separating fuel filter assemblies must meet the required fuel flow and filter specification. The filter must be mounted to a rigid surface above the “full” level of the fuel tank and accessible for servicing.

Fuel Filter Assembly, P/N 174176, meets all requirements for a water-separating fuel filter.

1 2 3

Typical Fuel Supply Configuration

1. Primer bulb

2. Water separating fuel filter

3. Anti-siphon valve, in fuel pick-up of tank

DRC6797

IMPORTANT: Avoid using “in-line” fuel filters.

The filter area and flow characteristics may not be adequate for high horsepower outboards.

Portable Fuel Tanks

Do not use portable fuel tanks for outboards larger than 115 HP. Inadequate fuel flow to high horse-

0070

power outboards can result in serious powerhead damage.

Outboard Fuel System Recommendations

Component 25 HP – 130 HP Models 135 HP – 250 HP Models

Fuel tank pickup tube 5/16 in. (7.9 mm) min. I.D. 3/8 in. (9.5 mm) min. I.D. Fuel fittings 1/4 in. (6.4 mm) min. I.D. 9/32 in. (7.1 mm) min. I.D. Fuel supply hoses 5/16 in. (7.9 mm) min. I.D. 3/8 in. (9.5 mm) min. I.D.

ALL MODELS

Fuel tank pickup screen 100 mesh, 304 grade stainless steel wire, 0.0045 in. wire diameter,

1 in. (25 mm) long

Antisiphon valve 2.5 in. (63.5 mm) Hg maximum pressure drop at 20 gph (76 l/hr)

flow

Remote fuel filter 0.4 in. Hg maximum pressure drop at 20 gph (76 l/hr) flow,

150 in.

Maximum fuel pump lift height Fuel pump should not be located more than 30 in. (76.2 cm) above

bottom of fuel tank

(1290 cm2) of filter area

Page 39

INSTALLATION AND PREDELIVERY

BOAT RIGGING

Oiling System Set-Up

Location IMPORTANT:

of the oil tank carefully. The oil tank is vented to the atmosphere. To avoid serious powerhead damage, be sure the oil tank is installed in a location that does not allow constant exposure to sunlight, rain, bilge water or spray.

Select a mounting location that provides:

• A solid place to mount the tank;

• A dry location that prevents exposure to rain or

spraying water;

• Access for adding oil;

• Access to oil-primer bulb; and

• Interference-free hose and wire routing to out-

board.

If necessary, the oil tank can be mounted further from the outboard than the supplied hoses and harness allow. The maximum length of oil supply hose that can be fitted to the oil tank is 25 ft. (7.6 m).

Consider the installation location

• Replacement hose must be designated for fuel

or oil use and approved for marine use.

• Extend wiring harness with 16 gauge AWG

wire.

• Protect connections with heat shrink tube.

• Maintain wire color and polarity when extending

harness.

An appropriately sized battery box may be used to conceal and protect the oil tank, if desired.

IMPORTANT: Be sure box includes drain holes

so it does not fill with water and contaminate oil.

IMPORTANT: Do not add hose to an existing oil

supply hose. If the oil tank requires a longer oil supply hose:

• Oil supply hose between the primer bulb and

outboard must be replaced with one continuous length of 1/4 in. (6.4 mm) hose.

• Maximum length of hose is 25 ft. (7.6 m).

000074

Mounting

Place tank in selected position. Mark one line under groove in tank bottom and lines at each end of tank.

1. Center line of oil tank

2. Ends of tank

Make sure hole locations provide enough clearance for fastening screws. Screws should not contact or penetrate hull.

44737

Page 40

INSTALLATION AND PREDELIVERY

BOAT RIGGING

Place floor bracket on center line between end lines. Use the inner bracket holes as guides to drill two 5/32 in. (4 mm) pilot holes.

COB5381

3 GALLON (11.4 L) TANK

Place rods into floor bracket and secure floor bracket with lag bolts.

1.8 GALLON TANK

Place rods into floor bracket and secure floor bracket with lag bolts.

1 2

1. Rods

2. Lag bolts

Place oil tank onto floor bracket. If cover is not pre-assembled, route oil supply hose and harness through the cover and position cover on the oil tank. Attach spring-loaded rods to cover.

1 2

22149A

1. Rods

2. Lag bolts

22241B

Place oil tank onto floor bracket. Assemble crossbar onto hook rods, install flat washers and locknuts. Tighten locknuts to securely hold tank.

48704

1. Crossbar DRC7418

Page 41

Oil Tank Profiles

INSTALLATION AND PREDELIVERY

BOAT RIGGING

1.8 Gallon Tank P/N 176995

Remote Oil Fill Kit (Optional)

The remote oil fill kit (P/N 176461) provides a deck-mounted fill tube, cap, a tank-mounted tube, and nut that replace the original oil tank cap assembly.

3 Gallon Tank

P/N 176996

Installation Recommendations

• Select a location on the deck of the boat that is

above the oil tank fill cap.

• Select a deck location which allows the required

length of 1½ in. I.D. fill hose to route as directly and as vertically as possible.

• Avoid inappropriate hose routings that could

distort the fill tube or tank tube.

• Refer to installation instructions provided with

remote oil fill kit.

A slanted area of the deck will allow water to drain away from the fill and is best suited for the installation.

DRC8123

Additional Items Required

• 1½ in. I.D. fill hose cut to required length. Fill

hose (P/N 123956) is available in 25 ft. (7.6 m) lengths.

• Two corrosion resistant 2 in. (50 mm) hose

clamps.

Page 42

INSTALLATION AND PREDELIVERY

BOAT RIGGING

Cable and Hose Installation

Before installation, identify all required wiring, cables, and hoses:

• Throttle and shift cables

• Instrument harnesses

• Battery cables and switches

• Oil tank sender harness

• Fuel supply hose

• Primer bulb or primer pump

• Oil supply hose

Determine whether any additional wiring or hoses will be needed for accessory gauges or batteries:

• Speedometer pick-up hose

• Mechanical water pressure gauge hose

• Accessory battery charging kit

• CANbus adapter harnesses

• CANbus water pressure sensor kit

• CANbus oil level sensor kit

12345

Cable and Wire Harness Routing

WARNING

Improper installation and routing of outboard controls could wear, bind, and damage components, causing loss of control.

Remote control cables, wiring, and hoses must follow a similar path into the lower motor covers. Select the best routing for the specific application.

All cables, wiring, and hoses must be long enough to provide adequate slack. Check clearances at all possible combinations of trim angles and steering positions.

6 7 8 9

Typical outboard installation

1. Oil tank

2. Anti-siphon valve

3. Water separating fuel filter

4. Starting battery

5. Accessory battery

6. Flexweave protective sleeve

7. Access cover

8. Primer bulb

9. Battery switch

Typical Small Splash Well DRC7799

DRC6487

Typical Large Splash Well DRC7797

Page 43

INSTALLATION AND PREDELIVERY

BOAT RIGGING

Fuel Hose

The fuel hose may be routed outside of the protective sleeve or conduit. Electric primers or manual primers may not require this consideration.

Typical Engine Bracket DRC7798A

Protective Sleeve/Conduit

Make sure all cables, wiring, and hoses have been identified and fitted to the appropriate lengths. Refer to OUTBOARD RIGGING on p. 52.

Next, bundle the components that route to the outboard with appropriate shielding, such as an expandable “flexweave” sleeve or a flexible conduit.

Route fuel hoses with enough slack to allow the primer bulb arrow to point “up” during use.

Install the primer bulb with the arrow pointing in the direction of fuel flow to the outboard.

Connect the fuel supply hose from the fuel tank to the fuel supply line at the outboard.

IMPORTANT: Do not permanently fasten this

connection until the boat's fuel system has been primed.

Oil Supply Hose

Evinrude E-TEC V4–V6 outboards use a single oil supply hose connected to the outboard and to the boat-mounted oil tank.

• Route the hose from the oil tank to the ¼ in. (6.4

mm) fitting of the oil supply line at the lower motor cover.

• Install the hose on the fitting using the proper

†

size Oetiker

clamp.

Flexible conduit installation 005138

Battery Cables

Evinrude outboards are equipped with premium quality battery cables that should be long enough for most installations.

When routing battery cables, be sure to:

• Route cables through the protective sleeve.

• Use the most direct path to route the battery

cables to the battery or battery switch.

1. Fuel supply hose and fuel fitting - 3/8 in. (9 mm)

2. Oil supply hose and fitting - 1/4 in. (6 mm)

003963

Page 44

INSTALLATION AND PREDELIVERY

BOAT RIGGING

†

Oetiker

Use Oetiker† clamps for making hose connections. These clamps provide corrosion resistance, minimize the potential for abrasion of rigging components, and provide solid, permanent connections.

The selection and installation of an Oetiker clamp is essential in the proper sealing of hose connections. The clamp identification numbers appear in millimeters on the side of the clamp, near the top of the ear. Refer to Oetiker Stainless Steel Step-

less Clamps chart for actual dimensions.

Clamp Servicing

WARNING

1. Clamp identification numbers 000093

DO NOT re-use Oetiker clamps. Fuel leakage could contribute to a fire or explosion.

The nominal size of the clamp should be chosen so that, when it is assembled on the connecting part, the outside diameter of the hose lies approximately in the middle of the clamping range of the clamp.

Oetiker Stainless Steel Stepless Clamps

CLAMP NO. NOMINAL O.D. INCHES MILLIMETERS

Replacement Clamp I.D. Inches MM Open Closed Open Closed

346930 95 3/8 9.5 0.374 0.307 9.5 7.8 348838 105 13/32 10.5 0.413 0.346 10.5 8.8 349516 113 7/16 11.3 0.445 0.378 11.3 9.6 347107 133 1/2 13.3 0.524 0.425 13.3 10.8 347108 138 17/32 13.8 0.543 0.449 13.8 11.3 346931 140 34/64 14 0.551 0.453 14 11.5 346785 145 9/16 14.5 0.571 0.472 14.5 12 346786 157 5/8 15.7 0.618 0.52 15.7 13.2 348839 170 11/16 17 0.669 0.571 17 14.5 346150 185 23/32 18.5 0.728 0.602 18.5 15.3 346151 210 13/16 21 0.827 0.701 21 17.8 346152 256 1 25.6 1.008 0.882 25.6 22.4 346153 301 1 3/16 30.1 1.185 1.063 30.1 26.9 349759 316 1 1/4 31.6 1.244 1.122 31.6 28.4 349729 410 1 5/8 41 1.614 1.492 41 37.9

Page 45

INSTALLATION AND PREDELIVERY

BOAT RIGGING

Clamp Installation

A constant stress should be applied to close the ear clamps. This method ensures a positive stress on the hose and does not result in excessive compression or expansion of the band material.

IMPORTANT: Use only Oetiker recommended

tools to close Oetiker stepless clamps. Oetiker pincers are available in the

Evinrude/Johnson Genuine Parts and Accessories Catalog (P/N 787145).

Clamp Removal

Method 1: Position Oetiker pincers across clamp

ear and cut clamp.

000108

Method 2: Lift end of stepless clamp with screwdriver.

DP0886

• Position correct size clamp over hose.

• Install hose on fitting.

• Close clamp ear fully with Oetiker pincers (pli-

ers).

1. Open clamp

2. Closed clamp

000092

000090

Method 3: Use Oetiker pincers (pliers) to grip clamp. Pull clamp off of connection and discard.

000091

Page 46

INSTALLATION AND PREDELIVERY

OUTBOARD INSTALLATION

Control Cable Identification IMPORTANT: Control cable function must be

identified before rigging outboard. Identify each control cable:

• Put the control handle into NEUTRAL position.

The throttle cable casing guide will retract completely and the shift cable casing guide will go to the midpoint of its travel.

1. Shift cable casing guide extended to midpoint

2. Throttle cable casing guide retracted

Extend the control cables and lubricate them with Triple-Guard grease.

DP0811

OUTBOARD INSTALLATION

Hull Preparation

Maximum Capacity

WARNING

Do not overpower the boat by installing an outboard that exceeds the horsepower indicated on the boat’s capacity plate. Overpowering could result in loss of control.

Before installing outboard:

• Refer to the boat manufacturer's certification

label for maximum horsepower rating.

• Refer to ABYC Standards to determine the

maximum horsepower capacity for boats without certification labeling.

30501

1029A

Mounting Surface

Inspect transom surface before drilling mounting holes.

• The transom should meet ABYC Standards.

• The transom must be flat.

• The transom angle should be approximately 14

degrees.

• Check transom strength and height.

The stern brackets must contact the flat surface of the transom. Modify trim that prevents the stern brackets from resting against the transom surface. Do not modify stern brackets.

Page 47

WARNING

DO NOT install an outboard on a curved or irregular surface. Doing so can wear, bind, and damage components, causing loss of control.

Transom Clearances

Make sure the transom and splash well area provide adequate clearances:

• The top edge of the transom should be wide

enough to allow full steering travel. The ABYC standard for most single outboard installations is 33 in. (84 cm).

• Check cable and hose routing clearances.

• Make sure there is clearance for mounting bolts

and washers. Check the inside area of the transom for obstructions before drilling holes.

INSTALLATION AND PREDELIVERY

OUTBOARD INSTALLATION

Transom Brackets and Jack Plates

When mounting an outboard on boats equipped with transom brackets or jack plates, refer to the manufacturer's recommendations.

• Confirm maximum weight and horsepower

capacities.

• Jack plate assemblies must provide a one-piece

mounting surface to support the outboard.

DR5704

Water Flow

Inspect the hull area directly in front of the mounting location.

• Boat-mounted equipment should not create tur-

bulence in the water flow directly in front of the outboard's gearcase. Turbulence or disruptions in the water flow directly in front of the gearcase will affect engine cooling and propeller performance.

• Avoid locating outboard centerlines within 3 in.

(76 mm) of bottom strakes on dual-outboard installations.

Mounting Hardware

WARNING

Use all mounting hardware supplied with the outboard to help ensure a secure installation. Substituting inferior hardware can result in loss of control.

The required outboard mounting bolts, backing plates, washers, and nuts are used to attach the outboard to the frame of the shipping pallet.

Refer to the outboard's parts catalog for alternate length mounting bolts or replacement parts.

• Use only Evinrude/Johnson Genuine Parts or

parts of equivalent type, strength, and material.

• Use the mounting hardware provided with out-

board whenever possible.

Page 48

INSTALLATION AND PREDELIVERY

OUTBOARD INSTALLATION

Transom Measuring and Drilling

Hull Centerline

Use the chines of the boat as reference points to locate the centerline of the boat transom.

Use a straightedge to draw a line connecting the port and starboard chines.

Use a framing square to accurately place a vertical line on the transom. The centerline of the hull should be in line with the keel, and perpendicular to the midpoint of the line connecting the chines.

IMPORTANT: Some steering systems may

require additional spacing. Refer to steering system manufacturer for recommendations.

The top edge of the transom should be more than twice the width of the dual-outboard centerline spacing dimension. Bracket installations may not require this consideration.

Measure the transom for dual-outboard spacing after the centerline of the hull is established.

Divide the spacing dimension by two. Use the resulting number to space the outboard centerlines from the hull centerline.

EXAMPLE: A 26 in. (660 mm) dual-outboard spacing would result in two outboard centerlines, each 13 in. (330 mm) from the hull centerline.

1234

1. Chine

2. Strake

3. Keel

4. Hull centerline

DR5568

Dual-Outboard Centerlines

The following table lists standard ABYC centerline spacing between outboards in dual installations:

V4 and V6 26 in. (660 mm)

Some applications may require changes in this dimension to avoid strakes, to adjust for transom height, or for performance reasons. Best performance can be determined only through testing. Refer to boat manufacturer for recommendations.

If the standard spacing does not allow full steering travel in a particular installation, it may be necessary to increase the spacing.

1 2 3

1. Port centerline

2. Hull centerline

3. Starboard centerline

DRC5527B

Page 49

INSTALLATION AND PREDELIVERY

OUTBOARD INSTALLATION

Transom Height

Make sure the transom height matches the length of the outboard to be installed.

• A 19 to 21 in. (48.3 to 53.3 cm) transom height

uses a 20 in. (50.8 cm) shaft outboard.

• The shaft length of the outboard being installed

should come close to matching the transom height of the boat.

Determine transom height by measuring from the top edge of the transom, along the centerline.

For dual-outboard installations, transom height should be measured at the outboard centerlines.

Use a straightedge as a reference to extend the bottom of the boat.

Position the straightedge along centerline. The distance from the top edge of the straightedge to the top edge of the transom is the actual transom height.

Position drill fixture on top of transom or bracket and align indicator points with centerline.

Transom drill fixture P/N 434367 (heavy duty) 24496

The indicators are affected by the squareness of the top edge of the transom. If either side of the fixture must be raised more than ¼ in. (6 mm) above the transom's top surface to make both indicators align, the transom must be modified.

IMPORTANT: DO NOT assume that the top

edge of the transom is straight. Position the drill fixture based on measurements aligning it to the bottom of the hull.

1. Top edge of transom

2. Actual transom height

DR5541

Transom Drilling Locations

All models use the standard ABYC 4-Bolt mounting pattern.

Transom drill fixture, P/N 434367 or P/N 385368, may be used as a guide for correct hole placement. If drill fixture is unavailable, refer to Drilling and Hardware Diagrams on p. 48 for measurements.

IMPORTANT: Maintain at least 1.75 in. (45 mm)

of transom surface above the top mounting bolts. Before drilling any mounting holes:

• Make sure the hole locations provide enough

clearance for mounting bolts and washers.

• Check the inside area of the transom for

obstructions.

• Check transom height(s) at centerlines.

Drill four ½ in. (13 mm) mounting holes in the appropriate locations.

IMPORTANT: Be sure to drill the required holes

perpendicular to transom surface.

Page 50

INSTALLATION AND PREDELIVERY

OUTBOARD INSTALLATION

Drilling and Hardware Diagrams

IMPORTANT: This is not a template.

2''

(50.8mm)

(203.2mm)

6 7/16"

(136.5mm)

6 7/16"

(136.5mm)

90˚

(50.8mm)

(203.2mm)

4 15/16"

(125.4mm)

4 15/16"

(125.4mm)

Quantity

1. Center of Transom 5. Bolt * 4

2. Top of Transom 6. 318272 Plate 2 327053 3 in. (76 mm)

3. 1/2” Bolt Hole Locations 7. 318273 Retainer 2 318573 3 1/2 in. (89 mm)

4. Outside of Transom 8. 319886 Screw 4 313327 4 in. (102 mm)

9. 307238 Washer 2 336676 4 1/2 in. (114 mm)

10. 320248 Washer 4 331578 5 in. (127 mm)

11. 313623 Nut 4 321577 6 in. (152 mm)

12. 318572 Cap 4

* Choose from the following bolt sizes:

000133m

Page 51

INSTALLATION AND PREDELIVERY

OUTBOARD INSTALLATION

Lifting the Outboard

Lifting Fixtures

WARNING

To avoid personal injury, make sure the lifting capacity of the hoist is at least twice the weight of the outboard.

DO NOT allow the lift hook or chain from the hoist to come in contact with any part of the engine during lifting.

Remove shipping carton. The mounting hardware used to attach the out-

board to the pallet is reused to fasten outboard to boat transom.

Use correct Lifting Fixture to lift outboard:

Model Lifting Fixture

90° V6 P/N 396748

Steering Systems

Mechanical Cables

All Evinrude outboards equipped with tilt tubes are compatible with mechanical steering systems that meet ABYC Standard P-17. Single-cable mechanical steering systems can be used on single or dual-outboard installations if an ABYC-approved steering link is used.

Dual-cable mechanical steering helps provide firm steering control at high speeds.

Extend the steering cable and lubricate the inner core before installation.

Position lifting tool on flywheel and seat the three screws completely.

1. Lifting fixture

2. 1 3/4 in.screws

Fasten appropriate chain hook to eye of tool. Carefully hoist outboard with chain and unbolt outboard mounting brackets from frame.

002419

ABYC-approved mechanical steering cable. 5873

IMPORTANT: Install steering cable through tilt

tube before mounting outboard on transom. Tighten nut securely.

WARNING

DO NOT use cable over pulley steering on 40 HP and larger outboards.

Page 52

INSTALLATION AND PREDELIVERY

OUTBOARD INSTALLATION

Manual Hydraulic Steering

Manual hydraulic steering systems use hydraulic fluid to transfer motion and load from the helm to the outboard.

Use only a hydraulic steering system designed for the specific application. Refer to the steering system manufacturer’s specifications for recommended applications.

Typical manual hydraulic steering 004948

Drag Links

Use the correct drag link to allow full steering travel:

Model Drag Link

90° V6 P/N 175125

Install cable wiper nut on tilt tube and connect drag link to the correct location on the steering arm. For single engine, single cable applications, the drag link should be installed in the rear hole.

IMPORTANT: Some hydraulic steering systems

require additional centerline spacing in dual-outboard installations. Refer to steering system manufacturer’s recommendations and to Dual- Outboard Centerlines on p. 46.

1. Drag link connection

2. Wiper nut

1 2 3

1. Rear Location (D)–Steering drag link connection

2. Middle Location (P)–Power steering connection (Refer to manufacturer’s instructions for hydraulic steering systems.)

3. Front Location (T)–Bar connection (multiple outboard installations)

002097

DRC7162

Page 53

INSTALLATION AND PREDELIVERY

OUTBOARD INSTALLATION

Outboard Mounting

IMPORTANT: Some rigging components, such

as steering cables, must be fitted to the outboard before the outboard is mounted to the transom. Determine what equipment will be installed before mounting.

Mounting Height

Boat performance depends on outboard mounting height.

Generally, the anti-ventilation plate of the gearcase should align with the bottom of the hull. Conventional V-hulls often perform well with the antiventilation plate approximately 1 in. (25 mm) above the bottom of the hull.

Boats that exceed 50 MPH may benefit from higher outboard heights. Consult the boat manufacturer for specific outboard mounting height information for a particular hull.

Test outboard and boat performance at different heights until the best performance is achieved.

IMPORTANT: Be sure that outboard water

pressure is not adversely affected by the mounting height of the outboard.

Mounting Bolt Installation IMPORTANT: Use a marine sealant rated for

above or below waterline use. RTV silicone is not approved for below waterline use. Polyurethane sealants are not easily removed and may damage outboard or boat mounting surfaces.

Apply marine sealer under hex heads of bolts, on the mounting plates, and to the bolt shanks.

Assemble transom mounting plates on mounting bolts.

Install the mounting bolts through the transom from the inside of the boat.

DR5536

Position the square aluminum transom mounting plates (when applicable) so the retainer holes are horizontal.

Position hex head of bolt with flats toward holes in the mounting plates. Install retainer over hex head of the bolt and secure it with screws provided.

Install all washers and nuts. Tighten to a torque of 40 ft. lbs. (54 N·m).

WARNING

If either side of the transom deforms or cracks when the bolts are tightened to their recommended torque, the transom construction may not be adequate or may be deteriorated. Structural failure of the transom could result in loss of boat control and injury to the occupants.

0078A

Page 54

INSTALLATION AND PREDELIVERY

OUTBOARD RIGGING

CAUTION

To prevent accidental starting while servicing, disconnect the battery cables at the battery. Twist and remove all spark plug leads.

Cable, Hose, and Wire Routing

Remove two screws and bracket that fasten the grommet to lower motor cover.

Refer to the following diagram to ensure proper positioning of rigging components in grommet.

1. Fuel supply hose

2. Fuel supply hose--alternate location

3. Oil supply hose

4. Oil tank sending unit harness

5. Battery cables

6. Main wire harness (MWS)

7. Shift cable

8. Throttle cable

9. Accessory charge wires

10. CANbus harness

11. Water pressure hose

12. Speedometer hose

000095

1. Grommet retaining bracket 003964

Route all hoses, control cables, and wiring through a protective sleeve or conduit into the boat and through the grommet.

The fuel hose may be routed through the protective sleeve or through an alternate hole in the lower motor cover grommet.

To route the fuel hose outside the sleeve, trim the material covering the alternate fuel hose slot in the grommet.

1. Alternate fuel hose location 003970

1. Alternate fuel hose location 003971

The main wiring harness, battery cables, oil tank sending unit harness, and any CANbus cables should be routed along the same path to the star-

Page 55

INSTALLATION AND PREDELIVERY

OUTBOARD RIGGING

board side of the powerhead. Secure all cables with clamps.

003974

IMPORTANT: After installation, make sure

there is enough clearance for all cables to avoid binding or chafing through all engine steering and tilting angles.

Control Cable Installation

Refer to Control Cable Identification on p. 44.

• Use long nose pliers to insert straight section of

clip into linkage pin hole.

1 2

1. Straight section

2. Angled section

DP0818 DP0817

• Push the clip towards the hole while lifting on

the curved end with the pliers.

• Be sure retainer clip fully engages the pin.

• Lock the retainer by moving the angled section

behind the straight section.

Remove remote control cable trunnion covers and cable attachment hardware.

1. Trunnion covers 005037

Cable Retainer Clip Installation

When installing retainer clips on control arm linkage pins, clips should be locked and must not be bent or deformed.

For proper installation, review the following steps:

• Place washer on pin.

• Position retainer clip with straight section on the

bottom and angled section on the top.

Locked Retainer Clip

1. Angled section behind straight section

DP0817A

Shift Cable Installation and Adjustment

Place the shift cable on the shift lever pin and install the washer and retainer clip.

IMPORTANT: Do not bend or deform clip.

Confirm that the remote control, gearcase, shift linkage, and shift cable are in NEUTRAL.

Hold the shift linkage in NEUTRAL. Push and pull on the shift cable and observe the

cable slack. Position the casing guide in the center of the slack.

Adjust shift cable trunnion to align with center of the trunnion block. Place cable trunnion in trunnion block.

Page 56

INSTALLATION AND PREDELIVERY

OUTBOARD RIGGING

Install trunnion cover and screw. Tighten retaining screw to a torque of 60 to 80 in. lbs. (7 to 9 N·m).

1. Shift cable retainer clip and washer

2. Shift cable trunnion

005038

Throttle Cable Installation and Adjustment

With remote control lever in NEUTRAL, pull firmly on firmly on throttle cable casing to remove slack.

Place throttle cable on throttle lever pin and install washer and retainer clip.

1. Throttle linkage, idle stop against crankcase 003968

Adjust the throttle cable trunnion to align with the trunnion block. Place the cable trunnion in the trunnion block.

IMPORTANT: Move control handle to FOR-

WARD and pull back slowly to NEUTRAL. Make sure the engine throttle lever is against the stop. If not, remove slack by adjusting cable trunnion.

1. Throttle cable retainer clip and washer 003967

With remote control lever in NEUTRAL, pull firmly on firmly on throttle cable casing to remove slack.

Install the trunnion cover and screw. Tighten the retaining screw to a torque of 60 to 80 in. lbs. (7 to 9 N·m).

1. Trunnion cover and screw, throttle cable 005039

Page 57

INSTALLATION AND PREDELIVERY

OUTBOARD RIGGING

Electrical Harness Connections

Remove harness connector cover.

003972

Before installing electrical connectors, check that the seal is in place. Clean off any dirt from connectors. Apply a light coat of Electrical Grease to the seal.

™

Install battery cables on starter solenoid and main ground stud.

1. Positive (+) battery connection

2. Ground (–) connection

003975

IMPORTANT: BE SURE all harnesses and

wires are not pinched, cannot contact flywheel, and do not interfere with moving throttle or shift linkages.

Replace harness connector cover.

1. Seal 42079A

Connect outboard main wire harness to boat main wire harness. Secure connectors in bracket. Refer to the diagram inside of the electrical cover.

1. Harness connections 003973

Water Pressure Gauge

If a mechanical water pressure gauge is used, install the water pressure hose fitting in the cylinder block. Use Pipe Sealant with Teflon, P/N 910048, on the threads of the hose fitting. Refer to installation instructions supplied with gauge.

Route the water pressure hose around the starboard side of the powerhead along the same path as the battery cables.

1. Water pressure hose fitting 005035

Page 58

INSTALLATION AND PREDELIVERY

OUTBOARD RIGGING

CANbus Connections

If the outboard will be used with I-Command, or other NMEA 2000 compliant CANbus instruments, the following connections will supply information to the network.

Connect the EMM CANbus connector to the CANbus Network Harness.

1. EMM CANbus connector 004265

Use a CANbus Ignition Harness, in place of the standard MWS harness, to connect the outboard to the key switch and trim/tilt control. Seal unused SystemCheck connector with 6-Pin Connector Seal, P/N 586076.

If installing a Deutsch-style I-Command network, connect the purple wire from the CANbus Ignition Harness to the CANbus network harness. This connection supplies power to the network when the key switch is on. Quick Connect-style network does NOT use this connection.

1 3

1. CANbus Ignition connector

2. Trim/Tilt connector

3. SystemCheck connector (with seal)

4. CANbus power supply connector

Route the harnesses around the starboard side of the powerhead along the same path as the battery cables.

006862

Page 59

INSTALLATION AND PREDELIVERY

OUTBOARD RIGGING

If a CANbus water pressure gauge is used, install Water Pressure Transducer Kit, P/N 5006214, in the cylinder block.

1. Water pressure transducer 005036

install the transducer lead in the engine wiring harness connector.

Use Evinrude Diagnostics software to activate CANbus control functions in the EMM. From the Settings screen, select Engine Options.

Engine Options Screen 006542

1. Water pressure transducer lead

2. Engine harness connector

3. Cap

If a CANbus oil level gauge is used, an optional CANbus oil level sender must be installed in the oil tank. Connect the oil level sensor harness to the boat CANbus network.

004120

Page 60

INSTALLATION AND PREDELIVERY

FUEL AND OIL PRIMING

Fuel Requirements

WARNING

Gasoline is extremely flammable and highly explosive under certain conditions. Improper handling of fuel could result in property damage, serious injury or death.

Always turn off the outboard before fueling.

Never permit anyone other than an adult to refill the fuel tank.

Do not fill the fuel tank all the way to the top or fuel may overflow when it expands due to heating by the sun.

Remove portable fuel tanks from the boat before fueling.

Always wipe off any fuel spillage. Do not smoke, allow open flames or

sparks, or use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling.

When using alcohol-extended fuels, be aware of the following:

• The boat’s fuel system may have different

requirements regarding the use of alcohol fuels. Refer to the boat’s owner guide.

• Alcohol attracts and holds moisture that can

cause corrosion of metallic parts in the fuel system.

• Alcohol blended fuel can cause engine perfor-

mance problems.

• All parts of the fuel system should be inspected

frequently and replaced if signs of deterioration or fuel leakage are found. Inspect at least annually.

IMPORTANT: Always use fresh gasoline. Gas-

oline will oxidize, resulting in loss of octane and volatile compounds, as well as the production of gum and varnish deposits which can damage the outboard.

Additives IMPORTANT: The only fuel additives approved

for use in Evinrude outboards are 2+4 tioner and Evinrude/Johnson Fuel System Cleaner. Use of other fuel additives can result

in poor performance or engine damage.

fuel condi-

Minimum Octane

Evinrude/Johnson outboards are certified to operate on unleaded automotive gasoline with an octane rating equal to or higher than:

• 87 (R+M)/2 AKI, or

• 90 RON

Use unleaded gasoline that contains methyl tertiary butyl ether (MTBE) ONLY if the MTBE con- tent does not exceed 15% by volume.

Use alcohol-extended fuels ONLY if the alcohol content does not exceed:

• 10% ethanol by volume

• 5% methanol with 5% cosolvents by volume

Evinrude/Johnson 2+4 Fuel Conditioner will help prevent gum and varnish deposits from forming in fuel system components and will remove moisture from the fuel system. It can be used continuously and should be used during any period when the outboard is not being operated on a regular basis. Its use will reduce spark plug fouling, fuel system icing, and fuel system component deterioration.

Evinrude/Johnson Fuel System Cleaner will help keep fuel injectors in optimal operating condition.

Page 61

INSTALLATION AND PREDELIVERY

FUEL AND OIL PRIMING

Fuel System Priming

Vent Line Clamp

In compliance with Federal Regulations, all outboards with a fuel vapor separator must be shipped with a vent line clamp installed. This clamp must be removed before priming the fuel system or starting the outboard for the first time.

004223

IMPORTANT: Failure to remove the clamp may

cause fuel starvation and poor running qualities.

Priming the Fuel System

Observe all fuel lines, both in the boat and on the outboard. Repair any fuel leaks.

WARNING

Failure to check for fuel leaks could allow a leak to go undetected, resulting in fire or explosion and may cause personal injury or property damage.

Oil Requirements

Evinrude/Johnson XD100, XD50, or XD30 outboard oils are recommended for use in Evinrude E-TEC outboards. If these oils are not available, you must use a TC-W3 certified oil.

Evinrude/Johnson XD100 outboard oil is highly recommended for all conditions and applications.

Engine Lubricant Below 32°F (0°C)

If the outboard will be operated in temperatures below freezing (32°F, 0°C), use Evinrude/Johnson XD100.

IMPORTANT: For new outboards, test low oil

warning before filling oil tank.

WARNING

Fuel vapors are highly flammable. Perform the following procedure in a well ventilated area. Extinguish all smoking materials and make certain no ignition sources are present.

Insert the fuel supply hose from the fuel tank into a suitable container. Squeeze the fuel primer bulb or activate the boat-mounted electric fuel primer until fuel flows from the fuel hose.

Once fuel flow is observed, connect fuel supply hose from fuel tank to hose fitting on outboard. Secure hose with Oetiker clamp.

Use the primer to fill the outboard’s fuel system. The high-pressure fuel circuits and injectors will

prime as the outboard is cranked with the starter.

Turn key switch to ON. The engine monitor warning display should show “LOW OIL.”

Add enough oil to raise level to at least one-quarter capacity.

The “LOW OIL” warning should not display.

IMPORTANT: Failure to follow these recom-

mendations could void the outboard warranty if a lubrication-related failure occurs.

Refer to ENGINE MONITORING SYSTEM on p. 101.

Page 62

INSTALLATION AND PREDELIVERY

FUEL AND OIL PRIMING

Oil Injection Rate

The Engine Management Module (EMM) controls the oil injection rate based on engine RPM. This rate can be adjusted for the type of oil being used, and also for powerhead break-in. Use Evinrude Diagnostics software to access these features.

The Set Oil Type option controls the injection rate for the oil being and typical operating conditions.

The TC-W3 oil type setting is the standard setting for all outboards. Set TC-W3 for:

• Operation with all TC-W3 outboard oils includ-

ing XD30, XD50, or XD100.

• Applications requiring maximum lubrication.

• Extreme applications (racing or harsh condi-

tions)

The XD100 setting provides an option to run the outboard at a reduced oil injection rate. This setting REQUIRES the use of Evinrude XD100 outboard lubricant and is not recommended for all applications.

Powerhead oil programming labels are provided to identify EMM oil programming. Install the correct label to alert user to specific oil requirements.

1. Evinrude/Johnson XD30 outboard lubricant (TC-W3)

YELLOW label

2. Evinrude/Johnson XD100 outboard lubricant (Premium)

BLUE label (Installed)

An XD100 Outboard Oil Decal, P/N 352369, is available to label boats equipped with outboards that have been programmed for the reduced oil injection ratio.

004119

Use the XD100 setting for:

• Conventional use (runabouts, cruisers)

• Moderate applications

1. Oil control setting 006805

CAUTION

Running an Evinrude E-TEC outboard on other grades of oil while set to the XD100 oil ratio will result in increased engine wear and shortened outboard life.

XD100 Outboard Oil Decal 004522

Install decals in a highly visible location, such as one of the following:

• Dashboard/deck of boat, next to key switch

• Deck of boat, next to the remote oil fill

• Deck of boat, next to oil tank assembly

• Oil tank cover

• Cover of oil tank compartment

• Attach to oil tank or oil fill cap.

IMPORTANT: Make sure the engine label and

boat decals match EMM programming.

Page 63

INSTALLATION AND PREDELIVERY

FUEL AND OIL PRIMING

Break-In Oiling

IMPORTANT: DO NOT add oil in the fuel tank

on Evinrude E-TEC models. The Engine Management Module (EMM) will auto-

matically supply extra oil to the engine during the first two hours of operation above 2000 RPM.

Follow these steps for outboard set-up:

• Use Evinrude Diagnostics software to make

sure the break-in program has been started. Refer to Oil Control Settings on p. 106.

• The oil tank should be filled and the oil level

marked for reference.

IMPORTANT: The operator must monitor the oil

tank level to confirm oil consumption. This may require several hours of operation above idle.

Oil Supply Priming

WARNING

Oil Distribution Manifold Priming

Squeeze the oil primer bulb to flow oil from the hose connection, through the filter, to the oil pump.

Visually inspect filter to ensure that all air has been purged.

Continue squeezing the primer until oil flows through the distribution manifold into the oil distribution hoses and to the crankcase fittings. All air must be eliminated from oil lines.

Use Evinrude Diagnostics software to make sure the EMM is programmed for the type of oil being used.

Start the outboard and use the oil priming function in the software for a minimum of 90 seconds to make sure the system is completely primed.

Always use caution while working around machinery with moving parts. The following set-up procedures require running tests that are performed with the outboard’s motor cover removed.

Oil Hose Priming

Insert the end of the oil supply hose (from the oil tank) into a suitable container.

Squeeze the oil primer bulb to flow oil from the oil tank.

Once oil flow is observed, connect the oil tank hose to the outboard’s oil supply hose and secure with 14.5 mm Oetiker clamp.

Dynamic Tests Screen

1. Prime Oil button

006814

Page 64

INSTALLATION AND PREDELIVERY

FUEL AND OIL PRIMING

Observe oil flow through the oil distribution hoses.

1. Oil distribution hoses (7) 004224

Make sure that oil flows through the rear oil distribution manifold to the cylinder block fittings.

Small bubbles are acceptable. Large bubbles must be eliminated through continued priming.

1. Oil distribution hose

2. Small bubbles

3. Large bubbles

004398

IMPORTANT: All clear “blue” oil distribution

hoses on the powerhead should fill with oil as the air is purged from the lines.

Repair any fuel or oil leaks. The oiling system can also be primed using the

Self-Winterizing feature if diagnostics software is not available. Refer to STORAGE on p. 86.

1. Rear oil distribution manifold 006863

Page 65

INSTALLATION AND PREDELIVERY

BEFORE START-UP

Gearcase Lubricant

With outboard in vertical position, check the gearcase lubricant level:

• Remove the lubricant level plug. Lubricant must

be even with the bottom of the threaded hole.

• A clean tie strap can be used as a “dip stick” if

the lubricant level is not obvious.

• Add HPF XR gearcase lubricant as needed.

1. Gearcase lubricant level 000072

Oil Level

Trim and Tilt Fluid

Make sure trim and tilt reservoir is full before running outboard:

• Tilt the motor up and engage the tilt support.

• Remove filler cap and check fluid level.

1. Filler cap DR22834

• Three Ram System–Add Power Trim/Tilt Fluid

or GM Dexron II, as needed, to bring level to the bottom of the fill plug threads.

Install the fill plug and tighten to a torque of 45 to 55 in. lbs. (5 to 6 N·m).

Make sure oil tank contains an adequate supply of the correct lubricant for the outboard and that the LOW OIL warning has been tested. Refer to Oil Requirements on p. 59.

When starting the outboard for the first time, refer to Oil Supply Priming on p. 61.

WARNING

Correct fluid level must be maintained to ensure operation of the impact protection built into the unit.

Page 66

INSTALLATION AND PREDELIVERY

RUNNING CHECKS

WARNING

DO NOT run outboard without a water supply to the outboard’s cooling system. Cool ing system and/or powerhead damage could occur.

DANGER

Fuel System

Perform running checks of the fuel system by following these steps:

• Squeeze fuel primer bulb until hard or activate

electric primer. Observe all fuel hoses and connections. Repair any leaks.

• Start outboard. Inspect all hoses and connec-

tions. Repair any leaks or misrouted hoses immediately.

Emergency Stop / Key Switch

Check emergency stop function. With outboard running at IDLE, pull safety lanyard from emergency stop switch. Outboard must stop immediately.

Remote Control Operation

Make sure that control can be easily moved into all gear and throttle settings. Do not shift remote control when outboard is not running.

Start-In-Gear Prevention

WARNING

Make certain that the starter will not operate when the outboard is in gear. The startin-gear prevention feature is required by the United States Coast Guard to help prevent personal injuries.

Engine Monitoring System

Attach emergency stop lanyard. Turn key switch to ON. Warning horn should

sound for 1/2 second. All SystemCheck warning lights should turn on at

the same time, then turn off one at a time.

Start outboard and shift to FORWARD. Turn outboard OFF while control is in FORWARD. Try to restart the outboard. Outboard should not

start. Shift back to NEUTRAL and restart outboard. Shift to REVERSE. Turn outboard OFF while con-

trol is in REVERSE. Try to restart the outboard. Outboard should not

start.

Page 67

INSTALLATION AND PREDELIVERY

RUNNING CHECKS

Tachometer Pulse Setting

Confirm accuracy of tachometer reading.

• Adjust dial on back of tachometer to required

setting (the outboard should not be running).

Outboard Model Tachometer Setting

40–300 HP 6 Pulse or 12 Pole

Water Pump Overboard Indicator

A steady stream of water should flow from the overboard indicator.

Operating Temperature

An outboard run at idle speed should achieve a temperature based on the engine’s thermostatic control. In general, the powerhead temperature should reach at least 104°F (40°C) after five minutes of idling. Check that the powerhead reaches idle temperature. Refer to specific SERVICE

SPECIFICATIONS on p. 10.

Idle Speed

Make sure the outboard idles within the specified idle RPM range. If the outboard is run on a flushing device, the idle speed and quality may not be representative of actual in water use.

Break-In

When the outboard is delivered, refer the customer to the break-in information in the Opera- tor’s Guide.

The Engine Management Module (EMM) automatically supplies extra oil to the engine during the first two hours of operation, above 2000 RPM.

1. Water pump overboard indicator DRC4952

Use the diagnostics software to confirm that the break-in program has been started. Refer to Oil Control Settings on p. 106.

Page 68

INSTALLATION AND PREDELIVERY

PROPELLERS

Propeller Selection

CAUTION

Selection of the wrong propeller could reduce engine service life, affect boat performance, or cause serious damage to the powerhead.

Water testing with various propeller designs and sizes is the best method of propeller selection.

The correct propeller, under normal load conditions, will allow the engine to run near the midpoint of the RPM operating range at full throttle. Refer to SERVICE SPECIFICATIONS on p. 10.

When selecting a propeller, consider the following:

• Use an accurate tachometer to determine the

engine’s full-throttle RPM.

• The outboard should be trimmed for top speed.

• Select a propeller that suits the customer’s

application and allows the engine to run near the midpoint of the full-throttle operating range when the boat has a normal load.

• Occasionally, one propeller will not cover a wide

range of boat applications — water skiing to high speed performance boating. In such cases, it might be necessary to have a propeller for each situation.

• Refer to the Evinrude/Johnson Genuine Parts

and Accessories Catalog for propeller styles

and sizes.

• Right-hand propellers are considered standard

rotation propellers. When propelling a boat forward, the propeller rotates in a right-hand (clockwise) direction as viewed from the rear.

• Left-hand propellers are considered counter-

rotation propellers. When propelling a boat forward, the propeller rotates in a left-hand (counterclockwise) direction as viewed from the rear.

1. Percentage of horsepower (kw)

2. Engine RPM

3. Horsepower curve

4. Full throttle operating range

5. Midpoint of full throttle operating range, horsepower rating in kilowatts (kw)

6. Engine is overloaded at full throttle

7. Engine is overspeeding at full throttle

DR1261

IMPORTANT: If the propeller blades have too

much pitch, the engine will operate below its normal range at full throttle. Power will be lost, and powerhead damage could occur. If the propeller blades have too little pitch, the engine will operate above its normal range and damage from overspeeding could occur.

1. Right-hand rotation (clockwise)

2. Left-hand rotation (counterclockwise)

WARNING

For dual-outboard installations, always check to be sure propellers are installed on the correct engines before aggressively operating the boat.

000033

Page 69

Propeller Hardware Installation

INSTALLATION AND PREDELIVERY

PROPELLERS

WARNING

When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and twist and remove all spark plug leads so the engine cannot be started accidentally.

Apply Triple-Guard grease to the entire propeller shaft before installing the propeller.

Install thrust bushing onto propeller shaft with shoulder of thrust bushing facing aft. Taper of bushing must match taper of propshaft.

Install propeller on propeller shaft by aligning splines and pushing until seated on the thrust bushing.

IMPORTANT: Depending on propeller style, dif-

ferent thrust bushings, spacers, and cotter pin keepers are used. See the Evinrude/Johnson Genuine Parts book for a complete listing and descriptions.

1 2 3

Models without cotter pin “keeper”

1. Thrust bushing

2. Spacer

3. Cotter pin

4. Propeller Nut

Wedge a block of wood between propeller blade and the anti-ventilation plate.

CO2917

Install the spacer, engaging the propeller shaft splines.

1 2 3 4 5

Models with cotter pin “keeper”

1. Thrust Bushing

2. Spacer

3. Propeller Nut

4. Cotter Pin

5. Keeper

DR4028

001992

Install the propeller nut and torque to:

• With Keeper – 70 to 80 ft. lbs. (95 to 109 N·m)

• Without Keeper – 120 to 144 in. lbs. (13.6 to

16.3 N·m)

If cotter pin holes in the propeller nut (without keeper) and propeller shaft are not aligned, tighten the nut until they are in line. Do not loosen.

Insert a new cotter pin through the propeller nut and shaft, or propeller nut keeper and shaft. Bend its ends over the nut to secure the assembly.

IMPORTANT: After fastening propeller nut,

make sure outboard is in NEUTRAL and carefully spin propeller. Propeller must turn freely and should not spin off center. If propeller appears to wobble, check for possible bent propeller shaft.

Page 70

INSTALLATION AND PREDELIVERY

FINAL ADJUSTMENTS

Tilt Limit Switch Adjustment

WARNING

If the outboard does not clear all boat parts when tilted fully or turned side to side, safety related parts could be damaged in the course of such outboard movement. Injuries could result from loss of boat control.

Adjust the tilt limit switch on all new outboard installations.

Check the clearance between outboard(s) and the boat’s motor well and transom area. Tilt outboard(s) to highest point of clearance and turn the steering system lock to lock.

If the outboard contacts the boat's motor well when fully tilted, adjust the tilt limit cam to reduce full-tilt position.

Place the outboard in normal operating position. Rotate the LOWER adjustment tab UP to reduce

the maximum tilt. Rotate the UPPER adjustment tab DOWN to increase the maximum tilt position.

1. Lower adjustment tab

2. Upper adjustment tab

Check the adjustment by tilting the outboard fully. Repeat this procedure until the tilt limit switch

stops the outboard's upward travel before it contacts the motor well.

DR4268

IMPORTANT: The tilt limit cam will not prevent

the outboard from overriding the adjustment if the outboard is tilted manually.

DR3916

To prevent damage to equipment, provide additional motor well clearance when it is needed. Consider either changing the outboard mounting position or modifying the boat if the possibility for interference and damage exists.

WARNING

Adjusting the tilt limit cam will NOT prevent the outboard from tilting fully and contacting the motor well if the gearcase hits an object at high speed. Such contact could damage the outboard and boat and injure boat occupants.

Page 71

INSTALLATION AND PREDELIVERY

FINAL ADJUSTMENTS

Trim Sending Unit Adjustment

Tilt the outboard and engage the tilt support. Temporarily install a thrust rod, P/N 436541, in the

number 3 hole.

29072

Loosen the sending unit screws, to allow the sending unit to pivot.

Observe the trim gauge. If the needle does not show center position, tilt the outboard up and adjust the sending unit by pivoting it up or down.

1. Needle at center position 000662

Lower the outboard against the thrust rod to check adjustment. Repeat adjustment, if necessary.

After adjustment is correct, tilt the outboard up, tighten the two sending unit screws, and remove the thrust rod.

1. Screws 27339

Disengage the tilt support. Lower the outboard against the thrust rod.

WARNING

When the outboard is returned to the customer, the trim limiter rod must be installed and in the same location as it was when the motor was brought in for service. Leaving the trim limiter rod out, or changing the adjustment, could allow the motor to unexpectedly trim in too far and cause loss of control.

Page 72

INSTALLATION AND PREDELIVERY

FINAL ADJUSTMENTS

Trim Tab Adjustment

WARNING

Improper trim tab adjustment can cause difficult steering and loss of control.

A propeller will generate steering torque when the propeller shaft is not running parallel to the water’s surface. The trim tab is adjustable to compensate for this steering torque.

1. Trim tab screw COA3663

IMPORTANT: A single trim tab adjustment will

relieve steering effort under only one set of speed, outboard angle and load conditions. No single adjustment can relieve steering effort under all conditions.

WARNING

To prevent accidental starting while servicing, twist and remove all spark plug leads.

If the boat pulls to the left or right when its load is evenly distributed, adjust the trim tab as follows:

• With the engine OFF, loosen the trim tab screw.

If the boat pulled to the right, move rear of the trim tab slightly to the right. If the boat pulled to the left, move rear of the trim tab slightly to the left.

• Tighten the trim tab screw to a torque of 35 to

40 ft. lbs. (47 to 54 N·m).

Test the boat and, if needed, repeat the procedure until steering effort is as equal as possible.

Outboards with High Transom Heights

The trim tab may be above the surface of the water when the outboard is trimmed out. Steering effort might increase. Lower the trim setting to submerge the trim tab and to reduce steering effort.

Dual Standard Rotation Outboards

Move both trim tabs equally and in the same direction.

Dual Outboards, One Counter and One Standard Rotation

Set both trim tabs to the center position.

Page 73

INSTALLATION AND PREDELIVERY

FINAL ADJUSTMENTS

Dual-Outboard Alignment

Dual outboards must be connected with a tie bar and adjusted to align the outboards for correct water flow to the gearcases and propellers.

Incorrect outboard alignment could cause one or more of the following:

• Propeller ventilation

• Reduction of top speed

• Improper boat tracking

• Engine overheat and powerhead damage

Follow the instructions provided by the tie-bar manufacturer for tie bar installation and adjustment.

Measure Alignment

The “toe-in” (gearcase leading edges closer together than propeller shaft centers) or “toe-out” (gearcase leading edges farther apart than propeller shaft centers) is determined as follows:

• Position outboards straight with the anti-ventila-

tion plates parallel with the bottom of the boat.

• Measure between propeller shaft centers.

Alignment Adjustment

Various boat/motor combinations respond differently to dual-outboard alignments. Each application must be thoroughly tested until the ideal combination of performance, steering, and cooling is found.

A common practice is to set-up the outboards parallel, or with a small amount of “toe-out,” and adjust inward until best results are achieved.

• A typical set-up with 2-stroke outboards

mounted directly on the transom often runs best with a slight amount of “toe-in.”

• Outboards mounted behind the transom on

motor brackets usually require “parallel” alignment or “toe-out.”

Adjust the outboard alignments by adjusting tie bar. Follow the tie bar manufacturer’s adjustment procedures.

Check steering operation. Make sure that the steering system operates properly at various trim angles.

Confirm Alignment

To confirm proper alignment, perform the following steps:

• Water test the boat.

• Monitor the water pressure for both outboards.

• Run the boat at various trim angles.

• Perform steering maneuvers and vary the throt-

tle settings.

• Monitor boat and outboard performance.

6365

• Measure between leading edges of gearcase.

6340

A sudden loss of water pressure or excessive propeller ventilation on one or both outboards may indicate a misalignment of the gearcases. Reset the outboard alignment and retest.

Page 74

INSTALLATION AND PREDELIVERY

NOTES

Technician’s Notes Related Documents

Bulletins

Instruction Sheets

Other

Page 75

MAINTENANCE

TABLE OF CONTENTS

INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

SACRIFICIAL ANODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

TESTING PROCEDURE – CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

METALLIC COMPONENT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

EXTERIOR FINISHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

WATER INTAKE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

ADDITIONAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

SWIVEL BRACKET AND TRAILERING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

THROTTLE AND SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

BATTERY AND BATTERY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

FUEL AND OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

OIL FILTERS AND OIL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

AIR SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

HOSES AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

EXHAUST PRESSURE FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

FUEL SYSTEM TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

INTERNAL ENGINE TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

ADDITIONAL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

PRE-SEASON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

OUTBOARD MOUNTING BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

BATTERY(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

POWER TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

SUBMERGED ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

ENGINE DROPPED OVERBOARD (NOT RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

ENGINE DROPPED OVERBOARD (RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

ENGINE DROPPED OVERBOARD (IN SALT WATER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

PROLONGED SUBMERSION (FRESH OR SALT WATER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Page 76

MAINTENANCE

INSPECTION AND MAINTENANCE SCHEDULE

Routine inspection and maintenance is necessary to prolong outboard life. The following chart provides guidelines for inspection and maintenance to be performed by an authorized Dealer.

IMPORTANT: Outboards used in rental, commercial, or other high hour applications require more fre-

quent inspections and maintenance. Adjust schedule for operating and environmental conditions.

Engine

Care

Description

Product

Engine Monitor self-test and warning horn, check Emergency stop circuit and lanyard, check operation Controls, steering and tilting; check operation Engine mounting hardware, re-tighten (40 ft. lbs.) Fasteners, tighten any loosened components Water intake screens, check condition Cooling system; check water pump indicator / water pressure Anticorrosion anodes, check condition Gearcase, check condition Propeller, check condition

Fuel and oil systems, inspect and repair leaks

(2)

Check battery connections and condition Access EMM information, resolve any service codes Electrical and ignition wires, inspect for wear or chafing Fuel filter, replace Oil filters, replace Gearcase lubricant, replace A

Spark plugs, inspect or replace Thermostats, inspect and check operation Grease fittings, lubricate

(2)

(3)

Power trim/tilt and fluid level, inspect B Propeller shaft splines, inspect and lubricate Starter pinion shaft, inspect and lubricate

(3)

Control cables, inspect and adjust Steering cable, inspect and lubricate C Water pump, inspect / replace

(more often if water pressure loss or overheating occurs)

Every 300 hours

Routine

Inspection

or every three

years

(1)

3 3

C D

3 3

(1) Average recreational use. Commercial use, heavy use, or use in salt or polluted water requires more frequent inspection and maintenance. (2) Emission-related component (3) Annually in salt water applications

A HPF XR Gearcase Lubricant

HPF Pro in high performance or commercial applications

B Power Trim/Tilt Fluid (Three ram hydraulic systems)

Biodegradeable TNT Fluid (Single ram hydraulic systems)

C Triple-Guard Grease D Starter Bendix Lube Only, P/N 337016

Page 77

MAINTENANCE

ANTI-CORROSION PROTECTION

Sacrificial Anodes

Galvanic corrosion occurs in fresh or salt water. Salt, brackish, and polluted water can accelerate corrosion. “Sacrificial” anodes are intended to protect the underwater metal components of the outboard from galvanic corrosion.

Outboards are equipped with three sacrificial anodes.

Testing Procedure – Continuity

Connect ohmmeter leads between engine ground and anode surface.

1. Meter lead to anode 000677

The meter should show little or no resistance. If resistance is high, check the following:

• Remove the anode and clean the area where

the anode is installed.

• Clean the mounting screws.

• Install the anode and test again.

1. Stern bracket anode

2. Propeller shaft bearing housing anode

(inside of gearcase housing)

3. Gearcase housing anode

Visually inspect anodes and metal components below water level. Erosion of anodes is normal and indicates the anodes are functioning properly.

DR5082

IMPORTANT: Anodes that are not eroding may

not be properly grounded. Anodes and the mounting screws must be clean and tight for effective corrosion protection.

For best anode performance:

• Replace all anodes that have eroded or disinte-

grated to two-thirds of their original size.

• Do not paint or apply protective coatings to

anodes or anode fasteners.

• Avoid using metal-based antifouling paint on the

boat or outboard.

Metallic Component Protection

Protect metal components on outboards from corrosion. Use the following products to minimize corrosion.

• Anti-Corrosion Spray provides a heavy, waxy

coating to protect components.

• “6 in 1” Multi-Purpose Lubricant provides a thin

film of anti-corrosion protection.

Exterior Finishes

Maintain the outboard’s exterior finish to prevent corrosion and reduce oxidation.

• Use automotive wax to protect the outboard’s

exterior finish from oxidation.

• Clean regularly using clean water and mild

detergent soap.

• Touch-up damage to painted surfaces promptly.

• Protect moving components with appropriate

lubricants.

Page 78

MAINTENANCE

COOLING SYSTEM

Check the condition of cooling system components regularly:

• water intake screens

• water pump

• all internal water passages

• thermostats

• all external water hoses and fittings

• vapor separator cooling passages and fittings

• EMM cooling passages and fittings

• overboard water pressure indicator.

Flushing

Flush the outboard with fresh water following each use in brackish, salt, or polluted water to minimize the accumulation of scale and silt deposits in cooling system passages.

The outboard can be flushed on the trailer or at dockside; running or not running.

Remove plug and nozzle (overboard indicator) from the flushing port.

004263

Thread garden hose into flushing port.

IMPORTANT: The outboard must be located in

a well ventilated area with appropriate ground drainage during the flushing procedures.

Keep water inlet pressure between 20 to 40 psi (140 to 275 kPa).

Flushing — Outboard Running

WARNING

To prevent injury from contact with rotating propeller, remove the propeller before flushing.

Refer to Propeller Hardware Installation on p. 67.

Place outboard in VERTICAL (DOWN) position in a well ventilated area.

004264

Shift the outboard to NEUTRAL with the propeller removed.

Turn water supply on. START outboard. Run it at IDLE only. Shut OFF the outboard. Turn off water supply and

remove garden hose. Reinstall plug and nozzle. Position the plug and

nozzle to allow the water stream to be seen from the helm.

Leave the outboard in VERTICAL (DOWN) position long enough for the powerhead to drain completely.

Reinstall propeller.

Page 79

MAINTENANCE

COOLING SYSTEM

Flushing — Outboard Not Running

Outboard can be in VERTICAL (DOWN) or TILTED (UP) position.

Remove plug and nozzle (overboard indicator) from the flushing port.

Thread garden hose into flushing port. Turn water supply ON. Flush outboard for at least five minutes. Turn off water supply and remove garden hose. Reinstall plug and nozzle. Position the plug and

nozzle to allow the water stream to be seen from the helm.

Position outboard in VERTICAL position (DOWN) long enough to allow the powerhead to drain completely.

Water Intake Screens

Inspect condition of water intake screens. Clean or replace as needed.

Confirm function of overboard water pressure indicator.

Clean or replace plug and nozzle as needed.

TYPICAL

1. Water intake screen

2. Overboard water pressure

drc4952arev

Additional Maintenance

• Check Engine Monitor function.

• Check operation or visually inspect thermostats

and pressure relief valve. Clean or replace as needed.

• Check that all water passages, hoses, and fit-

tings for both the EMM and the vapor separator flow water freely.

• Replace water pump.

Page 80

MAINTENANCE

LUBRICATION

Steering System

WARNING

Failure to regrease as recommended could result in steering system corrosion. Corrosion can affect steering effort, making operator control difficult.

Grease the stainless steel output end of the steering cable with Triple-Guard grease.

Use an appropriate cleaning solvent to remove corrosion and dirt from output end of cable prior to coating it with grease. Make sure wiper nut is installed and not damaged.

Swivel Bracket and Trailering Bracket

Lubricate the swivel bracket with Triple-Guard grease.

Apply grease until the grease begins to flow from the upper or lower swivel bracket areas.

Coat the pivot points of the trailering bracket with Triple-Guard grease.

1. Grease fitting

2. Pivot points

3. Lower swivel bracket area

DR5073

1. Steering cable

2. Wiper nut

DR29546

Tilt Tube

Lubricate the tilt tube grease fittings with TripleGuard grease.

1 1

1. Tilt tube fittings DR38798

Page 81

MAINTENANCE

LUBRICATION

Throttle and Shift Linkage

Disconnect the battery cables at the battery. Remove cable trunnion cover. Carefully, remove

throttle and shift cables from trunnion block.

IMPORTANT: DO NOT disturb cable trunnion

adjustments. Shift remote control into FULL THROTTLE/

REVERSE position to fully extend the plastic casing guides.

Apply Triple-Guard grease to:

• Pivot and slide area of the shift interrupt switch

bracket

• Cable attachment pins of both the throttle and

shift levers

• Brass inner casings of both the throttle and shift

cables.

Propeller Shaft

Debris from the water can become lodged around propeller shaft. Frequent inspection can minimize potential gearcase damage.

WARNING

When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and disconnect the battery cables at the battery.

Remove propeller. Refer to Propeller Hardware Installation on p. 67.

Inspect bushing and blade surfaces. Replace damaged or worn propellers.

Clean propeller shaft. Inspect propeller shaft seals. Replace damaged or worn seals.

Apply Triple-Guard grease to entire length of propeller shaft prior to installing propeller.

Reinstall propeller hardware and propeller.

1. Attachment pins, throttle and shift cables

2. Shift shaft grease fitting

3. Brass inner casings, throttle and shift cables

Shift the remote control to the NEUTRAL/IDLE position.

Install control cables. Check proper throttle and shift function.

DRC6500R

Gearcase Lubricant

Draining

WARNING

Gearcase lubricant may be under pressure and/or hot. If plug is removed from a recently operated outboard, take precautions to avoid injury.

IMPORTANT: Always check the fill level of the

gearcase lubricant at the upper plug before

Page 82

MAINTENANCE

LUBRICATION

removing the lower, drain/fill plug. A tie strap can be used to check lubricant level.

1. Tie strap 000072

Remove the lubricant level plug, then the lubricant drain/fill plug, and drain the lube from the gearcase into a container.

amount of water from normal water vapor condensation within the gearcase.

Refer to GEARCASE LEAK TEST on p. 286. Overheated lubricant will have a black color and

burned odor. Internal gearcase inspection is recommended

when lubricant is contaminated or shows signs of failure.

Filling

Refer to the INSPECTION AND MAINTENANCE SCHEDULE on p. 74 for service frequency and

recommended lubricants. Secure the gearcase in a vertical position. Remove the lubricant level plug and the lubricant

drain/fill plug. Slowly fill the gearcase with gearcase lube

through the drain/fill hole until it appears at the oil level hole. Filling the gearcase too quickly can cause air pockets and the gearcase may not fill completely. Clean plug seal area and install the lubricant level plug and new seal, then the lubricant drain/fill plug and new seal. Tighten them to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Lubricant level plug

2. Lubricant drain/fill plug

39514

Inspection

Inspect the lube and the magnets on the plugs for metal chips. The presence of metal fuzz can indicate normal wear of the gears, bearings, or shafts within the gearcase. Metal chips can indicate extensive internal damage.

Inspect the lubricant for water contamination. Water can make the lubricant milky in appearance. However, normal aeration can also cause the same appearance.

To check for water contamination, put lubricant into a glass container. Allow the oil to settle for a minimum of one hour to determine if there is an abnormal amount of water in the oil. Some gearcase lubricants are designed to mix with a small

1 2

1. Lubricant level plug

2. Lubricant drain/fill plug

002386

IMPORTANT: The recommended gear lubri-

cants are formulated for marine applications. Do not use automotive gear lubricants, engine oils, or any other oil or grease.

Page 83

Trim and Tilt

Check reservoir fluid level every three years or every 300 operating hours.

• System capacity is approximately 21 fl. oz. (620

ml).

• Tilt the outboard and engage the tilt support.

MAINTENANCE

LUBRICATION

1. Tilt support bracket 002279

• Remove the fill plug.

• Three Ram System–Add Power Trim/Tilt Fluid

or GM Dexron II, as needed, to bring level to the bottom of the fill plug threads.

Three Ram Trim System

1. Fill cap

004277

• Install the fill plug and tighten to a torque of 45

to 55 in. lbs. (5 to 6 N·m).

• Disengage tilt support.

• Cycle the unit at least five complete cycles to

purge all air from the system. When cycling the unit, hold the trim switch ON an additional 5 to 10 seconds after the unit reaches the end of its travel before activating the switch in the opposite direction.

WARNING

Correct fluid level must be maintained to ensure operation of the impact protection built into the unit.

Page 84

MAINTENANCE

BATTERY AND BATTERY CONNECTIONS

Check battery connections frequently. Periodically remove battery to clean and service connections.

WARNING

Battery electrolyte is acidic—handle with care. If electrolyte contacts any part of the body, immediately flush with water and seek medical attention.

• Confirm that battery meets the minimum engine

requirements.

• Connections must be clean and tight.

• Observe all wiring connections prior to disas-

sembly.

Disconnect battery negative (–) cable first and the battery positive (+) cable last.

Clean all terminals, battery posts, and connectors with a solution of baking soda and water. Use a wire brush or battery terminal tool to remove corrosion buildup. Rinse and clean all surfaces.

FUEL AND OIL SYSTEMS

Routine replacement of filters reduces the possibility of foreign material restricting the incoming fuel or oil supplies.

Replacement filter elements are available through Evinrude/Johnson Genuine Parts.

Fuel Filter

Evinrude E-TEC 90° V outboards are equipped with a water-sensing, water-separating fuel filter. Refer to FUEL COMPONENT SERVICING on p. 178.

1. Water-separating fuel filter 005022

Reinstall battery and tighten all connections securely. Refer to Battery Installation on p. 29.

IMPORTANT: DO NOT secure battery cables

with wing nuts. Coat all connections with Triple-Guard grease and

insulate to prevent shorts or spark arcing.

WARNING

Keep battery connections clean, tight, and insulated to prevent their shorting or arcing and causing an explosion. If the battery mounting system does not cover the connections, install covers.

Page 85

MAINTENANCE

FUEL AND OIL SYSTEMS

Oil Filters and Oil Reservoir

Perform visual inspections to identify oiling system leaks. Make certain the oil tank is filled and oil supply is not contaminated.

Evinrude E-TEC V model outboards are equipped with two serviceable oil filters: one is located in the oil injection tank, and one is located in the oil supply line before the oil lift pump.

Sample oil from bottom of oil injection tank. Confirm that oil is free of water or other contaminants..

1. Filter, oil supply line

2. Filter, oil injection tank

004250

42785

Air Silencer

The air silencer on Evinrude outboards maximizes air flow while minimizing noise.

004218

Routine cleaning of the air silencer is recommended to remove any accumulation of debris.

Hoses and Connections

Check condition of all hoses and connections in both the fuel and oil systems:

• Visually inspect all components.

• Observe all clamps, hoses, and connections

while outboard is running.

• Replace all damaged components.

• Repair all leaks.

WARNING

Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.

Page 86

MAINTENANCE

SPARK PLUGS

Spark plugs should be removed and examined periodically. Replace worn, fouled or damaged spark plugs.

Use only recommended spark plugs with the correct gap setting.

Spark Plug, Champion

QC8WEP @ 0.028 ± 0.003 in. (0.76 mm)

• Remove spark plugs and inspect condition.

• Set spark plug gap on new, replacement spark

plugs.

• Mark spark plugs for ground electrode orienta-

tion.

• Apply Electrical Grease to the ribbed portion of

the spark plug ceramic and to the opening of the spark plug cover to prevent corrosion.

• Install spark plugs using “indexing” procedure.

Indexing

Spark plug indexing positions the ground electrode of the spark plug opposite the fuel injector nozzle.

Put an ink mark on the ceramic of the spark plug in line with the OPEN side of the ground electrode. This mark will be used to orient the spark plug with the OPEN side of the ground electrode facing the fuel injector.

Apply Triple-Guard grease to the gasket surface of the spark plug. Install spark plug and tighten to a torque of 15 ft. lbs. (20 N·m).

If the mark is in unshaded area do not tighten anymore.

Spark Plug Indexing Diagram

1. Unshaded area

2. Shaded area

If the mark is in the shaded area, reset torque wrench to 30 ft. lbs. (41 N·m) and continue to turn until the mark is in the unshaded area.

If the mark does not reach the unshaded area before the torque of 30 ft. lbs. (41 N·m) is reached, the spark plug cannot be indexed for that cylinder. Try another spark plug and repeat the steps above.

004294

1. Ink mark

2. Open side

000758

Page 87

MAINTENANCE

EXHAUST PRESSURE FITTING

The exhaust pressure fitting is threaded into the adapter housing and protrudes into the inner exhaust.

1. Exhaust pressure fitting 005026

A hose is routed from this fitting to the EMM. Due to carbon accumulation in the exhaust, this fitting must be periodically de-carbonized or replaced.

Operation Test

Use the Evinrude Diagnostics software Monitor screen to confirm:

• barometric pressure reading; and

• changes in exhaust pressure reading.

With key ON, outboard NOT running, make sure the barometric pressure reading reflects actual atmospheric conditions.

With key ON, outboard NOT running, the exhaust pressure sensor reading should be close to zero. With the outboard running, make sure the exhaust pressure reading changes with throttle setting. This reading will vary, based on actual outboard exhaust pressure conditions.

If the exhaust pressure readings are not as described, clean or replace exhaust pressure fittings.

Engine Monitor Screen

1. Barometric pressure reading

2. Exhaust pressure reading

006958

Cleaning

Cleaning with Engine Tuner maintenance product can dissolve carbon build-up.

Spray Engine Tuner through the fitting and allow it to soak for four to six hours.

WARNING

If barometric pressure reading is inaccurate, remove exhaust/barometric pressure hose from EMM. Retest and observe engine Monitor screen. If barometric pressure reading is accurate with hose removed, replace hose and diaphragm assembly. and inspect exhaust fitting for restriction.

Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa).

Use compressed air to blow through the fitting. Limit the air pressure to 25 psi (170 kPa). Confirm movement of air through fitting.

IMPORTANT: Fitting does restrict air move-

ment.

Replace exhaust pressure fittings that are blocked and cannot be decarbonized.

Page 88

MAINTENANCE

STORAGE

IMPORTANT: DO NOT start outboard without a

water supply to the outboard’s cooling system. Cooling system and/or powerhead damage could occur.

Fuel System Treatment

Stabilize the boat’s fuel supply with Evinrude/ Johnson 2+4 Fuel Conditioner following the

instructions on the container.

Internal Engine Treatment

Remove the propeller, attach garden hose to flushing port and turn on water.

Evinrude E-TEC models are designed to be selfwinterizing using either of the following methods:

IMPORTANT: Engine MUST be in NEUTRAL

throughout these procedures.

Throttle Control Method

• Advance throttle control to 1/2 throttle (50%)

position and then start the outboard. All four SystemCheck lights will turn on and the out-

board will run at idle speed.

• After approximately 15 seconds, the System-

Check lights will go off. Move throttle to IDLE position. SystemCheck lights will light again.

• Wait another 15 seconds. SystemCheck lights

will go off. At this point, advance throttle to FULL (in neutral). SystemCheck lights will flash, indicating that outboard is in winterize mode.

• Outboard will automatically go to fast idle and

fog itself. Allow outboard to run until it shuts itself off (about one minute).

Software Control Method

Winterization can also be run using Evinrude Diagnostics software. With the outboard running,

start the process at the Settings/Adjustments screen and follow the instructions.

1. Winterization start button 006806

005149

After the outboard shuts itself off, turn key switch OFF, then detach garden hose.

IMPORTANT: When finished, leave the out-

board in vertical position long enough to completely drain the powerhead.

IMPORTANT: If SystemCheck lights do not

flash, or outboard runs above fast idle, immediately turn off outboard and start the procedure again.

Page 89

MAINTENANCE

PRE-SEASON SERVICE

Additional Recommendations

• Top off oil reservoir.

• inspect the fuel filter. If there is debris in the fuel

filter, it must be replaced.

• Replace gearcase lubricant.

• Remove and inspect propeller.

• Clean and grease propeller shaft.

• Blow water from gearcase speedometer pickup

system (gearcase speedometer models only).

• Lubricate all grease fittings and linkages.

• Inspect outboard, steering system, and con-

trols. Replace all damaged and worn components. Refer to manufacturer’s and lubrication recommendations.

• Touch up painted surfaces as needed. Coat

outer painted surfaces with automotive wax.

• Remove battery(s) from boat. Store in a cool,

dry location. Periodically charge battery(s) while stored. Refer to manufacturer’s maintenance recommendations when servicing batteries.

• Store outboard in upright (vertical) position.

• Check for fuel leakage.

WARNING

PRE-SEASON SERVICE

If the outboard was removed from the boat for storage, make sure it is reinstalled with factory specified hardware. Refer to the INSTALLATION

AND PREDELIVERY section for proper set-up.

Outboard Mounting Bolts

• Check and re-tighten outboard mounting bolts

to a torque of 40 ft. lbs. (54 N·m).

Gearcase Lubricant

• Check the lubricant level.

• Inspect gearcase for leaks. If leak is apparent,

pressure and vacuum test gearcase.

• Repair gearcase as needed.

Battery(s)

• Replace batteries that cannot be charged.

Power Trim and Tilt

• Remove filler cap and check fluid level.

• Inspect the power trim and tilt unit for leaks.

Repair as needed.

Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.

Operational Checks

• Steering system

• Remote controls

• SystemCheck gauge

• All other accessories and instrumentation Check Oil Injection Tank

•

Inspect the oil tank for leaks.

Check Fuel System

• Inspect entire fuel system for leaks prior to start-

ing outboard.

• Repair all leaks. Water Pump

• Make sure a steady stream of water flows from

overboard indicator.

WARNING

Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.

Page 90

MAINTENANCE

SUBMERGED ENGINES

Once an outboard has been submerged in fresh or salt water, it must be serviced within three (3) hours of recovery. Immediate service can minimize the corrosive affect that air has on the polished surfaces of the crankshaft, connecting rods, and internal powerhead bearings.

IMPORTANT: If outboard cannot be started or

serviced immediately, it should be resubmerged in fresh water to avoid exposure to the atmosphere.

Engine Dropped Overboard (Not Running)

Disconnect the battery cables at the battery. Rinse powerhead with clean water. Remove spark plug leads and spark plugs. Place outboard in horizontal position (cylinder

heads down). Slowly rotate flywheel in a clockwise rotation to work all water out of powerhead.

IMPORTANT: If sand or silt may have entered

the outboard, DO NOT attempt to start it. Disassemble and clean.

Disassemble all electrical connectors. Clean connectors and terminals, and treat with water displacing electrical spray. Apply Electrical Grease to terminals prior to reassembly. Coat all exposed solenoid terminals and engine grounds with Black

Neoprene Dip.

Clean and inspect all electrical components. Replace damaged or corroded components prior to returning the outboard to service. Electric starters should be disassembled, cleaned, flushed with clean water, and treated with water displacing electrical spray prior to reassembly.

Disconnect fuel supply hose from outboard. Drain and clean all fuel hoses, filters, and fuel tanks.

Disconnect oil supply hose and oil return hose from outboard. Drain and clean all oil hoses, filters, and oil tank assemblies.

Refill fuel tank with fresh fuel and oil tank with recommended oil.

Prime oil system and fuel system. Refer to FUEL AND OIL PRIMING on p. 58. Make sure all oil injection hoses are clean and filled with oil.

Make sure high pressure fuel system does not contain water. Flush as needed.

Inject a small amount of outboard lubricant into spark plug holes and install new spark plugs. Refer to Spark Plug Indexing on p. 84.

Reinstall all removed or disconnected parts. Use Evinrude Diagnostics software to:

• Start break-in oiling

• Check fuel pump operation

• Check injector operation (fuel and oil)

• Check timing (once outboard is running at full

operating temperature)

Run outboard below 1500 RPM for one-half hour.

Engine Dropped Overboard (Running)

Follow the same procedures as Engine Dropped Overboard (Not Running). However, if there is

any binding when the flywheel is rotated, it may indicate a bent connecting rod and no attempt should be made to start the outboard. Powerhead must be disassembled and serviced immediately.

Engine Dropped Overboard (In Salt Water)

Follow the same procedures used for Engine Dropped Overboard (Not Running) and Engine Dropped Overboard (Running). Disassemble

and clean outboards that have been submerged in salt water for prolonged periods of time. Clean or replace electrical components as necessary.

Prolonged Submersion (Fresh or Salt Water)

Outboards that have been dropped overboard and not recovered immediately, must be serviced within three hours of recovery. Follow the same procedures used for Engine Dropped Overboard

(Not Running) and Engine Dropped Overboard (Running).

Page 91

ENGINE COVER SERVICE

TABLE OF CONTENTS

UPPER COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

LATCH HOOK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

UPPER COVER CAP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

LOWER COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

LOWER COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

LOWER COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

LATCH HANDLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

TRIM SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Page 92

ENGINE COVER SERVICE

UPPER COVER SERVICE

Latch Hook Installation

Place hook into position on bracket.

006962

Apply Ultra-Lock to screw threads. Tighten screws to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

Upper Cover Cap Replacement

Place new upper cap into position.

006815

Tighten self-tapping screws to a torque of 24 to 36 in. lbs. (2.7 to 4 N·m).

006963

1. Upper cap screws 006964

Page 93

ENGINE COVER SERVICE

LOWER COVER SERVICE

Lower Cover Removal

Remove lower engine cover screws.

1. Lower cover screws 004122

Loosen port side cover slightly, and disconnect trim/tilt switch connector. Then, remove port and starboard covers.

Lower Cover Installation

Install the lower engine covers and tighten all screws to a torque of 24 to 36 in. lbs. (3 to 4 N·m).

1. Lower cover screws 004122

Connect trim/tilt switch connector.

005246

Page 94

ENGINE COVER SERVICE

LOWER COVER SERVICE

Latch Handle Installation

Apply a light coat of Triple-Guard grease to latch handle shaft. Insert handle into lower cover.

1. Triple-Guard grease 006827

Apply Ultra-Lock to screw threads. Place spring washer and hook into position and tighten screw to a torque of 180 in. lbs. (20 N·m).

Trim Switch Installation

Place switch into position through cover.

006746

Install nut on switch. Tighten nut to a torque of 10 to 16 in. lbs. (1 to 2 N·m).

006821

006747

Install electrical connector. Refer to CONNEC- TOR SERVICING on p. 160.

006748

Page 95

ENGINE MANAGEMENT MODULE (EMM)

TABLE OF CONTENTS

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

EMM INPUTS AND OUTPUTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

INTERNAL SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

EMM TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

55 V CIRCUIT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

12 V CIRCUIT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

BAROMETRIC PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

EXHAUST PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

EXTERNAL SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

ENGINE TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

SHIFT INTERRUPT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

CRANKSHAFT POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

KNOCK SENSOR – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

INTERNAL EMM FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

START ASSIST CIRCUIT (SAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

ROM VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

IDLE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

RPM LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

SHIFT INTERRUPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

ENGINE MONITOR AND WARNING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

FAULT CODE CREATION AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

ENGINE MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

S.A.F.E. WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

SHUTDOWN MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

DIAGNOSTIC SOFTWARE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

STATIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

DYNAMIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

STORED SERVICE CODES (FAULTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

HARD FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

PERSISTENT FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

STATIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

DYNAMIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

OIL CONTROL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

TPS CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

FUEL INJECTOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

REPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

SOFTWARE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

EMM TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

EMM SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

Page 96

ENGINE MANAGEMENT MODULE (EMM)

DESCRIPTION

The Engine Management Module (EMM) is a water-cooled engine controller. It controls many outboard systems including alternator output for the 12 V and 55 V circuits. Operating voltage is supplied to the EMM by the stator.

This section discusses the functions of the EMM and its various internal and external sensors. It also describes using Evinrude Diagnostics soft- ware to retrieve and adjust service information stored in the EMM

EMM Functions

The EMM controls the following processes and functions:

• Alternator output; 55 V and 12 V

• Start Assist Circuit (SAC) voltage boost

• Fuel and ignition timing and duration

• Fuel injector activation

• Oil injector pump activation

• Electric fuel pump control

• Idle speed control

• RPM limiter

• Electrical circuit monitoring

• Service code creation and storage

• Warning system activation

• ROM verification, self-test

• Choke-less cold starting

• Anti-knock compensation

• Output of diagnostic data

• Tachometer signal

• RPM profile and engine hours

• Oiling ratios

• Shift interrupt function

EMM Connections

IMPORTANT: EMM connections and wiring

must be clean and tight. Improper electrical connections can damage the EMM. DO NOT run the outboard with loose or disconnected wiring.

Make sure EMM connections are clean and tight.

• Engine wire harness to EMM connectors; J1-A,

J1-B, J2

• Stator to EMM connections; one 6-pin AMP and

J2 connector.

1. J2 connector

2. J1-A connector

3. J1-B connector

004197

LED Indicators

The EMM has LED indicators located next to the electrical connectors that provide information related to various electrical circuits.

IMPORTANT: LED 1 is toward the top of the

outboard (Closest to EMM J2 connector).

1. LED indicators 004198

When the ignition key is turned ON, LEDs 1, 3 and 4 should light, indicating that the SAC circuit, sensor circuits, and the stop circuit are working.

As the outboard is being started, all four LEDs should light and then go off in sequence. If any of the LEDs does NOT light during starting, refer to EMM LED INDICATORS on p. 116.

When the outboard is running, all LEDs should be off. If any LED is lighted while the outboard is running, refer to EMM LED INDICATORS on p. 116.

Page 97

ENGINE MANAGEMENT MODULE (EMM)

TnT

EMM INPUTS AND OUTPUTS DIAGRAM

453

6 7

3121

INPUTS

1 2 3 4

J1-A

J1-B

1. Engine Management Module (EMM)

2. Battery (12 volt)

3. Key switch (switched B+, start signal)

4. Stator

5. Knock sensor

6. Crankshaft Position Sensor (CPS)

7. Throttle Position Sensor (TPS)

8. Shift Interrupt Switch

9. Air Temperature Sensor (AT)

OUTPUTS

10. Oil Pressure Sensor (component of 18)

11. Engine Temperature Sensor(s)

12. Water in Fuel Sensor / Fuel Filter

13. Trim / Tilt Sending Unit

14. Water Pressure Sensor

15. LED indicators

16. Fuel Pump (high pressure)

17. Starter Solenoid

18. Oil Injection Pump and Manifold

w/adaptor harness

A B

19. Ignition Coil

20. Fuel Injector

21. Tachometer/SystemCheck Gauge

22. Diagnostic Connector

23. I-Command harness

24. Trim and Tilt Relay Module

25. Oil Level Switch

TnT

Page 98

ENGINE MANAGEMENT MODULE (EMM)

INTERNAL SENSORS

Sensor inputs and internal EMM controllers are used to control outboard operation. Use Evinrude Diagnostics software to troubleshoot the sensors. Refer to the EMM Service Code Chart at the back of this manual for a complete list of all engine fault codes.

Internal sensors are NOT serviceable. Reprogramming or replacement may be required to resolve EMM related issues.

EMM Temperature Sensor

Monitors the temperature of the fuel injector driver circuits.

If the EMM temperature exceeds 176°F (80°C) or the circuit fails, the EMM:

Activates S.A.F.E. Stores service code 25 EMM LED 4: ON (Running) Engine Monitor TEMP display: ON

If EMM temperature exceeds 212°F (100°C) or the circuit fails, the EMM:

If sensor reads less than -67°F (-55°C) or greater than 311°F (155°C) a sensor circuit fault is detected and the EMM:

Stores service code 23

EMM LED 3: OFF (Cranking) EMM LED 3: ON (Running)

55 V Circuit Sensor

Monitors the EMM’s 55 V alternator circuit. If system voltage exceeds 57 volts, the EMM:

Activates S.A.F.E. Stores service code 18 EMM LED 1: ON (Running) Engine Monitor CHECK ENGINE display: ON

If system voltage is less than 45 V between 500 and 1000 RPM, or is less than 52 V above 1000 RPM, the EMM:

Activates S.A.F.E. Stores service code 17 EMM LED 1: ON (Running) Engine Monitor CHECK ENGINE display: ON

Activates SHUTDOWN Stores service code 29 EMM LED 4: FLASHING Engine Monitor TEMP display: FLASHING

IMPORTANT: The outboard will not restart until

the engine cools below 212°F (100°C) and the EMM temperature returns to normal. Refer to SHUTDOWN MODE on p. 102.

If EMM temperature is less than -22°F (-30°C) or the circuit fails, the EMM:

Stores service code 24

EMM LED 3: OFF (Cranking) EMM LED 3: ON (Running)

12 V Circuit Sensor

Monitors the EMM’s 12 V alternator circuit. If battery voltage exceeds 15.5 volts, the EMM:

Stores service code 27 EMM LED 1: ON (Running) Engine Monitor LOW BATTERY display: ON

If battery voltage is less than 12 V below 2000 RPM, or is less than 12.5 V above 2000 RPM, the EMM:

Stores service code 26 EMM LED 1: ON (Running) Engine Monitor LOW BATTERY display: ON

Page 99

ENGINE MANAGEMENT MODULE (EMM)

EXTERNAL SENSORS

Barometric Pressure Sensor

Supplies the EMM with barometric pressure reading to compensate for changes in altitude and air density.

If the BP sensor reads less than 13 KPa or greater than 119.0 KPa, or the sensor or circuit fails, the

EMM:

Stores service code 44

If the BP sensor reads less than 70 KPa, the

EMM:

Stores service code 45

If the BP sensor reads greater than 105 KPa, the

EMM:

Stores service code 46

Exhaust Pressure Sensor

The exhaust pressure sensor monitors exhaust pressure during all running conditions to compensate for engine loads.

EXTERNAL SENSORS

The EMM provides a 5 V DC signal for sensor circuits. It monitors all sensor voltage inputs and compares them to predetermined acceptable ranges. Inputs that fall outside of the acceptable range create service codes.

Air Temperature Sensor

The air temperature sensor monitors the air temperature at the throttle body.

If the AT sensor voltage is out of the expected range, or the sensor or circuit fails, the EMM:

Stores service code 47

EMM LED 3: OFF (Cranking) EMM LED 3: ON (Running)

If the sensor reads less than -85 in. water, or greater than 85 in. water, or the sensor or circuit fails, the EMM:

Stores service code 87

EMM LED 3: OFF (Cranking) EMM LED 3: ON (Running)

If exhaust pressure is less than 40 in. water, the

EMM:

Stores service code 88

EMM LED 3: OFF (Cranking) EMM LED 3: ON (Running)

If exhaust pressure is greater than 80 in. water, the EMM:

Stores service code 89

EMM LED 3: OFF (Cranking) EMM LED 3: ON (Running)

Engine Temperature Sensor

Monitors cylinder head temperature. If cylinder head temperature exceeds 212° F

(100° C) below 2000 RPM for 3 seconds, the EMM:

Activates S.A.F.E. Stores service code 40 (port sensor) Stores service code 70 (stbd sensor) EMM LED 4: ON (Running) Engine Monitor TEMP display: ON

If cylinder head temperature exceeds 185°F (85°C) above 2000 RPM for 60 seconds, the EMM:

Stores service code 43 (port sensor) Stores service code 69 (stbd sensor) EMM LED 4: ON (Running) Engine Monitor TEMP display: ON

Page 100

ENGINE MANAGEMENT MODULE (EMM)

EXTERNAL SENSORS

If cylinder head temperature exceeds 194°F (90°C) above 2000 RPM for 3 seconds, the EMM:

Activates S.A.F.E.

If cylinder head temperature exceeds 248°F (120°C) for 3 seconds, the EMM:

Activates SHUTDOWN Stores service code 31 EMM LED 4: FLASHING Engine Monitor TEMP display: FLASHING

The outboard will not restart until the engine temperature returns to normal. Refer to SHUTDOWN MODE on p. 102.

If sensor values are less than -13°F (-25°C), or greater than 329°F (165°C), the EMM:

Stores service code 41 (port sensor) Stores service code 67 (stbd sensor)

EMM LED 3: OFF (Cranking) EMM LED 3: ON (Running)

If sensor values are below -4°F (-20°C), the EMM:

Stores service code 42 (port sensor) Stores service code 68 (stbd sensor)

EMM LED 3: OFF (Cranking) EMM LED 3: ON (Running)

Oil Pressure Sensor

The oil pressure sensor monitors oil pressure in the oil distribution manifold.

If the sensor does not detect pressure for 150 pump cycles, the EMM:

Activates S.A.F.E. Stores service code 38 EMM LED 4: ON (Running) Engine Monitor NO OIL display: ON

If outboard has been run for more than 5 hours with NO OIL faults (codes 34 & 38), the EMM:

Activates SHUTDOWN Stores a service code 33 EMM LED 4: FLASHING Engine Monitor NO OIL display: FLASHING

IMPORTANT: The outboard will restart for one

minute intervals until problem is resolved and

code is cleared. To clear code use the diagnostic software program.

If the sensor reads out of the expected range, or the sensor or circuit fails, the EMM:

Stores service code 71 EMM LED 3: ON (Running)

If cylinder head does not reach operating temperature (122°F / 50°C below 1000 RPM) in 10 minutes, the EMM:

Stores service code 58 (port sensor) Stores service code 59 (stbd sensor)

EMM LED 3: OFF (Cranking) EMM LED 3: ON (Running)

Shift Interrupt Switch

If the switch is stuck in the closed position, the EMM:

Stores service code 28 EMM LED 3: ON (Running)

If the sensor circuit indicates below expected range (<.4 V), the EMM:

Stores service code 72 EMM LED 3: ON (Running)

If the sensor circuit indicates above expected range (> 4.6 V), the EMM:

Stores service code 73 EMM LED 3: ON (Running)

BRP E225DHXSEM, E225DPLSEB, E225DPXSEB, E225DCXSEB, E225DPZSEB Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

ABBREVIATIONS USED IN THIS MANUAL

Units of Measurement List of Abbreviations

ENGINE EMISSIONS INFORMATION

Manufacturer’s Responsibility

Dealer’s Responsibility

Owner’s Responsibility

EPA Emission Regulations

MODEL DESIGNATION

MODELS COVERED IN THIS MANUAL

Identifying Model and Serial Numbers

SERVICE SPECIFICATIONS

STANDARD TORQUE SPECIFICATIONS

PRODUCT REFERENCE AND ILLUSTRATIONS

SPECIAL TOOLS

DIAGNOSTIC TOOLS

UNIVERSAL TOOLS

ELECTRICAL / IGNITION TOOLS

FUEL /OIL SYSTEM TOOLS

POWERHEAD TOOLS

GEARCASE TOOLS

TRIM AND TILT TOOLS

SHOP AIDS

INSTALLATION AND PREDELIVERY

BOAT RIGGING

Remote Controls

Battery Installation

Battery Switches and Multiple Batteries

Auxiliary Battery Charging

Battery and Switch Wiring Diagrams

Fuel System Requirements

Oiling System Set-Up

Cable and Hose Installation

OUTBOARD INSTALLATION

Hull Preparation

Transom Measuring and Drilling

Drilling and Hardware Diagrams

Lifting the Outboard

Steering Systems

Outboard Mounting

OUTBOARD RIGGING

Cable, Hose, and Wire Routing

Control Cable Installation

Electrical Harness Connections

Water Pressure Gauge

CANbus Connections

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

Trim and Tilt Fluid

RUNNING CHECKS

Fuel System

Emergency Stop / Key Switch

Remote Control Operation

Start-In-Gear Prevention

Engine Monitoring System

Tachometer Pulse Setting

Water Pump Overboard Indicator

Operating Temperature

Idle Speed

Break-In

PROPELLERS

Propeller Selection

Propeller Hardware Installation

FINAL ADJUSTMENTS

Tilt Limit Switch Adjustment

Trim Sending Unit Adjustment

Trim Tab Adjustment

Dual-Outboard Alignment