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

...

Main Menu

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™

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

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

SAFETY INFORMATION

Before working on any part of the outboard, read the SAFETY section at the end of this manual.

This manual is written for qualified, factory-trained technicians who are already familiar with the use

of Evinrude ual is not a substitute for work experience. It is an organized guide for reference, repair, and maintenance of the outboard(s).

This manual uses the following signal words identifying important safety messages.

/Johnson® Special Tools. This man-

DANGER

Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

WARNING

Indicates a potentially hazardous situation which, if not avoided, CAN result in severe injury or death.

Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so to protect yourself, as well as the people around you.

It is understood that this manual may be translated into other languages. In the event of any discrepancy, the English version shall prevail.

To reduce the risk of personal injury, safety warnings are provided at appropriate times throughout the manual.

DO NOT make any repairs until you have read the instructions and checked the pictures relating to the repairs.

Be careful, and never rush or guess a service procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol use, to name a few. Damage to a boat and outboard can be fixed in a short period of time, but injury or death has a lasting effect.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate personal injury or property damage. It also may be used to alert against unsafe practices.

IMPORTANT: Identifies information that will

help prevent damage to machinery and appears next to information that controls correct assembly and operation of the product.

These safety notices mean: ATTENTION!

BECOME ALERT! YOUR SAFETY IS INVOLVED!

When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Using substandard parts could result in injury or product malfunction.

Torque wrench tightening specifications must be strictly followed. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts.

If you use procedures or service tools that are not recommended in this manual, YOU ALONE must decide if your actions might injure people or damage the outboard.

DANGER

Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off. Remove propeller before servicing and when running the outboard on a flushing device.

DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.

WARNING

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

The motor cover and flywheel cover are machinery guards. Use caution when conducting tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and clothing away from rotating parts.

During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service.

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

The electrical system presents a serious shock hazard. DO NOT handle prima ry or secondary ignition components while outboard is running or flywheel is turning.

Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system.

Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure.

Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling.

Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and causing an explosion.

Always work in a well ventilated area. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak.

Definite resistance to tightening must be felt when reusing a locking fastener. If replacement is indicated, use only authorized replacement or equivalent.

INTRODUCTION

ABBREVIATIONS USED IN THIS MANUAL

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

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

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

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

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

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)

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

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)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

+ 382 hidden pages

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