BRP E25D, E30T, E40D, E50D, E60D User Manual
...
*216018*
65 HORSEPOWER
WRL, WRY Commercial Models
2011 Model Year
FEATURES AT A GLANCE
Easy to Own and Operate
• Three-Year Limited Warranty
• No Operational Break-In Procedure
• Easy Starts (no choking or priming)
• Digital Engine Management
• Self Flushing Cooling System
• Long Term Storage Design
• Simplified Winterization Procedure
• Digital Diagnostics
• Low Oil Usage
• CANbus Capable
Durable and Reliable
• Full Corrosion Protection
• Evinrude E-TEC Lubrication System
• Auto-Calibrated Linkage
• Robust, Heavy-Duty Design
• Posi-Lock Latches
• Extra Capacity Water Pump
• Iridium Spark Plugs
• Vibration Isolated Electronics
• Beltless 25 Amp Charging System
• Stainless Steel Thermostats
• Nickel/Chrome-Faced Piston Rings
• Micro Finished Connecting Rods/Crankshaft
1
Cleaner and Quieter
• EPA Emissions Compliance
• European Union Emissions Compliance
• California 2-Star Emissions Compliance
• Sealed Fuel System
• Low Friction Design (No powerhead
gears, belts, cams, oil scraping rings,
or mechanical oil pump)
• Full Length Insulated Lower Pans
• Quiet Signature Sound
• Air Intake/Silencer
• Idle Air Bypass
1
One-Year for Commercial / Three-Year for Normal Recre-
ational Use
The following trademarks are the property of Bombardier Recreational Products Inc. or its affiliates:
Evinrude® Evinrude®/Johnson® XD30™ I-Command™
Evinrude® E-TEC® BRP Logo S.A.F.E.™
Evinrude®/Johnson® Genuine Parts 2+4™ Fuel Conditioner SystemCheck™
Evinrude®/Johnson® XD100™ HPF XR™ Gearcase Lubricant Triple-Guard™ Grease
Evinrude®/Johnson® XD50™ HPF Pro™ Gearcase Lubricant
© 2010 BRP US Inc. All rights reserved.
Dear Boating Enthusiast,
Congratulations on your purchase of our industry-leading Evinrude E-TEC outboard!
Your purchase comes with the full commitment and backing of the BRP Outboard
Engine team. We know your Evinrude E-TEC outboard will provide you with years of
reliable use, and we hope you will enjoy using it as much as we enjoyed designing
and building this innovative product.
You can be proud you purchased an Evinrude E-TEC outboard with the following
benefits.
EASY TO OWN & OPERATE
With your Evinrude E-TEC outboard there is no more time wasted in the shop. In fact,
you only have to bring your Evinrude E-TEC outboard in for dealer scheduled maintenance every 300 hours or every three years of normal recreational use. That's
three trips to the shop in nine years… four trips in twelve years… five trips in fifteen
years… you get the picture! And if that is not enough, with your new outboard you
will have zero oil changes, absolutely no break-in period, and a simple winterization
process that can be done at the boat ramp or in your driveway. We are proud of how
easy we have made it for you to own this outboard. Hopefully it means you will be
spending more time on the water each year.
POWER & PERFORMANCE
Evinrude E-TEC outboards have been engineered to outperform anything on the water—acceleration, top-end speed, any size, any horsepower, across the line. And for
your buddies who own a four-stroke? Well, they cannot touch our power-to-weight
ratio. And you can tell them that no four-stroke comes close to the pure power and
torque of an Evinrude E-TEC outboard.
DURABILITY / QUALITY / RELIABILITY
Fewer parts. Fewer problems. Every Evinrude E-TEC outboard component is tested
and retested for maximum performance and longer life. Parts are bigger and stronger
to work harder and last longer.
CLEAN & QUIET
Evinrude E-TEC outboards are designed to comply with the strictest emissions regulations. Even the sealed fuel system minimizes evaporative emissions. And thanks
to the sophisticated, acoustically tuned air intake and exhaust systems, you will not
be filling the air with a lot of noise either.
BRP is proud you have purchased this technology-leading Evinrude E-TEC outboard
engine. We thank you for your business and wish you many years of enjoyable use.
Happy Boating,
Yves Leduc
Vice President, General Manager
Outboard Engines
TABLE OF CONTENTS
USING YOUR E-TEC OUTBOARD
Safety Information on the Outboard . . . . . . . . . . . . . . . . 12
Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hang Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remote Control Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil and Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oiling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine Starting / Stopping - Tillers models . . . . . . . . . . . . . . . . . . . . . . . 20
Shifting and Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Tilt Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Impact Damage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Special Operating Conditions . . . . . . . . . . . . . . . . . . . . . 30
Salt Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Weedy Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Shallow Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Under Tow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dual Outboard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cold and Freezing Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Transporting the Outboard . . . . . . . . . . . . . . . . . . . . . . . 32
Trailering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Transporting / Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Routine Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . 33
MAINTENANCE
Engine Emissions Information . . . . . . . . . . . . . . . . . . . . 36
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Service Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Submerged Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4
Outboard External Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Scratch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Hull Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Long-Term Storage (Winterization) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Pre-Season Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
PRODUCT INFORMATION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Transom Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installing the Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Water Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Product Warranty Information . . . . . . . . . . . . . . . . . . . . . 51
Readiness Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . 63
Change of Address / Change of Ownership . . . . . . . . . . 65
Confirmation of Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5
ABOUT THIS GUIDE
This Operator’s Guide is an essential part of
your Evinrude E-TEC outboard. It contains
pertinent information which, if followed, will
provide you with a thorough understanding
needed for proper operation, maintenance,
care, and—above all—safety. Safety is our
first priority and it should be yours too. It is
strongly recommended you read this Guide
from cover to cover. The more you know and
understand about your Evinrude E-TEC outboard, the greater the safety and pleasure
you will get from using it. Following this recommendation will assure the completeness of
the information essential to your safety, the
safety of any passengers, and other water users.
This Operator’s Guide identifies important
safety messages.
Although the mere reading of such information does not eliminate the hazard, the understanding and application of the information
will promote the correct use of your outboard
engine.
Outside North America please contact your
Dealer or distributor for details about boating
safety.
This Operator’s Guide uses the following signal words identifying important safety messages.
DANGER
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury
WARNING
Indicates a hazardous situation
which, if not avoided, could result in
death or serious injury
CAUTION
situation which, if not avoided, could
result in minor or moderate injury.
Indicates a hazardous
Warning Symbols in this Guide
How can you reduce the risk of death, personal injury, and possible property damage? This
Operator’s Guide answers such questions
and are contained in boxes highlighted by the
Safety Alert Symbol. It is imperative to read,
understand, and follow these comments.
This Guide should be kept in a waterproof bag
with the outboard at all times during operation. If the product ownership is transferred,
this Guide should be forwarded to the new
owners.
A responsible, educated boater will fully appreciate the pleasures of boating and will be a
safe boater. Boating Safety Classes are conducted by the U.S. Coast Guard Auxiliary, the
U.S. Power Squadron and some Red Cross
Chapters. For information about classes, call
toll free 1-800-336-BOAT.
For additional information about boating safety and regulations, call:
• U.S. Coast Guard Boating Safety Hotline
1-800-368-5647.
NOTICE
which, if not followed, could severely
damage engine components or other
property.
IMPORTANT: Identifies information that will
help with assembly and operation of the product.
Additionally, Bombardier Recreational Products (BRP) has identified key information that
is essential to the operation of your Evinrude
E-TEC outboard.
Key information appears throughout this
Guide in gray boxes with a key above the
text. This highlighted information is a vital reference when using your outboard.
Indicates an instruction
6
IMPORTANT SAFETY MESSAGES
This Operator’s Guide contains essential information to help prevent personal injury and
damage to equipment. Safety messages appear throughout this Guide in the applicable
section.
Be careful! Human error is caused by many
factors: carelessness, fatigue, overload, preoccupation, unfamiliarity of operator with the
product, drugs and alcohol to name a few.
Damage to your boat and outboard can be
fixed in a short period of time, but injury or
death, has a lasting effect.
WARNING
For your safety and the safety of others, follow all safety warnings and
recommendations. Do not disregard
any of the safety precautions and
instructions.
Anyone operating your boat should
first read and understand this guide
before they operate your boat and
outboard.
SAFETY MEASURES — General
To fully appreciate the pleasures, enjoyment and excitement of boating there are
some basic rules that should be observed and followed by any boater.
Some rules may be new to you and others may be common sense or obvious...
irrespective, take them seriously!
Be sure at least one of your passengers
knows how to handle your boat in case of
an emergency.
Remember, gasoline fumes are flammable and explosive. Always adhere to the
fueling procedure contained in this Operator’s Guide and those given to you by
the fueling station. Always verify fuel level before use and during the ride. Apply
the principle of 1/3 fuel to destination, 1/
3 back and 1/3 reserve fuel supply. Do
not carry spare fuel or flammable liquids
in any storage or engine compartments.
Whenever running the engine, assure
there is proper ventilation to avoid the accumulation of carbon monoxide (CO),
which is odorless, colorless, and tasteless, and can lead to unconsciousness,
brain damage, or death if inhaled in sufficient concentrations. CO accumulation
can occur while docked, anchored, or underway, and in many confined areas
such as the boat cabin, cockpit, swim
platform, and heads. It can be worsened
or caused by weather, mooring and operating conditions, and other boats. Avoid
exhaust fumes from your engine or other
boats, provide proper ventilation, shut off
your engine when not needed, and be
aware of the risk of backdrafting and conditions that create CO accumulation. In
high concentrations, CO can be fatal
within minutes. Lower concentrations are
just as lethal over long periods of time.
Avoid standing up or shifting weight suddenly in light weight boats.
Keep your passengers seated in seats.
The boat’s bow, gunwale, transom and
seat backs are not intended for use as
seats.
All passengers should know the location
of emergency equipment and how to use
it.
Know the marine traffic laws and obey
them.
All safety equipment and personal floatation devices must be in good condition
and suitable for your type of boat. Always
comply with the regulations that apply to
your boat.
Insist on the use of personal floatation
devices, approved by the U.S. Coast
Guard, by all passengers when boating
conditions are hazardous, and by children and nonswimmers at all times.
Proceed with caution and at very low
speed in shallow water. Grounding or
abrupt stops may result in personal injury
or property damage. Also be alert for debris and objects in the water.
7
Insist on the use of personal floatation
devices, approved by the U.S. Coast
Guard, by all passengers when boating
conditions are hazardous, and by children and nonswimmers at all times.
Proceed with caution and at very low
speed in shallow water. Grounding or
abrupt stops may result in personal injury or property damage. Also be alert for
debris and objects in the water.
Be familiar with the waters you are operating in. The gearcase of this outboard
extends below the water surface and
could potentially come in contact with
underwater obstructions. Contact with
underwater obstructions may result in
loss of control and personal injury.
Respect no wake zones, rights of other
water users and the environment. As the
"skipper" and owner of a boat you are
responsible for damage to other boats
caused by the wake of your boat. Allow
no one to throw refuse overboard.
Do not operate your boat if you are under the influence of drugs or alcohol.
High performance boats have a high
power-to-weight ratio. If you are not experienced in the operation of a high performance boat, do not attempt to
operate one at, or near, its top speed until you have gained that experience.
Become completely familiar with the
control and operation of your boat and
outboard before embarking on your first
trip or taking on a passenger(s). If you
have not had the opportunity to do so
with your Dealer, practice driving in a
suitable area and feel the response of
each control. Be familiar with all controls
before applying the throttle above idle
speed. As the operator, you are in control and responsible for safe operation.
SAFETY MEASURES — Installation
and Maintenance
The outboard must be correctly installed. Failure to correctly install the
outboard could result in serious injury,
death or property damage. We strongly
recommend that your Dealer install your
outboard to ensure proper installation.
Do not overpower your boat by using an
engine that exceeds the horsepower indicated on the boat’s capacity plate.
Overpowering could result in loss of
control. If your boat has no capacity
plate, contact your Dealer or the boat’s
manufacturer.
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.
Only perform service procedures which
are detailed in this Operator’s Guide. Attempting to perform maintenance or repair on your outboard if you are not
familiar with the correct service and
safety procedure could cause personal
injury or death. Further information can
be obtained from your authorized
Evinrude/Johnson Dealer. In many instances proper tools and training are required for certain service or repair
procedures.
Maintain your boat and engine in top
condition at all times. Adhere to the
Maintenance Schedule on page 37.
Operate your boat and outboard prudently and have fun. Do not forget that
all persons must assist other boaters in
case of emergency.
Prevent injury from contact with rotating
propeller; remove propeller before flushing or before performing any maintenance.
8
X IMPORTANT SAFETY MESSAGES
PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS
BRP reserves the right to make changes at any time, without notice, to features, specifications
and model availability, and to change any specification or part at any time without incurring
any obligation to update older models. The information in the Guide is based on the latest
specifications available at the time of publication.
Photographs and illustrations used in this Guide might not depict actual models or equipment
but are intended as representative views for reference only.
Certain features of systems discussed in this Guide might not be found on all models in all
marketing areas.
Owner’s Identification
United States and Canada — At the time of purchase, your Dealer will complete your outboard registration forms. Your portion provides proof of ownership and date of purchase.
Outside United States and Canada — See your Dealer or distributor for details.
Model and Serial Numbers
The model and serial numbers appear on a plate attached to the stern bracket or swivel bracket. Record your outboard’s:
Model Number _______________________
Serial Number ________________________
Purchase Date _______________________
Ignition Key Number ___________________
Stolen Outboards
United States and Canada — Report stolen outboards to your local dealer or distributor.
Outside United States and Canada — Report the theft to the Bombardier Recreational Prod-
ucts distributor where the outboard was registered.
Technical Literature
BRP offers technical literature specifically for your outboard. A service manual, a parts catalog, or an extra Operator’s Guide can be purchased from your selling Dealer. For the name
and location of the nearest Evinrude Dealer in the United States and Canada visit
www.evinrude.com.
9
DECLARATION OF CONFORMITY
• Application of Council Directives:
Directive 94/25/EC as amended by 2003/44/EC – Recreational-Craft
• Relevant Harmonized Standard(s):
•EN ISO 8178-1
•EN ISO 14509
• Relevant Directive(s):
Directive 89/336EC as amended by 2004/108/EC – Electromagnetic Compatibility
• Relevant Harmonized Standard(s):
•EN ISO 55012:2007
•EN ISO 61000-6-1:2007
•EN ISO 61000-4-2:2008
•EN ISO 61000-4-3:2008
• Product Type:
Marine Outboard 2-Stroke Cycle SI Engine
• Manufacturer:
BRP US Inc.
10101 Science Drive
Sturtevant, WI 53177
• EC Type Certificate:
Engine Model(s)
E15D, E15H,E25D, E25T, E30D, E30T EXBOMB009 SDBOMB023
E40D, E50D EXBOMB002 SDBOMB012
E60D EXBOMB002 SDBOMB013
E65W EXBOMB006 SDBOMB020
E55M EXBOMB007 SDBOMB020
E75D, E90D, E90W EXBOMB003 SDBOMB014
E115D, E115H, E130D EXBOMB004 SDBOMB022
E150D, E150H, E175D, E200DP, E200DS, E200DC EXBOMB005 SDBOMB015
E200H, E200DH, E225D, E225H, E250DP, E250DC,
DE250P, DE250C
E250H, E250DH EXBOMB001 SDBOMB021
E300D, DE300P, DE300C EXBOMB008 SDBOMB021
Exhaust Emissions
Certificate Number
EXBOMB001 SDBOMB016
Sound Emissions
Certificate Number
Engine models represented here are partials; additional suffixes are added to define additional
features or accessories which do not affect certification.
I, the undersigned, hereby declare that the product specified above conforms to the above Directive(s) and Standard(s).
10
George Broughton
Director, Engineering Outboards Engines
USING YOUR
EVINRUDE E-TEC
OUTBOARD
USING YOUR E-TEC
OUTBOARD
11
Using Your E-TEC Outboard
SAFETY INFORMATION ON THE OUTBOARD
This outboard comes with a hang tag and labels containing important safety information
about the operation of the outboard. Any person who operates this outboard should read
and understand this safety information.
WARNING SYMBOLS
The following symbols are used together to
indicate “CAUTION: Read the engine’s
Operator’s Guide before preceding.”
HANG TAG
All outboards are shipped with the following
hang tag attached.
CAUTION: Read your Operator’s
Guide before starting engine.
12
REMOTE CONTROL DECALS
WARNING
Operator's
Guide
Locate, read and
understand operator's
guide and all warnings.
Failure to do so could
result in serious injury.
Attach engine shut-off cord
(Lanyard) to operator.
X SAFETY INFORMATION ON THE OUTBOARD
WARNING
Shift position
Reverse / Neutral / Forward
13
Using Your E-TEC Outboard
COMPONENT IDENTIFICATION
1
2
3
5
7
6
8
4
Item Description Item Description
1 Air Inlet, Tilt Handle 5 Stop Button / Emergency Stop
Switch
2 Water Pump Indicator, Flushing Port 6 Tilt Support
3 Engine Cover Latch 7 Clip and Lanyard Assembly
4 Anti-Corrosion Anodes 8 Water Intake Screens
14
Starboard
10
X COMPONENT IDENTIFICATION
12
11
9
Port
13
14
15
Item Description Item Description
16
17
18
9 Fuel Filter 14 Steering Handle and Twist Grip™
10 Spark Plugs 15 Air Silencer
11 Throttle Friction Screw 16 Oil Fill Cap
12 Shift Lever 17 Oil Tank
13 Starter Handle 18 EMM (Engine Management Module)
Throttle
15
Using Your E-TEC Outboard
OIL AND FUEL
OIL REQUIREMENTS OILING SYSTEM
Evinrude/Johnson Brand Oils
Evinrude/Johnson outboard oils are formulated to give best engine performance while
controlling piston and combustion chamber
deposits, providing superior lubrication, and
ensuring maximum spark plug life.
The following outboard oils are recommended for use in your Evinrude E-TEC outboard:
• Evinrude/Johnson XD100;
• Evinrude/Johnson XD50; or
• Evinrude/Johnson XD30.
Evinrude/Johnson XD100 Oil
Evinrude/Johnson XD100 oil is preferred
for your Evinrude E-TEC outboard. This
synthetic formula oil provides uncompromised lubrication and superior performance,
even in extreme conditions—especially in
cold temperatures down to 0°F (-17°C).
If requested, an authorized dealer can program your Evinrude E-TEC outboard EMM
for the exclusive use of Evinrude/Johnson
XD100. Only an authorized Evinrude deal-
er can program your outboard for this optional benefit.
Oil consumption is reduced if the outboard is
programmed for exclusive use of Evinrude/
Johnson XD100 as compared to using a conventional oil.
IMPORTANT: If your EMM has been programmed for Evinrude/Johnson XD100,
DO NOT use any other oil unless in an emer-
gency. If Evinrude/Johnson XD100 is temporarily unavailable, a one-time-only use of an
oil that meets NMMA TC-W3 certification
standards is allowed. If you discontinue using
Evinrude/Johnson XD100, you MUST first return to your Dealer to have the EMM reprogrammed back to the original factory setting.
If the “LOW OIL” warning light illuminates,
you have approximately five hours of normal
operation before running out of oil. Refill the
oil tank at next convenient opportunity.
Always “top off” your oil tank prior to prolonged usage or long trips.
New outboards are programmed to use additional oil during the first two hours of operation above 2000 RPM.
Refer to Engine Overheating on page 29.
NOTICE
under 32°F (0°C), Evinrude/Johnson
XD100 oil must be used.
Always keep an extra supply of outboard oil in
the boat. Refer to Oil Requirements on page
16.
If you run the oil tank empty, you MUST refill
the oil tank and prime the oil system before
using the engine. Refer to Filling the Oil
Tank on page 17 and Priming the Oil System on page 16.
When operating in conditions
Priming the Oil System
The oiling system MUST be primed before
using the outboard if:
• The outboard is new (Oil system MUST be
primed);
• You run completely out of oil; or
• The outboard is laid down for transportation
or storage.
Prime the oiling system by performing Long-
Term Storage (Winterization) on page 40.
Other Oils
If Evinrude/Johnson brand oils are not available, you must use an oil that meets NMMA
TC-W3 certification standards.
IMPORTANT: Failure to follow oil specifications could void the engine warranty if a lubrication-related failure occurs.
16
X OIL AND FUEL
Filling the Oil Tank
Release the port and starboard engine cover
latches by turning each handle downward.
Pull up on the tilt handle to release the engine
cover seal on the engine cover.
Remove the engine cover to access the oil
tank.
Remove the filler cap and fill the tank with the
recommended outboard lubricant, as specified in Oil Requirements on page 16.
1
1. Tilt handle
Replace the filler cap and tighten securely.
Reinstall the engine cover.
IMPORTANT: The oil tank capacity is 2.0
quarts (1.9 liters).
17
Using Your E-TEC Outboard
FUEL REQUIREMENTS
WARNING
Gasoline is extremely flammable
and highly explosive under certain
conditions. Follow the instructions
in this section explicitly. Improper
handling of fuel could result in property damage, serious injury or
death.
Leaking fuel is a fire and explosion
hazard. All parts in the fuel system
should be inspected frequently and
replaced if signs of deterioration or
leakage are found. Inspect the fuel
system each time you refuel, each
time you remove the engine cover
and annually.
Follow these instructions to ensure
safety when handing fuel:
• Always turn off the engine 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, or allow open flames, or
sparks or use electrical devices such
as cellular phones in the vicinity of a
fuel leak or while fueling.
• Always work in a well ventilated area.
NOTICE
Gasoline will oxidize; the result is loss of
octane, volatile compounds, and the production of gum and varnish deposits
which can degrade the fuel system.
Always use fresh gasoline.
Alcohol Fuels
Your outboard has been designed to operate
using the specified fuels; however, 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 blended fuel may cause engine performance problems
NOTICE
moisture that can cause corrosion of
metallic parts in the fuel system.
Using alcohol-extended fuels is acceptable
ONLY if the alcohol content does not exceed:
• 10% ethanol by volume; or
• 5% methanol with 5% cosolvents by volume.
Alcohol attracts and holds
FUEL ADDITIVES
The only fuel additives approved for use in
your Evinrude E-TEC outboard are:
• Evinrude/Johnson 2+4 Fuel Conditioner
• Evinrude/Johnson Fuel System Cleaner
Use of other fuel additives can result in
poor performance or engine damage.
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.
Minimum Octane
Your outboard is certified to operate on unleaded automotive gasoline with an octane
rating equal to or higher than:
• 87 (R+M)/2 AKI — Inside the U.S.
• 90 RON — Outside the U.S.
Using unleaded gasoline that contains methyl
tertiary butyl ether (MTBE) is acceptable
ONLY if the MTBE content does not exceed
15% by volume.
18
X OIL AND FUEL
FUEL SYSTEM INFORMATION
WARNING
If engine is equipped with a quickdisconnect fuel hose, you MUST
disconnect the fuel hose from the
engine and the fuel tank to prevent
fuel leaks:
• Whenever the engine is NOT being
used
• Whenever the engine is being trailered
• Whenever the engine is in storage
NOTE: A small amount of fuel may
be released when the fuel connector
is disconnected.
Store portable fuel tanks in well-ventilated areas, away from heat
sources and open flames. Close the
vent screw of the fuel tank cap, if
equipped, to prevent escape of fuel
or fuel vapors which could accidentally ignite. Do not allow disconnected fuel hoses to leak fuel.
Fuel Connector
If equipped, disconnect fuel hose connectors
from the engine’s fuel connector when the engine is not in use.
1
007004
1. Fuel connector
IMPORTANT: Fuel distribution hoses in the
boat must deliver fuel at a specific flow rate.
Minimum inside diameter of fuel hoses must
be 5/16 in. (7.9 mm).
Fuel systems with built-in tanks, particularly
those that include antisiphon valves and filter/
primer units, may have restrictions not allowing the engine fuel pump to deliver sufficient
fuel under all conditions. This can result in a
loss of performance. If a performance problem exists, see your Dealer.
Fuel System Priming - Rope Start
Models
If the outboard is run out of fuel, refill the fuel
tank and squeeze the primer bulb until firm.
Prime the electric fuel pump by first removing
the emergency stop switch clip and then pulling the rope at least two times. This will cause
the fuel pump to fill the injectors. Replace the
emergency stop switch clip and follow the
normal starting procedure.
19
Using Your E-TEC Outboard
OPERATION
SAFETY INFORMATION ENGINE STARTING / STOPPING -
TILLERS MODELS
WARNING
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.
Refer to the Routine Inspection Checklist
on page 33 for pre-launch checks before using your Evinrude E-TEC outboard.
NOTICE
engine before attempting to start it.
Engine damage can occur quickly.
Be sure the water intake screens are below
the water surface.
You MUST supply water to the
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.
WARNING
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. Always shut off the
engine when near people in the
water.
WARNING
The engine cover is a machinery
guard. DO NOT operate your outboard with the cover off unless you
are performing maintenance or
emergency starting, and then be
careful to keep hands, hair, and
clothing clear of all moving parts.
Contact with moving parts could
cause injury.
Connecting the Fuel Hose
Connect the fuel hose to the fuel connector.
1
007004
1. Fuel connector
If equipped, open vent screw on fuel tank cap.
Squeeze fuel primer bulb, outlet end up, until
firm.
Emergency Stop Switch
The emergency stop switch is on the steering
handle. Use of the emergency stop feature is
highly recommended on all boats.
Be familiar with the waters you are operating in. The gearcase of this outboard
extends below the water surface and
could potentially come in contact with
underwater obstructions. Contact with
underwater obstructions may result in
loss of control and personal injury.
20
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