Evinrude 100, 250, 115, 135, 150 Operator's Manual

Operator's Guide

100 thru 250 HORSEPOWER

FPL, FSL, FPX,
FCX, FPZ, FCZ,
FHL

Our First Words to the Owner/Operator

This Operator’s Guide is an essential part of your
which, if followed, will provide you with a thorough understanding needed for proper operation, mainte­nance, care and above all safety!

The safety section of this Guide comes first because it is our first priority and it should be yours too. It is
strongly recommended that you read this Guide from front cover to rear cover. Following this recommen­dation will assure the completeness of the information that is essential to your safety, the safety of any
passengers and other boaters. An Operator’s Readiness Test has been prepared on the last page of this
Guide.

Be safe! All passengers should be familiar with the proper operation of your boat and
Be certain they fully understand and respect the controls and operation. Each operator is responsible for
the safety of all passengers and other boaters. Please make safety your first priority and complete a boat­ing safety course through your local Coast Guard, Power Squadron, Red Cross or State Boating Law
Agency.

The pleasures of owning and operating an
rewards for following our recommendations will be worthwhile. Remember that YOU are the key to safety.
Good safety practices not only protect you but also protect the people around you.

Having fun is what it’s all about and, with your cooperation, the pertinent information in this Guide can en­sure a safe and enjoyable experience.

Enjoy the great outdoors on the water...

Evinrude

Evinrude

outboard can be significant. We strongly believe the

outboard. It contains pertinent information

Evinrude

outboard.

WARNING

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.

For your safety and the safety of others, read this Guide from cover to cover and 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 motor.

The following trademarks are the property of Bombardier Motor Corporation of America or its affiliates:

Evinrude® 2+4® fuel conditioner

Evinrude direct injection oil S.L.O.W.

Evinrude®/Johnson® Genuine Parts System Check®

Evinrude®/Johnson® XD25™ formula Triple-Guard® grease

Hi-Vis® gearcase lubricant Ultra-HPF

Johnson®

™

™

gearcase lubricant

Contents

GENERAL INFORMATION ................................................................................................... 2

SAFETY — THE RIGHT PLACE TO GET STARTED ................................................................................................ 2

PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS ................................................................... 4

BOMBARDIER LIMITED WARRANTY FOR

SOLD IN THE UNITED STATES AND CANADA ................................................................................................ 5

BOMBARDIER LIMITED WARRANTY FOR

SOLD OUTSIDE THE UNITED STATES AND CANADA ................................................................................... 7

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT ............................................................................ 8

FEATURES ............................................................................................................................................................... 12

ENGINE SPECIFICATIONS ...................................................................................................................................... 14

REMOTE CONTROL ................................................................................................................................................. 17

ENGINE MONITORING ...................................................................................................... 19

FUEL AND OIL ................................................................................................................... 21

FUEL ......................................................................................................................................................................... 21

OIL ............................................................................................................................................................................. 21

ADDITIVES ................................................................................................................................................................ 22

FUEL SYSTEM .......................................................................................................................................................... 22

OIL SYSTEM ............................................................................................................................................................. 23

BREAK-IN (10 HOURS) ............................................................................................................................................ 25

ENGINE STARTING ........................................................................................................... 26

BEFORE START-UP ................................................................................................................................................. 26

ENGINE STOPPING ................................................................................................................................................. 28

SHIFTING AND SPEED CONTROL ......................................................................................................................... 28

FUEL ECONOMY ...................................................................................................................................................... 28

OPERATION ....................................................................................................................... 29

POWER TRIM AND TILT .......................................................................................................................................... 29

PROPELLER SELECTION ....................................................................................................................................... 32

MOORING ................................................................................................................................................................. 32

FLUSHING ................................................................................................................................................................ 33

ENGINE OVERHEATING .......................................................................................................................................... 34

TRAILERING ............................................................................................................................................................. 35

IMPACT DAMAGE .................................................................................................................................................... 36

STORING .................................................................................................................................................................. 36

SPECIAL OPERATING CONDITIONS ..................................................................................................................... 37

MAINTENANCE .................................................................................................................. 38

ENGINE EMISSIONS INFORMATION ...................................................................................................................... 38

10-HOUR INSPECTION ............................................................................................................................................ 38

OFF-SEASON STORAGE ........................................................................................................................................ 39

PRE-SEASON SERVICE .......................................................................................................................................... 40

BATTERY .................................................................................................................................................................. 41

ADJUSTMENTS ........................................................................................................................................................ 43

LUBRICATION .......................................................................................................................................................... 44

WATER PRESSURE ................................................................................................................................................. 46

START ASSIST CIRCUIT FUSE ............................................................................................................................... 46

SPARK PLUGS ......................................................................................................................................................... 46

POWER DISTRIBUTION PANEL ............................................................................................................................. 47

PROPELLER ............................................................................................................................................................. 48

ANTI-CORROSION ANODES ................................................................................................................................... 49

TROUBLE CHECK CHART ...................................................................................................................................... 50

ENGINE MAINTENANCE AND INSPECTION SCHEDULE ..................................................................................... 51

EVINRUDE

EVINRUDE

OUTBOARD ENGINES

OUTBOARD ENGINES

© 2003 Bombardier Motor Corporation of America. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Motor Corporation of America or its affiliates.

1

GENERAL INFORMATION

SAFETY — THE RIGHT PLACE TO GET STARTED

This Operator’s Guide contains essential informa­tion to help prevent personal injury and damage to
equipment. It will acquaint the operator and pas­sengers with the
trols, operation, maintenance and boating safety
measures. Make sure all operators read, under­stand and follow the contents. This Guide should be
kept in a waterproof bag with the product at all times
during operation. If the product ownership is trans­ferred, this Guide should be forwarded to the sub­sequent owners.

This Operator’s Guide uses the following signal
words identifying important safety messages.
These safety alert signal words mean:

ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!

Evinrude

outboard and its con-

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.

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.

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.

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. Outside North America
please contact your DEALER or distributor for de­tails about boating safety.

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! Fail­ure to follow this safety information and safe
boating rules could result in injury to you, your
passengers or other water users.

Become completely familiar with the control
and operation of your boat and motor 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 — Operation

Be sure at least one of your passengers
knows how to handle your boat in case of an
emergency.

All passengers should know the location of
emergency equipment and how to use it.

All safety equipment and personal flotation
devices must be in good condition and suit­able for your type of boat. Always comply with
the regulations that apply to your boat.

Contact with rotating propeller is likely to result
in serious injury or death. Do not allow anyone
near a propeller, even when the engine is off.
Propeller blades can be sharp and can contin­ue to turn even after the engine is shut off. Al­ways shut off the engine when boat is near
people in the water.

2 - General Information

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.

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.

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.

Insist on the use of personal flotation devices,
approved by the U.S. Coast Guard, by all pas­sengers when boating conditions are hazard­ous, and by children and nonswimmers at all
times.

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.

Know the marine traffic laws and obey them.

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.

Do not operate your boat if you are under the
influence of drugs or alcohol.

High performance boats have a high power­to-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.

For more information, see your

Johnson

to High Performance Boating, P/N 335763.

DEALER for a copy of Introduction

Evinrude/

SAFETY MEASURES — Installation and Maintenance

Outboard Installation

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.

Maintenance

When replacement parts are required, use

Evinrude®/Johnson® Genuine 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

Johnson

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 Engine Mainte-
nance and Inspection Schedule.

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.

DEALER. In many instances proper

or parts

Evinrude/

General Information - 3

PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS

WARNING

When replacement parts are required, use

Evinrude/Johnson Genuine Parts

with equivalent characteristics, including
type, strength and material. Using substan­dard parts could result in injury or product
malfunction.

Bombardier Motor Corporation of America

the right to make changes at any time, without no­tice, to features, specifications and model availabil­ity. The right is also reserved 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. The continuing accuracy of this Guide cannot
be guaranteed.

Certain features of systems discussed in this Guide
might not be found on all models in all marketing ar­eas.

Owner’s Identification

North America — At the time of purchase, your

DEALER will complete your outboard registration
forms. Your portion provides proof of ownership
and date of purchase.

Outside North America — See your DEALER or
distributor for details.

or parts

reserves

Stolen Outboards

North America — Report your outboard as stolen

to Customer and Dealer Support Services, 250
Seahorse Drive, Waukegan, IL 60085 U.S.A. Give
the outboard’s model and serial numbers and en­close a copy of the police report.

Outside North America — Report the theft to the

Bombardier

istered.

Technical Literature

Bombardier Motor Corporation of America

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

da visit www.evinrude.com.

Declaration of Conformity

Bombardier Motor Corporation of America

that the outboard to which this Operator’s Manual
applies conforms to the essential requirements out­lined in CE Machinery Directive 98-37-EC, as
amended.

George Broughton
Director of Outboards

distributor where the outboard was reg-

offers

DEALER in the United States and Cana-

declares

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 ____________________________

4 - General Information

BOMBARDIER LIMITED WARRANTY FOR 2004

EVINRUDE

OUTBOARD ENGINES

SOLD IN THE UNITED STATES AND CANADA

1. SCOPE OF THE LIMITED WARRANTY

Bombardier Motor Corporation of America* ("Bombardier") warrants its

Evinrude

dealers in the fifty United States and Canada ("Product") from defects in material or workmanship for the period

and under the conditions described below.

2. WARRANTY COVERAGE PERIOD

This limited warranty will be in effect from the date of purchase by the first retail consumer or the date the Product is first
put to use, whichever occurs first, for a period of:

THIRTY-SIX (36) CONSECUTIVE MONTHS for private, recreational use; or

TWELVE (12) CONSECUTIVE MONTHS for commercial use, except that emission-related components providing input
to emission controls (e.g. sensors) are warranted for twenty-four (24) months or two hundred (200) hours of engine use,
whichever occurs first. The Product is used commercially when it is used in connection with any work or employment that
generates income, during any part of the warranty period. The Product is also used commercially when, at any point dur­ing the warranty period, it is installed on a boat that has commercial tags or is licensed for commercial use.

The repair or replacement of parts or the performance of service to Product under this warranty does not extend the life
of this limited warranty beyond its original expiration date. All
stalled by an authorized dealer at the time of sale, including but not limited to propellers, bear the standard Bombardier
parts and accessories one-year limited warranty.

California residents who purchased or warranty-registered a Product in California should refer to Bombardier's California
Emissions Control Warranty Statement.

3. CONDITIONS TO HAVE WARRANTY COVERAGE

This warranty coverage is available only on
thorized to distribute
bardier specified pre-delivery inspection process has been completed and documented by the purchaser and Dealer.
Warranty coverage only becomes available upon proper registration of Product by Dealer or owner.

Only the original purchaser and any subsequent owners who reside in the United States and Canada and have pur­chased Product from a U.S. or Canadian Dealer are eligible for warranty registration and warranty coverage hereunder.
Such limitations are necessary in order to allow Bombardier to protect the safety of its products, its consumers, and the
general public.

As outlined in the Operator's Guide, timely routine required maintenance must be performed to maintain warranty cover­age. Bombardier may require proof of proper maintenance prior to authorizing warranty coverage.

Evinrude

products in the country in which the sale occurred ("Dealer"), and then only after the Bom-

Evinrude

outboard engines purchased as new and unused from a dealer au-

Evinrude

® outboard engines sold by authorized

Evinrude/Johnson® Genuine Parts

and accessories in-

4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE

The registered owner must notify an authorized Dealer within two (2) days of the appearance of a defect. Owner must
bring Product, including any defective part therein, to Dealer promptly after the appearance of the defect, and in any
event, within the warranty period, and must provide Dealer with reasonable opportunity to repair the defect. The expenses
of transporting Product to and from Dealer for warranty service are to be borne by the owner.

If the Product has not previously been registered, the owner may also be required to present proof of purchase to Dealer
for warranty repairs. Owner is required to sign the repair/work order prior to the start of the repair in order to validate the
warranty repair.

All parts replaced under this warranty become the property of Bombardier.

5. WHAT BOMBARDIER WILL DO

Bombardier's obligations under this warranty are limited to, at its sole discretion, repairing or replacing parts of Product
found to be defective in material or workmanship, in the reasonable judgment of Bombardier. Such repair or replacement
of parts will be done without charge for parts and labor, at any authorized Dealer. Bombardier's responsibility is limited
to making the required repairs or replacements of parts with new or Bombardier-certified re-manufactured parts. No claim
of breach of warranty shall be cause for cancellation or rescission of the sale of Product to owner.

In the event that warranty service is required outside of the fifty United States or Canada, owner will bear responsibility
for any additional charges due to local practices and conditions, such as, but not limited to, freight, insurance, taxes, li­cense fees, import duties, and any and all other financial charges, including those levied by governments, states, territo­ries and their respective agencies.

Bombardier reserves the right to improve, modify or change Products from time to time without assuming any obligation
to modify Products previously manufactured.

General Information - 5

6. EXCLUSIONS — The following are not warranted under any circumstances:

• Replacement of parts due to normal wear and tear;

• Routine maintenance parts and services including but not limited to: maintenance requirements, engine and lower unit
oil changes, lubrication, valve and linkage adjustments and replacement of fuses, zinc anodes, thermostats, timing
belts, starter motor bushings, trim motor brushes, filters, propellers, propeller bushings and spark plugs;

• Damage caused by improper or lack of installation, maintenance, winterization and/or storage, failure to follow the pro­cedures and recommendations in the Operator's Guide;

• Damage resulting from removal of parts, improper repairs, service, maintenance, or modification, or use of parts or
accessories not manufactured or approved by Bombardier, which in its reasonable judgment, are either incompatible
with Product or adversely affect its operation, performance, or durability, or resulting from repairs done by a person
that is not an authorized Dealer;

• Damage caused by abuse, misuse, abnormal use, neglect, racing, improper operation or operation of the Product in a
manner inconsistent with the recommended operation described in the Operator's Guide;

• Damage resulting from external damage, accident, submersion, water ingestion, fire, theft, vandalism or any act of
God;

• Operation without proper fuel, oil or lubrication, or with fuels, oils or lubricants which are not suitable for use with the
Product (see the Operator's Guide);

• Damage resulting from rust or corrosion;

• Damage caused from cooling system blockage by foreign material;

• Damage resulting from sand or debris in the water pump;

• Cosmetic or paint changes due to exposure to the elements.

This warranty will be voided in its entirety and rendered null and void where:

• Product has been altered or modified in such a way so as to adversely affect its operation, performance or durability,
or change its intended use, horsepower or emission levels; or

• Product is or has been used for racing at any point, even by a prior owner.

7. LIMITATIONS OF LIABILITY

ALL WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MER­CHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE LIFE OF THE
EXPRESS LIMITED WARRANTY.

ALL INCIDENTAL, CONSEQUENTIAL, DIRECT, INDIRECT OR OTHER DAMAGES OF ANY KIND ARE EXCLUDED
FROM COVERAGE UNDER THIS WARRANTY INCLUDING, BUT NOT LIMITED TO: expense for gasoline, expense

for transporting Product to and from Dealer, removal of Product from a boat and reinstallation, mechanic’s travel time, in­and-out of water charges, slip or dock fees, trailering or towing, storage, telephone, cell phone, fax or telegram charges,
rental of a like or replacement Product or boat during warranty services or down time, taxi, travel, lodging, loss of or dam­age to personal property, inconvenience, cost of insurance coverage, loan payments, loss of time, loss of income, reve­nue or profits, or loss of enjoyment or use of Product.

SOME STATES, PROVINCES, OR JURISDICTIONS DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS OF
INCIDENTAL OR CONSEQUENTIAL DAMAGES, OR OTHER EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT,
THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE
OTHER LEGAL RIGHTS WHICH MAY VARY FROM STATE TO STATE, OR PROVINCE TO PROVINCE.

No distributor, Dealer or any other person is authorized to make any affirmation, representation or warranty regarding
Product other than those contained in this limited warranty and, if made, shall not be enforceable against Bombardier.
Bombardier reserves the right to modify this warranty at any time, being understood that such modification will not alter
the warranty conditions applicable to the Products sold while this warranty is in effect.

8. TRANSFER

If the ownership of Product is transferred during the warranty coverage period, this warranty shall also be transferred and
be valid for the remaining coverage period provided that the former or new owner promptly contacts Bombardier or Dealer
and gives the name and address of the new owner.

9. CONSUMER ASSISTANCE

• In the event of a controversy or dispute in connection with this Bombardier limited warranty, Bombardier recommends
that you first try to resolve the issue at the dealership level by discussing the issue with Dealer’s service manager or
owner;

• If further assistance is required, please contact the Bombardier Customer Support Services, 250 Sea Horse Drive,
Waukegan, IL 60085, 1-847-689-7090.

Revision April 2003
* Engines sold in Canada are distributed and serviced by Bombardier Inc.

6 - General Information

BOMBARDIER LIMITED WARRANTY FOR

SOLD OUTSIDE THE UNITED STATES AND CANADA

EVINRUDE

OUTBOARD ENGINES

For a copy of the Limited Warranty, see your Bombardier distributor/dealer authorized to distribute
the country in which the sale occurs.

If further assistance is required, please contact Bombardier Customer Support Services, 250 Sea Horse Drive, Waukeg­an, Illinois, 60085, or the affiliate of Bombardier where the Product was registered for warranty.

Evinrude

products in

General Information - 7

CALIFORNIA EMISSION CONTROL WARRANTY

STATEMENT

Your

Evinrude

Air Resources Board. The label has one, two, three, or four stars. A hangtag, provided with your outboard,
describes the meaning of the star rating system.

The Symbol for Cleaner Marine Engines:

Cleaner Air and Water

Better Fuel Economy

Longer Emission Warranty

One Star – Low Emission

The one-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet the
Air Resource Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission stan­dards. Engines meeting these standards have 75% lower emissions than conventional carbureted two­stroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.

Two Stars – Very Low Emission

The two-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet the
Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emission stan­dards. Engines meeting these standards have 20% lower emissions than One Star – Low Emission en­gines.

Three Stars – Ultra Low Emission

The three-star label identified engines that meet the Air Resources Board's Personal Watercraft and Out­board marine engine 2008 exhaust emission standards. Engines meeting these standards have 65% low­er emissions than One Star – Low Emission engines.

Four Stars – Super Ultra Low Emission

The four-star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marine
engine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may also
comply with these standards. Engines meeting these standards have 90% lower emissions than One Star
– Low Emission engines.

For more information: Cleaner Watercraft – Get the Facts

outboard with Direct Injection has a special environmental label required by the California

The Star Label means Cleaner Marine Engines

For a healthier lifestyle and environment.

Burns up to 30 to 40 percent less gas and oil than conventional
carbureted two-stroke engines, saving money and resources.

Protects consumer for worry free operation.

1-800-END-SMOG
www.arb.ca.gov

8 - General Information

YOUR EMISSION CONTROL WARRANTY RIGHTS AND OBLIGATION

The California Air Resources Board and Bombardier Motor Corporation of America (“Bombardier”) are
pleased to explain the emission control system warranty on your
In California, new outboard engines must be designed, built, and equipped to meet the State's stringent
anti-smog standards. Bombardier must warrant the emission control system on your outboard for the pe-

Evinrude

outboard with Direct Injection.

riods of time listed below provided there has been no abuse, neglect, or improper maintenance of your
outboard.

Your emission control system may include parts such as the carburetor or fuel injection system, the igni­tion system, and catalytic converter. Also included may be hoses, belts, connectors, and other emission­related assemblies.

Where a warrantable condition exists, Bombardier will repair your outboard at no cost to you, including
diagnosis, parts, and labor, provided that such work is performed by an authorized Bombardier dealer.

Manufacturer's Limited Warranty Coverage

This emission limited warranty covers
Bombardier for sale in California, that are originally sold in California to a California resident, or subse­quently warranty registered to a California resident. The Bombardier North America Limited Warranty con­ditions for

Evinrude

outboards with Direct Injection are still applicable to these models with the necessary

Evinrude

outboards with Direct Injection certified and produced by

modifications.

Select emission control parts of your
of purchase by the first retail consumer or the date the product is first put to use, whichever occurs first,
for a period of 4 years, or for 250 hours of use, whichever occurs first.

However, warranty coverage based on the hourly period is only permitted for outboards equipped with the
appropriate hour meters or their equivalent. If any emission-related part on your engine is defective under

Evinrude

outboard with Direct Injection are warranted from the date

warranty, the part will be repaired or replaced by Bombardier.

Parts covered are:

1. Electrical System 4. Air Induction System

A. EMM (Engine Management Module) A. Reed Valves
B. Spark Plugs and Wires B. Throttle Body Assembly
C. Ignition Coils C. Throttle Linkage
D. Wiring Harness

2. Exhaust System A. Oil Injector
A. Powerhead to Lower Unit Adapter Plate B. Oil Lift Pump
B. Exhaust Pressure Fitting C. Oil Lines, Fittings, and Clamps
C. Inner Exhaust Housing
D. Exhaust Back Pressure Hose and Diaphragm 6. Sensors
E. Intake Manifold and Exhaust Manifold A. Air Temperature Sensor

3. Fuel System C. Throttle Position Sensor
A. Fuel Lift Pump D. Water Temperature Sensor (Port Cylinder Head)
B. Fuel Supply Pump E. Thermostat
C. Fuel Injectors
D. Vapor Separator 7. Gaskets
E. Fuel Lines, Fittings, and Clamps A. All Emission Component Gaskets

5. Oil System

B. Crank Position Sensor

General Information - 9

The emission warranty covers damage to other engine components that is caused by the failure of a war­ranted part.

The Bombardier Operator's Guide provided contains written instructions for the proper maintenance and
use of your outboard. All emission warranty parts are warranted by Bombardier for the entire warranty pe­riod of the outboard, unless the part is scheduled for replacement as required maintenance in the Opera­tor's Guide.

Emission warranty parts that are scheduled for replacement, as required maintenance, are warranted by
Bombardier for the period of time before the first scheduled replacement date for that part. Emission war­ranty parts that are scheduled for regular inspection but not regular replacement are warranted by Bom­bardier for the entire warranty period of the outboard. Any emission warranty part repaired or replaced
under the terms of this warranty statement is warranted by Bombardier for the remainder of the warranty
period of the original part. All parts replaced under this limited warranty become the property of Bombar­dier.

Maintenance receipts and records should be transferred to each subsequent owner of the outboard.

Owner's Warranty Responsibilities

As the outboard owner, you are responsible for the performance of the required maintenance listed in your
Operator's Guide. Bombardier recommends that you retain all receipts covering maintenance on your out­board, but Bombardier cannot deny warranty solely for the lack of receipts or your failure to ensure the
performance of all scheduled maintenance.

However, as the outboard owner, you should be aware that Bombardier may deny you warranty coverage
if your outboard or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifi­cations.

You are responsible for presenting your outboard to an authorized Bombardier dealer as soon as a prob­lem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.

For any questions regarding your warranty rights and responsibilities, or for the name and location of the
nearest authorized Bombardier dealer, contact Bombardier Customer Support Services, 250 Sea Horse
Drive, Waukegan, IL 60085, 1-847-689-7090, or visit www.evinrude.com.

10 - General Information

NOTES

General Information - 11

FEATURES

3

1,2

4

5

20

10

19

11

15

21

13

14

12

16

9

6

17

22

8

18

7

000061A

Item Description Item Description

1 Power Distribution Panel 13 Oil Supply Fitting

2 Fuses & Spare Fuse Holder 14 Oil Return Fitting

3 Starter Assist Circuit Fuse 15 Battery Cable

4 Accessory Battery Connection 16 Engine Wire Harness

5 Tilt Support 17 Speedometer Pick-up Connector

6 Anti-Corrosion Anode 18 Water Intake

7 Lubricant Drain Fill Plug 19 Air Silencer

8 Lubricant Level Plug 20 Fuel Filter: 100HP-175HP Models

9 Power Tilt & Trim Reservoir 21 System Check Gauge

10 Tilt Limiter Cam 22 System Check Tachometer

11 Engine Cover Latch 23 Oil Tank Kit

12 Fuel Fitting

(1) not supplied with outboard

23

(1)

(1)

(1)

12 - General Information

11

13

1

2

14

3
4

15

5

16

Item Description Item Description

1 Trailering Tilt Switch: 100HP-175HP 8 Model & Serial Number Plate

Trailering Tilt Switch: 200HP-250HP 9 Flushing Port

On Starboard Side 10 Water Pump Indicator

2 Power Tilt & Trim: Manual Release 11 Fuel Filter: 200HP-250HP Models

3 Trailering Bracket 12 Motor Cover Latch

4 Trim Limiter Rod 13 Remote Control

5 Water Intake 14 Steering Connector Kit

6 Trim Tab 15 Trim Gauge

7 ECI Label 16 Oil Return Hose

(1) not supplied with outboard

(1)

(1)

12

9,10

8

7

6

000062

General Information - 13

ENGINE SPECIFICATIONS

100, 115 Models

Displacement 105.4 cu. in. (1726 cc)

Engine Type 60° V, 4 Cylinder, Two-Cycle,

Full Throttle Operating Range 100, 115 - 5250 to 5750 RPM

(1)

Power

Idle RPM in Gear

Ignition Timing

Emission Control System:
per SAE J1930

Fuel Requirements

(2)

(2)

(2)

(2)

Oil

Warning Signals Controlled by the engine’s

Battery, Minimum 500 CCA (620 MCA) 12 volt

Spark Plug

(2)(3)

Torque

Start Assist Circuit Fuse

Fuses Refer to Power Distribution Panel

Fuel Filter

Alternator 35-Amp, Fully Regulated

Gearcase - Lubricant
Capacity

Pwr. Trim/Tilt - Fluid Capacity 21 fl. oz. (622 ml)

(4)

Propeller

(7)

Weight

Sound at Driver’s Ear
(LpA) ICOMIA 39.94

Transom Height L Models - 19 1/2 to 20 in. (495 to 508 mm)

Direct Injection

100 - 100 HP (74.6 kw) @ 5500 RPM
115 - 115 HP (85.8 kw) @ 5500 RPM

650 ± 50

Not Adjustable

ECM, DFI (Engine Control Module, Direct Fuel Injection)

87 Pump Posted AKI (90 RON) - Refer to Fuel and Oil

Evinrude

direct injection oil - Refer to Fuel and Oil

EMM

Refer to ECI Label
15-22 ft. lbs. (20-30 N·m)

Evinrude

P/N 514768

Evinrude

P/N 502906

Evinrude Ultra-HPF™

gearcase lubricant

L Models - 26 fl. oz. (770 ml)
X Models - 42 fl. oz. (1250 ml)

Refer to Propeller Selection

L Models - 365 lbs. (166 kg)
X Models - 390 lbs. (177 kg)

80.8 dB(A)

X Models - 24 1/2 to 25 in. (622 to 635 mm)

14 - General Information

135, 150, 175 Models

Displacement 158 cu. in. (2589 cc)

Engine Type 60° V, 6 Cylinder, Two-Cycle,

Full Throttle Operating Range 135, 150 - 4750 to 5250 RPM

(1)

Power

Idle RPM in Gear

Ignition Timing

Emission Control System:
per SAE J1930

Fuel Requirements

(2)

(2)

(2)

(2)

Oil

Warning Signals Controlled by the engine’s

Battery, Minimum 675 CCA (845 MCA) 12 volt

Spark Plug

(2)(3)

Torque

Start Assist Circuit Fuse

Fuses Refer to Power Distribution Panel

Fuel Filter

Alternator 35-Amp, Fully Regulated

Gearcase - Lubricant
Capacity

Pwr. Trim/Tilt - Fluid Capacity 21 fl. oz. (622 ml)

(4)

Propeller

(7)

Weight

Sound at Driver’s Ear
(LpA) ICOMIA 39.94

Transom Height L Models - 19 1/2 to 20 in. (495 to 508 mm)

Direct Injection

175 - 5250 to 5750 RPM

135 - 135 HP (100.7 kw) @ 5000 RPM
150 - 150 HP (111.9 kw) @ 5000 RPM
175 - 175 HP (130.5 kw) @ 5500 RPM

650 ± 50

Not Adjustable

ECM, DFI (Engine Control Module, Direct Fuel Injection)

87 Pump Posted AKI (90 RON) - Refer to Fuel and Oil

Evinrude Direct Injection

OR 107 amp-hour

oil - Refer to Fuel and Oil

EMM

(5)(6)

Refer to ECI Labels
15-22 ft. lbs. (20-30 N·m)

Evinrude

P/N 514768

Evinrude

P/N 502906

Evinrude Ultra-HPF™

gearcase lubricant
40 fl. oz. (1190 ml) Counter Rotation
44 fl. oz. (1300 ml) Standard Rotation

Refer to Propeller Selection

L Models - 423 lbs. (192 kg)
X Models - 443 lbs. (201 kg)

78.2 dB(A)

X Models - 24 1/2 to 25 in. (622 to 635 mm)

General Information - 15

200, 225, 250 Models

Displacement 200 cu. in. (3279 cc)

Engine Type 90° V, 6 Cylinder, Two-Cycle,

Full Throttle Operating Range 200 - 5000 to 6000 RPM

(1)

Power

Idle RPM in Gear

Ignition Timing

Emission Control System:
per SAE J1930

Fuel Requirements

(2)

(2)

(2)

(2)

Oil

Warning Signals Controlled by the engine’s

Battery, Minimum 675 CCA (845 MCA) 12 volt

Spark Plug

(2)(3)

Torque

Start Assist Circuit Fuse

Fuses Refer to Power Distribution Panel

Fuel Filter

Alternator 35-Amp, Fully Regulated

Gearcase - Lubricant
Capacity

Pwr. Trim/Tilt - Fluid Capacity 21 fl. oz. (622 ml)

(4)

Propeller

(7)

Weight

Sound at Driver’s Ear
(LpA) ICOMIA 39.94

Transom Height L Models - 19 1/2 to 20 in. (495 to 508 mm)

(1) Rated following the standards of ICOMIA 28.83, ISO 3046 and NMMA.

(2) Emission Control Information.

(3) Any other spark plug will cause ignition problems.

(4) Not supplied in all marketing areas.

(5) Use a 750 CCA (940MCA) battery when operating in temperatures below 32°F (0°C).

(6) Under extraordinary electrical load or environmental conditions, use of a 107 amp-hour minimum.

Generally available in group 29 size.

(7) Does not include propeller or fuel.

Direct Injection

225, 250 - 5500 to 6000 RPM

200 - 200 HP (149.2 kw) @ 5750 RPM
225 - 225 HP (167.8 kw) @ 5750 RPM
250 - 250 HP (184.4 kw) @ 5750 RPM

650 ± 50

Not Adjustable

ECM, DFI (Engine Control Module, Direct Fuel Injection)

87 Pump Posted AKI (90 RON) - Refer to Fuel and Oil

Evinrude Direct Injection

oil - Refer to Fuel and Oil

EMM

OR 107 amp-hour

(5)(6)

Refer ECI Label
15-22 ft. lbs. (20-30 N·m)

Evinrude

P/N 514768

Evinrude

P/N 502906

Evinrude Ultra-HPF™

gearcase lubricant
40 fl. oz. (1190 ml) Counter Rotation
44 fl. oz. (1300 ml) Standard Rotation

Refer to Propeller Selection

L Models - 515 lbs. (234 kg)
X Models - 537 lbs. (244 kg)
Z Models - 548 lbs. (249 kg)

80.8 dB(A)

X Models - 24 1/2 to 25 in. (622 to 635 mm)
Z Models - 29 1/2 to 30 in. (749 to 762 mm)

16 - General Information

REMOTE CONTROL

WARNING

If you choose a non­trol, be sure it has a start-in-gear prevention
feature. This feature can prevent injuries
resulting from unexpected boat movement
when the engine starts.

IMPORTANT: When selecting the remote control

system for your boat, specify
nents.

Evinrude

wiring kits designed specifically for your
outboards.
stroke your outboard needs for positive shift and
throttle control, and they incorporate such safety
and convenience features as:

• Start-in-gear prevention

• Plug-in compatibility with
ing system

Evinrude

1. Handle - shift and throttle

2. Trim/tilt switch (where equipped)

3. Neutral lock tab

4. Fast idle button

5. Throttle Friction Control

offers remote controls, cables and

Evinrude

concealed side mount control

Evinrude

controls deliver the cable

remote con-

Evinrude

Evinrude

compo-

Evinrude

modular wir-

Evinrude

1. Handle - shift and throttle

2. Trim/tilt switch (where equipped)

3. Fast idle button

4. Throttle friction control

5. Emergency stop clip and lanyard

Evinrude

1. Handle - shift and throttle

2. Trim/tilt switch (where equipped)

3. Neutral lock tab

4. Fast idle lever

5. Emergency stop clip and lanyard

Binnacle mount control

Side mount control

General Information - 17

Emergency Stop/Key Switch

A combination emergency stop switch and key
switch is a feature of
controls and all
the emergency stop feature is highly recommended
on all boats.

Connect the clip to the emergency stop/key switch.
Snap the lanyard to a secure place on the opera­tor’s clothing or life vest — not where it might tear
away instead of activating the stop switch. Discon­necting the clip and lanyard will stop the engine and
prevent the boat from becoming a runaway if the
driver moves beyond the range of the lanyard. If the
lanyard is too long, it can be shortened by knotting
or looping it. DO NOT cut and retie the lanyard. In
an emergency situation, the engine can be started
without the clip in place. Follow the normal starting
procedure. Reinstall a clip as soon as possible.

1. Clip

2. Emergency stop / key switch

3. Lanyard

Evinrude

Evinrude

prewired remote

control wiring kits. Use of

WARNING

Avoid knocking or pulling the clip off the
stop switch during normal boating. Avoid
bumping the key if operating without the
clip on the switch. The resulting unexpected
loss of forward motion can throw occupants
forward, causing injury.

Your emergency stop switch can be effec­tive only when in good working condition.
At each outing, inspect clip and lanyard for
cuts, breaks, or wear. Replace worn or dam­aged parts.

Keep the lanyard free from obstructions and
entanglements.

At each outing, test the system’s operation.
With the engine running, remove the clip
from the switch by pulling the lanyard. If the
engine does not stop running, see your
DEALER.

18 - General Information

ENGINE MONITORING

IMPORTANT: Your outboard must be equipped

with the

System Check

your outboard without the
monitor will void your warranty for failures related to
the functions monitored on your engine.

When you turn the key switch ON, the

Check

engine monitor horn performs a self-test by
sounding a 1/2-second beep. The gauge self-tests
by turning the warning lights on, then off in se­quence. During engine start-up, pause with the key
switch in the ON position to observe the horn and
gauge perform the self-test. If the self-test does not
happen as stated, see your DEALER.

The

System Check

ator with a 10-second beep of the horn and a warn­ing light on the gauge when certain engine
problems occur. The appropriate warning light

will stay on until the problem is corrected or the
key switch is turned OFF.

If the engine management module (
that the problem could cause permanent engine
damage, it will also limit engine speed to 1200
RPM. This additional protection feature is referred
to as

S.L.O.W.

than 1200 RPM when the
ed, it will shake noticeably. Under certain operating
conditions the

® engine monitor. Operating

System Check

engine monitor alerts the oper-

™ If the engine was running faster

EMM

S.L.O.W

will shut OFF the engine.

engine

System

EMM

) senses

. system activat-

1

1.

System Check

2.

System Check

“NO OIL”

There is an oil delivery problem. Serious engine
damage can occur quickly. The

S.L.O.W.

If the oil tank is empty, add the recommended oil.
If the oil tank is not empty, seek assistance and/or

return to safe harbor. DO NOT exceed 1000 RPM.
See your DEALER.

Gauge
Gauge with Tachometer

2

EMM

will activate

CAUTION

In the

S.L.O.W.

limited. Under certain conditions, the
engine’s limited speed may reduce maneu­verability of your boat.

If the

S.L.O.W.

are unable to correct the problem, seek
assistance and/or return to safe harbor.
Serious engine damage, engine shutoff,
and/or reduced maneuverability may be
imminent.

mode, the engine speed is

mode is activated and you

“WATER TEMP” or “HOT”

The engine is overheating. Serious engine damage
can occur quickly. The
Under certain conditions the
engine.

A continuous "WATER TEMP" or “HOT” light with

S.L.O.W.

ing condition. Shut OFF the engine and refer imme­diately to Engine Overheating.

A flashing "WATER TEMP" or “HOT” light — The

EMM

dition. The engine will shut OFF and will not restart
until the engine cools.

— The

has identified a progressive overheating con-

EMM

will activate

EMM

will shut OFF the

EMM

has identified an overheat-

Engine Monitoring - 19

S.L.O.W.

“CHECK ENGINE” or “CHK ENG”

The

EMM

lem.
A flashing "CHECK ENGINE" or "CHK ENG" light

— The
condition related to the fuel system. The engine will
shut OFF and cannot be restarted.

has identified a potentially serious prob-

EMM

has identified an abnormal operating

WARNING

If the engine shuts OFF and the “CHECK
ENGINE” or “CHK ENG” light is flashing,
the engine cannot be restarted. A hazardous
fuel condition may exist. Seek assistance to
return to port.

A continuous "CHECK ENGINE" or "CHK ENG"
light with
problem that will cause engine damage if it is not
addressed. Seek assistance and/or return to safe
harbor. See your DEALER.

A continuous "CHECK ENGINE" or "CHK ENG"
light without
problem that should be addressed by your DEAL­ER as soon as practical to avoid operational difficul­ties.

“LOW OIL”

Oil in the oil tank is at reserve level (about 1/4 full).
Fill the oil tank with recommended oil as soon as
possible to avoid emptying the tank. Refer to Filling
the Oil Tank.

S.L.O.W.

S.L.O.W.

— The

— The

EMM

has identified a

EMM

has identified a

20 - Engine Monitoring

FUEL AND OIL

FUEL

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.

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.

Your outboard is certified to operate on unleaded
automotive gasoline with an octane rating equal to
or higher than that specified in Minimum Octane
chart. When using gasoline that contains MTBE or
alcohol, follow these guidelines:

Using unleaded gasoline that contains methyl ter­tiary butyl ether (MTBE) is acceptable ONLY if the
MTBE content does not exceed 15% by volume.

Using alcohol-extended fuels is acceptable ONLY if
the alcohol content does not exceed:

10% ethanol by volume
5% methanol with 5% cosolvents by volume

Minimum Octane

Inside the U.S. 87 (R+M)/2 AKI

Outside the U.S. 90 RON

Your outboard has been designed to operate using
the above 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 attracts and holds moisture that can cause
corrosion of metallic parts in the fuel system.

Alcohol blended fuel can cause engine perfor­mance problems.

IMPORTANT: Always use fresh gasoline. Gasoline
will oxidize and weather; the result is loss of octane,
volatile compounds and the production of gum and
varnish deposits which can damage the outboard.

WARNING

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.

OIL

Evinrude

for your Evinrude outboard. It is formulated with

special additives for the cleaning power a direct in­jection outboard needs for longer life. This synthetic
blend oil also provides superior lubrication to re­duce engine component wear and maintain top per­formance.

Evinrude

gine performance while controlling piston and com­bustion chamber deposits, providing superior
lubrication, and ensuring maximum spark plug life.

If

Evinrude

must use an NMMA-certified TC-W3 oil such as

Evinrude/Johnson XD25 formula

degradable Outboard oil.
When operating under 32°F (0°C),

gradable Outboard oil must be used.

IMPORTANT: Failure to follow this recommenda­tion could void the engine warranty if a lubrication­related failure occurs.

direct injection oil is recommended

brand oils are formulated to give best en-

direct injection oil is not available you

or

Evinrude

Evinrude

Bio-

Biode-

Fuel and Oil - 21

ADDITIVES

IMPORTANT: The only fuel additives approved by

Bombardier
2+4

Cleaner. Use of other fuel additives can result in
poor performance or engine damage.

Evinrude 2+4

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 your engine isn’t
being operated on a regular basis. Its use will re­duce spark plug fouling, fuel system icing and fuel
system component deterioration.

Evinrude

injectors in optimal operating condition.

for use in your

® fuel conditioner and

fuel conditioner will help prevent

Fuel System Cleaner will help keep fuel

Evinrude

Evinrude

outboard are
Fuel System

Prime the fuel system by holding the fuel primer
bulb with its outlet end up and squeezing it until
firm.

FUEL SYSTEM

Connecting the Fuel Hose

WARNING

The outboard must be correctly installed.
Failure to correctly install the outboard
could result in property damage, serious
injury or death. We strongly recommend
your DEALER install your outboard to
ensure proper installation.

If the fuel hose is disconnected for any reason, seal
it to prevent spillage. Cap the fuel fitting to prevent
contamination.

Connect the fuel hose to the 3/8 in. (9 mm) fuel fit­ting. Fasten hose securely with clamp (18,5 mm)
from owner’s kit.

IMPORTANT: Fuel distribution hoses in the boat
must deliver fuel at the rate of flow needed by the
engine. Minimum inside diameter of fuel hoses
must be 3/8 in. (9 mm).

Fuel systems with built-in tanks, particularly those
that include antisiphon valves and filter/primer
units, may have restrictions that will not allow the
engine fuel pump to deliver sufficient fuel under all
conditions. This can result in a loss of performance
and possible engine damage. If a performance
problem exists, see your DEALER.

To avoid difficulty when restarting, never run the
engine with the fuel hose disconnected or run the
engine out of fuel.

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

2. Oil supply fitting - 1/4 in. (6 mm) - Yellow stripe

3. Oil return fitting - 5/16 in. (8 mm) - Blue stripe

22 - Fuel and Oil

OIL SYSTEM

If the oil hoses are disconnected for any reason,
seal them to prevent spillage. Install caps on the oil
fittings to prevent contamination.

You must use an oil tank equipped with a filter, an
oil supply hose, and an oil return hose. The oil sys­tem must be purged if air is in the oil supply hose.
Refer to Installing the Oil Supply Hose.

Installing the Oil Supply Hose

IMPORTANT: To avoid engine damage from lack

of lubrication, make sure you purge the system.
Make sure all connections are airtight. Anytime
the oil supply hose has been disconnected, you
must prime the oil system before reconnecting the
supply hose and operating the engine.

Connect the oil supply hose to the oil inlet fitting on
the motor. Secure with the small clamp (13.8 mm)
from the owner’s kit.

Install the oil tank by following the instructions pro­vided with the unit.

IMPORTANT: Consider the installation location 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. Periodically inspect the oil
tank for evidence of water.

Filling the Oil Tank

Remove the filler cap and fill the tank with recom­mended outboard lubricant, as specified in Fuel

and Oil. Replace the filler cap and tighten securely.

IMPORTANT: Always keep a supply of oil in the

tank. If you run the tank dry, you MUST purge the
oil system of air before using the engine.

1. Oil supply hose - 1/4 in. (6 mm) - Yellow stripe

2. Oil inlet fitting - 1/4 in. (6 mm) - Yellow stripe

3. Clamp (13.8 mm) from owner’s kit

Hold the open end of the oil return hose fitting over
a container. With its outlet end up, squeeze the oil
fill bulb repeatedly until about 8 oz. (250 ml) of oil
have been pumped and the supply hose is purged
of all air.

1. Oil return hose fitting - 5/16 in. (8 mm) - Blue
stripe

Fuel and Oil - 23

Installing the Oil Return Hose

Connect the oil return hose to the oil return hose fit­ting on the motor. Secure with the clamp (15.7 mm)
from the owner’s kit.

1. Oil return hose - 5/16 in. (8 mm) - Blue stripe

2. Oil return hose fitting - 5/16 in. (8 mm) - Blue
stripe

3. Clamp (15.7 mm) from owner’s kit

WARNING

Prevent injury from moving engine compo­nents. Before starting the engine...

Shift it to NEUTRAL

Keep hands, clothes, hair clear of power­head

Remove the propeller if you use a flushing
device

Read Engine Starting, ENGINE STOPPING

Start the engine and run at idle only. Restrict the oil
return hose for about 15 - 20 seconds. Shut off the
engine.

1. Restrict Oil return hose - 5/16 in. (8 mm) - Blue
stripe

24 - Fuel and Oil

BREAK-IN (10 HOURS)

IMPORTANT: Follow this procedure to protect your

new outboard during its initial hours of operation.
Careful break-in allows internal engine components
to seat properly, resulting in maximum engine life
and performance.

Failure to carefully follow the break-in procedures
can result in engine damage.

The engine management module (
matically supply extra oil to the engine during the
first five hours of operation above 2000 RPM.

Perform the 10-hour break-in procedure with the
boat and engine in the water, using an appropriate
propeller.

DO NOT perform break-in using a flushing device.
DO NOT start-up or run the engine out of the water.
DO NOT leave a running engine unattended.

IMPORTANT: BEFORE the first start-up of your
new engine:

Read Engine Starting, Engine Stopping, and
Shifting and Speed Control.

Perform prelaunch check of all equipment.

Launch the boat and start the engine according
to the procedures in Engine Starting. AFTER
start-up:

Verify water pump operation often. Look for a
steady stream of water from the water pump indica­tor. If the stream of water stops, shut off the engine
to prevent damage. Find and correct the cause, or
see your DEALER, before you continue.

Verify shift function by shifting into gear and observ­ing that the boat moves and that the movement is in
the same direction as the shifter. Refer to Shifting
and Speed Control.

EMM

) will auto-

Change engine RPM often. Avoid holding a throttle
setting longer than 15 minutes.

1. First 10 minutes of operation — Operate the
engine in gear at fast idle ONLY.

2. Next 50 minutes — Operate engine in gear
below 3500 RPM.

DO NOT hold a constant throttle setting. Change
engine speed every 15 minutes.

With easy planing boats, use full throttle to quickly
accelerate boat onto plane. Immediately reduce
throttle to one-half as soon as boat is on plane. BE
SURE boat remains on plane at this throttle setting.

3. Second Hour — Use Full throttle to accelerate
boat onto plane, then reduce throttle setting to
three-quarters. BE SURE boat remains on plane at
this throttle setting.

At intervals, apply full throttle for periods of one to
two minutes, returning to three-quarters throttle for
a cooling period.

Change engine speed every 15 minutes.

4. Next Eight Hours — Avoid continuous full
throttle operation for extended periods.

Change engine speed every 15 minutes.
DO NOT exceed recommended maximum engine

RPM. Refer to Engine Specifications.

Fuel and Oil - 25

ENGINE STARTING

DANGER

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

The engine cover is a machinery guard. DO
NOT operate your outboard with the cover
off unless you are performing maintenance,
and then be careful to keep hands, hair, and
clothing clear of all moving parts. Contact
with moving parts could cause injury.

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. Always shut off
the engine when near people in the water.

If the fuel tank has an operable vent, open it.
Squeeze the fuel primer bulb, outlet end up, until
firm.

If equipped with an electric fuel primer pump, acti­vate it for about 20 seconds.

BEFORE START-UP

If the fuel hose and/or oil hoses are not connected,
refer to Fuel System and Oil System, to install
them now.

Review and follow Break-in (10 hours) if the en­gine is new.

You MUST supply water to the engine before at­tempting to start it. Engine damage can occur
quickly. Refer to Engine Overheating or Flushing.

Be sure the engine is in RUN position. Refer to
Power Trim and Tilt or Tilting.

26 - Engine Starting

Connect the clip to the emergency stop/key switch.
Snap the lanyard to a secure place on the opera­tor’s clothing or life vest — not where it might tear
away instead of activating the stop switch.

1. Clip

2. Emergency Stop Clip / key switch

3. Lanyard

IMPORTANT: The engine will start and run without
the clip connected to the key switch. However, we
strongly recommend that the operator use the clip
and lanyard anytime the engine is running. Refer to
Emergency Stop/Key Switch.

Move the remote control handle to NEUTRAL.

16

1. Concealed side mount control

2. Binnacle mount control

DO NOT advance the throttle before start-up. Ad­vancing the throttle overrides the electronic idle
control system. After the engine starts, the engine
management module (
es idle speed. Idle speed will decrease as the en­gine warms up. Wait until idle speed decreases
before you shift into gear.

2

EMM

) automatically increas-

WARNING

IMPORTANT: The starter motor can be damaged if

operated continuously for more than 10 seconds.
Upon start-up, release the key.
If the engine did not start, release the key momen-

tarily, then try again.
Each time the key switch is turned from OFF to ON,

the warning system will self-test. Refer to Engine
Monitoring. If the warning system fails to self-test
during start-up, see your DEALER.

If your outboard doesn’t react normally to this start­ing procedure or if it fails to start, refer to Trouble

Check Chart.

After Engine Starts

IMPORTANT: DO NOT advance the throttle when

operating the engine in NEUTRAL. Advancing the
throttle can cause the engine to over-rev, which can
result in severe engine damage.

Check the water pump indicator. A steady stream of
water indicates the water pump is working. If a
steady stream of water from the water pump indica­tor is not visible, stop the engine. Refer to Engine

Overheating.

DO NOT attempt to shift the engine into
FORWARD or REVERSE while it is running
at fast idle. Shifting under this condition can
result in sudden boat movement, resulting
in injury.

Turn the key switch fully clockwise to the START
position. Crank the engine no longer than 10 sec­onds.

Engine temperature will determine the length of the
period of fast idle after start-up — the warmer the
engine, the shorter the period of fast idle.

Engine Starting - 27

ENGINE STOPPING

Move control handle to NEUTRAL.
Turn key switch counterclockwise to the OFF posi-

tion. Remove the key when the boat will be unat­tended.

To avoid difficulty when restarting, never stop the
engine by running it with the fuel hose disconnected
or otherwise running it out of fuel.

SHIFTING AND SPEED CONTROL

IMPORTANT: Carefully check the function of all

control and engine systems before leaving the
dock. DO NOT shift the engine into FORWARD or
REVERSE while it is shut off.

If the following directions are not suitable for your
boat’s control, see your DEALER before proceed­ing.

Shifting

With engine running and control handle in NEU­TRAL:

Concealed Side Mount Control

Unlock the control handle (lift the neutral lock tab by
squeezing the hand grip). Briskly and decisively,
move the control handle fore or aft — until it engag­es the gear detent.

Binnacle Mount Control

Briskly and decisively, move the control handle fore
or aft — until it engages the gear detent.

IMPORTANT: When shifting from FORWARD to
REVERSE or from REVERSE to FORWARD,
pause at NEUTRAL until the engine is at idle speed
and the boat has slowed.

Speed Control

After gear engagement, move the control handle
slowly in the same direction to increase speed.

FUEL ECONOMY

The economy throttle range can save fuel, depend­ing on boat load and hull design. When boat reach­es top speed, throttle back from FULL SPEED to
the economy throttle range. You will save fuel with­out a noticeable loss of speed.

1. NEUTRAL Lock Tab Hand Grip

28 - Engine Starting

1. Concealed Side Mount Control

2. Binnacle Mount Control

OPERATION

DANGER

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.

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. Always shut off
the engine when near people in the water.

POWER TRIM AND TILT

WARNING

The power tilt is often used to tilt the engine for
clearance when beaching, mooring, or launching.

1. Trim Range

2. Tilt Range

Trim Gauge

The trim gauge indicates the bow position that is
achieved by the trim angle of your motor.

Any malfunction of the power trim and tilt
unit could result in loss of shock absorber
protection if an underwater obstruction is
hit. Malfunction can also result in loss of
reverse thrust capability.

The trim system features a trim range of 21°:
You can pivot the engine to any position within this

range while underway and at any boat speed.
The power trim is normally used to improve accel-

eration, speed, and ride quality and to adjust for
changing water conditions.

The tilt system will tilt your engine an additional 54°:
While positioned within the tilt range, DO NOT run

the engine faster than idle speed. If idling a tilted
engine, keep its water intakes submerged at all
times.

Operation - 29

Manual Release

WARNING

Keep everyone clear of a tilted engine when
backing out the manual release screw. The
engine could drop suddenly and forcibly. Be
sure to tighten the manual release screw
after manually repositioning the engine.
Tightening the screw also reactivates the
engine’s shock absorber protection and
reverse thrust capability.

If needed, the outboard will tilt up or down manually:
Turn the manual release screw counterclockwise,

slowly, until it lightly contacts its retaining ring —
about 3 and 1/2 turns.

Reposition the engine.
Tighten the manual release screw to hold the en-

gine in its new position.

If the tilted engine’s cover contacts the boat’s motor
well, limit the maximum tilt by following the proce­dures in Adjustments, Tilt Limiter Cam.

Trimming

To operate the power trim, push and hold the trim/
tilt switch in the desired bow direction, either bow­up or bow-down. The engine will move until the
switch is released or the engine reaches its maxi­mum position.

The boat will be properly trimmed when the trim an­gle provides a bow position that results in the best
boat performance for your operating conditions.

You must use a speedometer and tachometer to
determine boat and engine performance at different
trim positions. To help maintain steering stability
and good performance, always maintain the proper
trim angle which, varies depending on the combina­tion of boat, motor, propeller and operating condi­tions.

To familiarize yourself with power trim, make test
runs with the boat’s bow at various positions. Note
the time it takes for the boat to plane, the tachome­ter and speedometer readings, and the ride and ac­tion of the boat.

1. Manual Release Screw

Tilting

To operate the power tilt, push and hold the trim/tilt
switch in the bow-up or bow-down position. The en­gine will tilt up or down until the switch is released
or the engine reaches the end of its travel.

1. Bow Up

2. Bow Down

30 - Operation

Bow-Up

BOW-UP position will give the best fuel economy
and highest top speed.

Operating Conditions:

In the bow-up position, your boat may tend to pull to
the left. If this condition exists, correct it by applying
a clockwise force with the steering wheel to keep on
a straight path. The trim tab can also be adjusted to
compensate for steering wheel torque, but adjust
the trim tab only if bow-up is commonly used. Refer
to Trim Tab.

When the motor is trimmed to full bow-up position,
the boat’s bow will tend to rise above the water.

Excessive bow-up trim may cause propeller ventila­tion, resulting in propeller slippage.

WARNING

When operating in rough water or crossing
a wake, excessive bow-up trim may result in
the boat’s bow suddenly rising skyward;
possibly ejecting occupants.

WARNING

Some boat/motor/propeller combinations
may encounter boat instability and/or high
steering torque when operated at high
speed at or near the motor’s trim range lim­its (full bow-up or bow-down). Boat stability
and steering torque can also vary due to
changing water conditions. If any adverse
conditions occur, reduce throttle and/or
adjust trim angle to maintain control. If you
experience boat instability and/or high
steering torque, see your DEALER to cor­rect these conditions.

Bow-Down

BOW-DOWN position will give the best accelera­tion onto plane and the best towing power for skiing.
The bow-down position is normally used for accel­erating from a standing start or from idle speed.

Operating Conditions:

In the bow-down position, your boat may tend to
pull to the right. If this condition exists, correct it by
applying a counterclockwise force with the steering
wheel to keep on a straight path. The trim tab can
also be adjusted to compensate for this steering
wheel torque, but adjust the trim tab only if bow­down is commonly used. Refer to Trim Tab.

When the motor is trimmed to full bow-down posi­tion, the boat’s bow will tend to go deeper into the
water (plow).

IMPORTANT: Some boats plow, or are difficult to
plane, when operated in the trim’s lowest position.
If your boat handles unsuitably when trimmed fully
bow-down, set the angle adjusting rod or trim limiter
rod to limit the travel of the power trim. If your motor
is not equipped with this rod, purchase one from
your DEALER.

WARNING

If the bow of the boat plows the water at
high speeds, the boat may bow steer or spin
suddenly; possibly ejecting occupants.

Operation - 31

PROPELLER SELECTION

MOORING

To select the correct propeller for your boating ap­plication, your boat and motor MUST be water test­ed. See your DEALER for assistance.

Refer to Propeller, before removing or installing
propeller.

IMPORTANT: The correct propeller for your boat,
under normal load conditions, will allow the engine
to run near the midpoint of the RPM operating
range at full throttle. Refer to Engine Specifica-
tions.

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. Right-Hand (clockwise)

2. Left-Hand (counterclockwise)

You may moor your boat with the motor’s gearcase
out of the water by using its tilt feature. Depending
on the model, refer to Tilting or Power Trim and

Tilt.

IMPORTANT: DO NOT use the tilt support lever
while trailering. Refer to Trailering.

Engage the tilt support lever if you intend to leave

the motor tilted for a period of time:
Tilt the motor UP using the trailering tilt switch.
Flip the tilt support lever down.
Lower the motor until the tilt support lever rests sol-

idly on the stern brackets.

Disengage the tilt support lever:
Tilt the motor UP.
Flip the tilt support lever up.
Lower the motor to operating position.

WARNING

If you have a dual engine installation that
includes a counter-rotating engine and you
remove the propellers, always check to be
sure they are installed on the correct
engines before aggressively operating your
boat. Shift each motor individually into
FORWARD or REVERSE, at idle speed only.
If the boat moves opposite the direction
indicated by the remote control handle, the
wrong propeller has been installed on the
motor being checked. Install the correct
propeller and confirm your installation
using the above method before any attempt
is made to operate the boat.

32 - Operation

FLUSHING

DANGER

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.

Flush your engine with fresh water as soon as pos­sible after each use in salty, polluted, or brackish
water to minimize the formation of deposits that can
clog cooling passages.

Flush the engine on the trailer or at dockside while
it is: tilted or vertical, running or stopped.

Outboard — Running

WARNING

Prevent injury from contact with rotating
propeller; remove the propeller before
flushing.

3. Install flushing device (if needed) and garden

hose.

4. Start the water — keep pressure between 20 ­40 psi (140 - 300 kPa).

5. Start the engine — run it at idle only and flush
it for at least five minutes.

6. Shut off the engine, remove the flusher (if
used), and install the plug. If the plug is also the
water pump indicator, turn it so the water
streams out to the side, where it can be seen
easily from the helm.

7. Leave the outboard in vertical position long
enough to completely drain the powerhead.

1. Place the engine in vertical position in a well­ventilated area with good drainage.

2. Remove the plug from the flushing port.

Outboard Not Running

1. The outboard may be in a tilted or vertical posi-

tion.

2. Remove the plug from the flushing port.

3. Install flushing device (if needed) and garden

hose.

4. Start the water and flush the engine for at least
five minutes — keep pressure between 20 - 40
psi (140 - 300 kPa).

5. Remove the flusher (if used); install the plug. If
the plug is also the water pump indicator, turn it
so the water streams out to the side, where it
can be seen easily from the helm.

6. Lower the outboard to vertical position long
enough to completely drain the powerhead.

Operation - 33

ENGINE OVERHEATING

IMPORTANT: Do not run your engine — even for a

brief start-up without supplying water to it. Refer to
Flushing.

While boating, the engine’s water intakes must stay
completely submerged and unobstructed. Observe
proper transom height and trim angle. While the en­gine is running, the engine’s water pump indicator
must discharge a steady stream of water. Check
the indicator often, especially when operating in
weeds, mud and debris-laden water and at extreme
trim angles.

1. Water intake screens

2. Water pump indicator

If the engine overheats, its
monitor will sound the warning horn and turn on the
"WATER TEMP" or HOT light. Also, the
protection system will immediately limit the engine’s
speed to 1200 RPM. If the engine was running fast­er than 1200 RPM when the
vated, it will shake noticeably. The protection
system must be RESET before the engine will op­erate at speeds over 1200 RPM. Under certain con­ditions the

The following conditions must be met to RESET the
system:

The engine must be shut off and the cooling tem­perature restored.

EMM

will shut off the engine.

System Check

S.L.O.W.

system acti-

engine

S.L.O.W.

S.L.O.W.

IF the
stream from the water pump indicator becomes in­termittent or stops, reduce speed to idle and:

Shift to NEUTRAL.
SHUT OFF the engine.
Tilt the motor up.
Clean the intake screens of any blockage.
Clean the water pump indicator of any blockage.
Lower the motor.
Restart the engine and run at idle.
IF cleaning the screens and indicator does not re-

store the water pump indicator’s steady discharge,
SHUT OFF the engine and do not attempt to oper­ate it. See your DEALER.

IF cleaning the screens and indicator does restore
the water pump indicator’s steady discharge, you
might have to run for two minutes in NEUTRAL to
allow the engine to cool and the light to go off.

If the warning light stays on after two minutes,
STOP the engine and see your DEALER.

IMPORTANT: You must restore cooling to the en­gine to avoid serious engine damage. If you do not
restore cooling to the engine the
progressive overheating condition and shut off the
engine. The "WATER TEMP" or HOT light will flash.
The engine will not restart until the engine is al­lowed to cool.

After any overheat, have your DEALER:
Torque the cylinder head screws.
Inspect the water pump for excessive wear or dam-

age.
Inspect the thermostats.
Inspect the engine for leaks.

protection system activates and the

EMM

will identify a

34 - Operation

TRAILERING

WARNING

Keep everyone clear of stern area when
raising or lowering the outboard. Personal
injury or death can result from contact with
moving parts of the outboard.

Trailering Bracket

To engage bracket — Tilt the motor fully using

the tilt switch inside the boat or the trailering tilt
switch.

1. Trailering tilt switch

2. Tilt switch inside boat

Pull down the trailering bracket. A detent will hold
the bracket in position. Lower the motor until the
trailering bracket locks into place in the stern brack­ets.

To disengage bracket — Tilt the motor fully. Re­turn the trailering bracket to its stowed position.
Lower the motor to its vertical position.

Trailer your boat with the motor in a vertical posi­tion. If your trailer does not provide adequate road
clearance, the motor can be trailered while tilted by
using the motor’s trailering bracket.

IMPORTANT: DO NOT use the tilt support lever
when trailering.

Operation - 35

IMPACT DAMAGE

Your engine has a shock absorption system de­signed to help withstand damage from impact with
underwater objects at low to moderate speeds.
However, high speed impacts with rigid underwater
objects like pilings or boulders can be beyond the
capability of the absorption system. Such impacts
can result in serious damage to your engine and in­jury to boat occupants from the engine or its parts
entering the boat. Occupants can also be ejected or
injured by falling against portions of the boat as a
result of rapid deceleration following impacts. When
boating in unfamiliar, shallow, or debris-laden wa­ters, seek information on safe boating areas and
navigation hazards from a reliable local source. Re­duce your speed and keep a sharp lookout!

The engine’s shock absorption system does not
work while operating in reverse. If you back into an
object, either in the water or while trailering, your
boat and engine can be seriously damaged.

If you hit any object, stop immediately and examine
the engine for loosening of attaching hardware and
clamp screws, if equipped. Inspect for damage to
swivel and stern brackets, steering components,
and components in the area of impact. Also, exam­ine the boat for structural damage. Tighten any
loosened hardware. If the collision occurred in the
water, proceed slowly to harbor. Before boating
again, have your DEALER thoroughly inspect all
components.

WARNING

Failure to inspect for damage could result in
sudden, unexpected component failure,
loss of boat control, and personal injury.
Unrepaired damage could reduce your boat
and engine’s ability to resist future impacts.

STORING

To avoid difficulty when restarting, never run the
engine with the fuel hose disconnected or run the
engine out of fuel.

If you must tilt the motor to remove it from the water,
lower it and allow the cooling system to drain com­pletely as soon as you clear the launch area.

Between uses, store your motor in a vertical posi­tion.

For recommendations on extended periods of stor­age, refer to Off-Season Storage.

36 - Operation

SPECIAL OPERATING CONDITIONS

Salt Water

Flush the engine internally after use in salt, polluted
or brackish water to help prevent mineral deposits
from clogging cooling passages. Your outboard has
a built-in flushing port to facilitate flushing. Refer to
Flushing.

During use in salt or brackish water, additional an­odic protection for the boat and outboard may be re­quired.

During long periods of mooring, tilt the gearcase out
of the water — except in freezing temperatures.
Upon removal from salt water, leave it in a vertical
position until its cooling system has drained.

Weedy Water

Weeds block water intakes and cause your out­board to overheat. Weeds on the propeller create
vibration and reduce boat speed.

Run at slow speeds and in REVERSE frequently to
clear weeds from the propeller and water intakes.
Check the water pump indicator often.

If REVERSE operation does not clear away weeds,
SHUT OFF the engine. Remove weeds from pro­peller area and water intakes before operating at
higher speed.

Boat Bottom and Engine External Finish

The condition of your boat’s bottom affects perfor­mance. A covering of marine growth reduces
speed. For maximum performance, keep the boat’s
running surface clean by wiping it dry after each use
and washing it occasionally.

After operating your outboard, rinse it with fresh wa­ter and wipe it dry. Apply
Spray to any surface subject to corrosion, but avoid
the anti-corrosion anode(s).

Periodically, wash the entire boat and outboard with
soapy water and apply a coat of automotive wax.
Leave the engine cover in place when washing the
outboard.

High Altitude

Your engine’s
for changes in altitude. However, if you consistently
boat above 3000 ft. (900 m), you will experience a
slight loss of power due to reduced air density.

If your engine drops below the recommended RPM
operating range at full throttle, have your DEALER
select a lower pitch propeller.

If you return to sea level, have your DEALER install
the original propeller and verify correct RPM oper­ating range.

EMM

Evinrude

will automatically compensate

Anti-Corrosion

Shallow Water

IMPORTANT: Serious engine damage will occur if

the gearcase is allowed to drag on the waterway
bottom.

Freezing Weather

DURING operation in freezing weather, keep the
gearcase submerged at all times.

Upon removing your motor from the water, leave it
in a vertical position until its cooling system is
drained.

IMPORTANT: Water that has leaked into the gear­case, or remained in the cooling system or other
components can freeze, causing serious engine
damage.

IMPORTANT: If your outboard’s gearcase is
equipped with an integral speedometer pickup, all
water must be cleared from the hose to prevent
gearcase damage. Refer to Off-Season Storage.

Submerged Engine

If your engine has been under water, have it ser­viced immediately upon recovery. If immediate

service is unavailable, resubmerge it in fresh water
to avoid prolonged exposure to the atmosphere.

After submersion, all boat and engine electrical,
fuel and oiling systems must be inspected for signs
of water intrusion. Your DEALER should perform
this service.

Dual Engine Operation

When you are maneuvering at slow speed, be sure
both engines are running, even if one or both are in
NEUTRAL.

If it is necessary to return to harbor with one engine
not running, you should not attempt to operate the
boat above planing speed. Tilt the inoperative en­gine high enough to keep its propeller out of the wa­ter.

Under Tow

Should you require a tow from another boat:
Shift your engine to NEUTRAL.
Tilt its gearcase out of the water.
Off-load all persons into another boat.
Keep towing speed slower than planing speed.

Operation - 37

MAINTENANCE

Maintenance, replacement, or repair of the
emission control devices and systems may be
performed by any marine SI (spark ignition) en­gine repair establishments or individual.

ENGINE EMISSIONS INFORMATION

Manufacturer’s Responsibility

Beginning with 1999 model year engines, manufac­turers of marine engines must determine the ex­haust emission levels for each engine horsepower
family and certify these engines with the United
States of America Environmental Protection Agen­cy (EPA). An emissions control information label,
showing emission levels and engine specifications,
must be placed on each engine at the time of man­ufacture.

Dealer’s Responsibility

When performing service on all 1999 and more re­cent

Evinrude

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 engine 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 Responsibility

The owner/operator is required to have engine
maintenance performed to maintain emission levels
within prescribed certification standards.

The owner/operator is not to, and should not allow
anyone to, modify the engine 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.

outboards that carry an emissions

EPA Emission Regulations

All new 1999 and more recent
manufactured by Bombardier 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 engines. 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 practicable, 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 3 rd St. NW
Washington, DC 20001

EPA INTERNET WEB SITE:

www.epa.gov

Evinrude

outboards

10-HOUR INSPECTION

After 10 hours of operation, your new engine will be
broken in and its mechanical parts will have seated.
At that time all systems should be checked and any
adjustments needed should be made.

Your DEALER will perform this 10-hour Inspection
at your request and expense (based on local rates),
according to what your engine needs — refer to En-

gine Maintenance and Inspection Schedule, 10-
Hour Inspection for a partial list.

Follow consistent preventive maintenance by hav­ing your DEALER check and service your engine
once a year or after each 100 hours of operation,
whichever comes first.

38 - Maintenance

OFF-SEASON STORAGE

You must protect against natural environmental
conditions that can be damaging to an outboard
motor. Temperature and humidity changes while
your outboard motor is not in use can cause corro­sion of internal engine parts when they are not pro­tected. Fuel remaining in your fuel tank and in the
engine will oxidize and weather which can result in
loss of octane and can cause gum deposits in the
fuel system. Your warranty does not cover engine
failure caused by these conditions. We strongly rec­ommend that you have your DEALER prepare your
outboard for the off-season.

To do the off-season storage preparations yourself,
gather the supplies and perform the steps that fol­low:

2+4

fuel conditioner

Triple-Guard
Ultra-HPF
Storage Fogging Oil

Stabilize the engine’s fuel supply with
ditioner during the last hours of operation to ensure
proper stabilization, following instructions on the

container for mixture. Be sure to run the engine
long enough for the treated fuel to reach the en­gine.

grease

gearcase lubricant

spray can

2+4

fuel con-

WARNING

Prevent injury from moving engine compo­nents. Before starting the engine:

Shift it to NEUTRAL.

Keep hands, clothes, hair clear of power­head.

Remove the propeller if you use a flushing
device.

Storage Fogging Oil —

on the can, fog the engine by spraying through the

holes in the throttle plates in the throttle bodies.

Ignition, oil, and fuel systems — Check for mis­placed leads and damaged or deteriorated parts.
Be sure starter solenoid terminal boot and all con­nectors are in place.

Screws, bolts, nuts — Tighten any that are
loose.

Propeller — Remove and examine. If damaged,
see your DEALER. Clean the propeller shaft and lu­bricate it. Refer to Propeller.

Gearcase speedometer pickup, if equipped —

Disconnect the speedometer hose at the upper
connection. With air pressure no more than 25 psi
(167 kPa), blow all water from the gearcase speed­ometer pickup system. Reconnect speedometer
pickup after all the water has been removed.

Following instructions

IMPORTANT: Provide a water supply to the engine

and start it — run it at idle only.
To run the engine on a flusher, refer to Flushing.
To avoid difficulty when restarting, never run the

engine with the fuel hose disconnected or run the
engine out of fuel.

Maintenance - 39

Lubrication — Refer to Lubrication to drain and
refill the gearcase and for lubricating points on the
engine.

Touch up painted surfaces and wax the engine’s
exterior.

Store the engine on the boat (or an engine stand) in
a vertical, self-draining position.

If you cannot store the engine in the recommended
vertical position, be sure the cooling system is
drained completely. Never place the gearcase high­er than the powerhead. Any water remaining in the
exhaust passages can run into the cylinders and
cause serious damage.

If you remove an "installed" engine, examine all
hardware you loosened or removed from the en­gine and its steering, throttle, and shift systems.
Replace damaged or missing parts with

Johnson Genuine Parts

Battery — Remove it, clean it, check its condition
and water level, then charge it. Store it in a place
that’s cool and dry, out of direct sunlight. Check the
water level and charge it periodically during the
storage period.

Oil system — Leave the oil hoses connected. If
you must disconnect them to remove the engine
from the boat for storage, cap the fittings and plug
the hoses.

Oil tank — Inspect the oil tank for contamination
and/or water. Fill with recommended oil to reduce
or prevent condensation from forming in the tank
during storage.

Portable fuel tank — Disconnect the hose from
the tank. Remove the hose from the engine if the fit­ting is a quick-disconnect. If not, and the hose is se­cured to the engine, leave it connected. Secure the
hose to protect it.

, or equivalent.

Evinrude/

WARNING

Store fuel tanks in a well-ventilated area,
away from heat and open flame. Prevent
escape of liquid or vapors which could acci­dentally ignite.

Close the filler cap vent screw, if equipped.

Be sure the disconnected fuel hose doesn’t
drip.

PRE-SEASON SERVICE

Remove your outboard from storage and prepare it
for a season of reliable service by performing a gen­eral check and a few preventive maintenance pro­cedures.

Examine all loosened or removed hardware and
any steering, throttle, and shift systems. Replace
damaged or missing parts with

Genuine Parts

or equivalent.

Evinrude/Johnson

WARNING

Failure to carefully reattach the outboard
and its control systems with factory-speci­fied hardware can result in sudden, unex­pected loss of boat control.

Oil system — Check for evidence of water in the

oil tank. If present, see your DEALER. If no water is
evident, top off the oil tank. Refer to Fuel and Oil
Section, Oil System.

Disconnected oil hoses — Follow the directions
in Fuel and Oil Section, Oil System, to reinstall the
hoses and reestablish oil flow.

Undisturbed oil hoses — If the oil hoses were
left connected, no special attention to the oil system
is required.

With the propeller removed, check the gearcase for
leakage. If leakage is evident, the gearcase seals
should be replaced. See your DEALER.

Anticorrosion anodes — Check condition. Refer
to Anti-Corrosion Anodes.

Install the propeller unless you will run the engine
on a flusher for your pre-season servicing. If so, in­stall the propeller after you shut off the engine and
disconnect the flusher.

Refer to Flushing, to use the engine’s flushing sys­tem. Refer to Propeller to install the propeller.

WARNING

Prevent accidental contact with a rotating
propeller; always remove it when using a
flusher to run the engine.

40 - Maintenance

Top off fuel tank with fresh fuel.

Battery — Charge fully and install. Refer to Bat­tery.

WARNING

Do not use a booster battery and jumper
cables to start the engine. Fumes vented
can cause explosion and fire, resulting in
property damage, serious injury or death.

Refer to Engine Monitoring and review your en­gine’s warning system self-test routine. During your
preseason start-up, make sure the warning system
self-tests properly. If it doesn’t, see your DEALER.

Follow Engine Starting in the Engine Starting
Section and start the engine. Let it idle while you:

Observe running quality - if poor, refer to Trouble
Check Chart or see your DEALER.

Observe water pump operation. Water must flow
from the water pump indicator in a steady stream. If
it doesn’t, shut off the engine and investigate. Refer
to Engine Overheating.

Stop the engine and check the fuel system for
leaks.

WARNING

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

BATTERY

Each outboard needs one battery that is:

• 12-volt, heavy-duty, designated "marine"

• Vented/refillable or maintenance-free

Rated according to the minimum requirements in
Engine Specifications.

Deep-cycle batteries are suitable IF they meet or
exceed the minimum CCA requirements.

Ask your DEALER about your outboard’s require­ments before installing longer battery cables or a
battery switch.

Never install an after-market battery isolator. Your
outboard has a built-in accessory battery charging
feature. Refer to Accessory Battery Connection.

Installation

Read and understand the safety information sup­plied with your battery BEFORE you begin installa­tion.

IMPORTANT: You must use the adapter clamps
and starwashers supplied with this outboard when
installing the main battery cables to the cranking
battery. Any other type of installation can damage
the electrical system or

Make sure all components are clean and free of
corrosion.

Connect the RED (+) main cable to the positive (+)
battery post. Connect the BLACK (-) main cable to
the negative (-) battery post.

If you have marine battery posts, install each main
cable on the clamp adapter with a starwasher be­low it. Install all wires from accessories on the
threaded portion of the post.

EMM

.

1. Main Cable

2. Starwasher

3. Accessory wires

Maintenance - 41

If you have automotive battery posts, place a star­washer on the clamp adapter first, then the main ca­ble, and then the wires from the accessories.

1. Starwasher

2. Main Cable

3. Accessory wires

Tighten all connections securely and coat the in­stallation with

Triple-Guard

grease.

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 covers. Check often to
see that connections stay clean and tight.

Service

Before servicing the battery or the outboard, re­move both battery cables from the battery, BLACK
(-) cable first. Keep metal objects from contacting
either battery post.

IMPORTANT: Service electrical components only
while the outboard is NOT running. Be careful when
identifying positive and negative battery cables and
posts. If you touch the wrong post with a battery ca­ble, even briefly, the charging system will be dam­aged.

WARNING

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

Accessory Battery Connection

Your outboard is equipped with a feature to inde­pendently charge an accessory battery. The charg­ing system can charge the cranking and accessory
batteries at the same time. See your DEALER.

IMPORTANT: DO NOT use wing nuts on battery
connections even if they came with the battery.
Wing nuts can loosen and cause errant warning
signals or electrical system damage.

42 - Maintenance

IMPORTANT: The accessory battery connection
must only be used to charge a single 12-volt battery
or two 12-volt batteries wired in parallel. The acces­sory connection must not be used to charge either
battery in a 24-volt system.

ADJUSTMENTS

Trim Tab

WARNING

Improper trim tab adjustment can cause dif­ficult steering.

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.

IMPORTANT: A single trim tab adjustment will re­lieve steering effort under only one set of speed,
motor angle and load conditions. No single adjust­ment can relieve steering effort under all speed,
motor angle and load conditions. If the boat pulls to
the left or right when its load is evenly distributed,
adjust the trim tab as follows:

With the motor shut OFF, loosen the trim tab
screw. If the boat pulled to the right, move the rear
of the trim tab slightly to the right. If the boat pulled
to the left, move the rear of the trim tab slightly to
the left.

Tilt Limiter Cam

If your outboard contacts the boat’s motor well
while tilting, adjust the tilt limiter cam to limit maxi­mum tilt-up:

Place the outboard in its normal operating position.

Rotate the tilt limiter cam — pull its tab forward and
up to REDUCE the amount of tilt UP.

Check your adjustment — tilt the outboard fully and
adjust further, if necessary. Return the outboard to
vertical position for each adjustment, and repeat
your check after each adjustment.

WARNING

Adjusting the tilt limiter 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.

Tighten the trim tab screw to a torque of 35-40 ft.
lbs. (47-54 N·m).

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

High motor installations — The trim tab might
be above the water when the motor is trimmed out.
Steering effort might increase. Steering effort will
be reduced if you trim the motor in and submerge
the trim tab.

Dual standard rotation motors — Move both
trim tabs equally and in the same direction.

Dual motors (one counter and one standard ro­tation) — Set both trim tabs to the center position.

Maintenance - 43

LUBRICATION

Gearcase

Replace gearcase lubricant after first 10 hours of
operation. Check level and condition of lubricant af­ter next 50 hours of operation. Add lubricant if nec­essary.

Thereafter, check level and condition of lubricant
every 50 hours. Replace lubricant every 100 hours
of operation or once each season, whichever oc­curs first. Refill with
If not available,
lube can be used, however, long term durability
may be affected with continued use. See your
DEALER.

IMPORTANT: The recommended gear lubricants
include special additives for marine applications.
Do not use automotive gear lubricants, 2-stroke or
4-stroke engine oil, or any other oil or grease for
gearcase applications.

With motor in normal operating position:
Remove drain/fill plug and lubricant level plug from

side of gearcase and completely drain gearcase of
old lubricant.

Examine drained lubricant for metal filings, milky
appearance, or black color with burnt odor. If old lu­bricant has any of those characteristics, see your
DEALER. If drained lubricant is in good condition,
continue.

Place tube of lubricant in drain/fill hole and fill slowly
until lubricant appears at lubricant level hole. See
Engine Specifications for gearcase capacity.

Install lubricant level plug before removing tube
from drain/fill hole. Drain/fill plug can then be in­stalled without loss of lubricant.

Securely tighten both plugs.

Ultra-HPF

Hi-Vis®

gearcase lubricant.

or other marine gearcase

Steering System

The installer was instructed to grease the steering
cable ram during installation. Periodic regreasing of
the steering cable ram with
required. Refer to Engine Maintenance and In-
spection Schedule for lubrication frequency. Refer
to steering system manufacturer’s information
when servicing boat’s steering system.

Triple-Guard

grease is

WARNING

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

Power Trim and Tilt Fluid Reservoir

Tilt the motor up and engage the tilt support. De­pending on your model, refer to Tilting or Power
Trim and Tilt. Remove filler cap and check fluid
level. If necessary, add enough
Power Trim/Tilt and Power Steering Fluid to bring
the fluid level even with the bottom of the fill cap
hole when the unit is at full tilt.

Evinrude/Johnson

1. Drain/fill Plug

2. Lubricant Level Plug

44 - Maintenance

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

Lubrication Points

Refer to Engine Maintenance and Inspection
Schedule for lubrication frequency and recom-

mended lubricant.

1. Trailering bracket lubrication points

1. Tilt tube lubrication points

200 - 250 models

1. Throttle linkage lubrication points

200 - 250 models

1. Throttle linkage lubrication points

2. Starter Bendix lubrication points

100 - 175 models

1. Shift /Throttle lubrication points

200 - 250 models

1. Shift/Throttle lubrication points

Maintenance - 45

WATER PRESSURE

An optional water pressure gauge is recommended
to monitor cooling system pressures. Noticing
changes in water pressure can help prevent engine
overheating. The water pressure gauge must be
connected at the correct point to ensure the most
accurate pressure readings. Follow the installation
instructions included with the water pressure
gauge:

100 - 115 models, water pressure

Fuse Failure

A blown starter assist circuit fuse will not allow the
engine to crank. Replace it with a fuse of the same
rating.

Repeated failures of fuse indicate a serious prob­lem. Do not replace it with higher rated fuse; see
your DEALER for service.

Fuse Replacement

Remove cover; install good fuse of the same rating.

IMPORTANT: Failure to install cover securely will
cause electrical problems.

SPARK PLUGS

135 - 250 models, water pressure

START ASSIST CIRCUIT FUSE

The start assist circuit provides extra voltage to the
fuel injectors during cranking.

Be sure that all active and spare fuses are in good
condition. Always carry spare fuses.

46 - Maintenance

WARNING

The ignition system presents a serious
shock hazard. The primary circuit operates
in excess of 250 volts; the secondary circuit
operates in excess of 25,000 volts. Use cau­tion to avoid injury from shock or injury
resulting from your reaction to shock. Do
not handle primary or secondary ignition
components while the engine is cranking or
running.

IMPORTANT: The spark plugs should be serviced

by an

Evinrude

tion of the spark plug to fuel injector. Incorrect spark
plug maintenance can lead to engine damage. Re­fer to Engine Maintenance and Inspection
Schedule.

DEALER to insure correct orienta-

POWER DISTRIBUTION PANEL

Fuse Panel Chart

A power distribution panel on your outboard con­trols and protects the electrical systems. The panel
includes 7 mini-fuses and 4 power relays. The cov­er holds spare fuses and a puller. Refer to Fuse
Panel Chart for rating, color, position, and circuit
information.

Be sure that all active and spare fuses are in good
condition. Always carry spare fuses.

Fuse Failure

A minor electrical problem can blow a fuse. Re­place it with a fuse of the same rating.

Repeated failures of fuses in the same position in­dicate a serious problem. Do not replace with high­er rated fuses; see your DEALER for service.

Fuse Replacement

Remove the retaining screws and panel cover.
Identify and remove the failed fuse; install a good

fuse of the same rating.
Install the panel cover and screws; tighten securely.

IMPORTANT: Failure to install the panel cover se­curely will cause electrical problems.

Pos. Rating

& Color

1 10-Amp

Red

2 10-Amp

Red

3 10-Amp

Red

4 10-Amp

Red

5 10-Amp

Red

6 10-Amp

Red

7 10-Amp

Red

8 Relay

911Relay Power Trim/Tilt 586224

10 Relay Fuel Pump 586224

Circuit P/N

Oil Injector 514766

V4 - No. 1 & 3 Injectors
V6 - No. 1 & 4 Injectors

V4 - Spare Fuse
V6 - No. 3 & 6 Injectors

Fuel Pump 514766

Ignition Circuit 514766

V4 - No. 2 & 4 Injectors
V6 - No. 2 & 5 Injectors

Key Switch,
Accessories

EMM

Circuits

EMM

, Ignition and Stop

514766

514766

514766

,

514766

586224

Maintenance - 47

PROPELLER

WARNING

When servicing the propeller, always shift
the outboard to NEUTRAL position, turn the
key switch OFF and disconnect battery pos­itive (+) cable so the engine cannot be
started accidentally.

IMPORTANT: Apply

tire propeller shaft before installing the propeller. At
least annually, remove the propeller and check for
debris. Clean the shaft and regrease it before rein­stalling a propeller.

Triple-Guard

grease to the en-

Installation

Slide thrust washer onto shaft with shoulder facing
aft.

Slide propeller onto shaft, engaging the splines and
seating it on the thrust bushing.

Slide spacer onto the shaft and engage the propel­ler shaft splines.

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

100 FPL, FSL, and 115 FPL, FSL models

Install Propeller nut and tighten to a torque of 120
in. lbs. (14 N·m).

Continue to tighten propeller nut until nut slots and
cotter pin hole are aligned. Install new cotter pin
and bend ends to secure.

100 FPL, FSL, and 115 FPL, FSL models

1. Thrust washer

2. Spacer

3. Propeller nut

4. Cotter pin

All other models

Install propeller nut and tighten to a torque of 70-80
ft. lbs. (95-108 N·m).

Install keeper on propeller nut, align keeper slots
and cotter pin hole.

Install new cotter pin and bend ends to secure.

All other models

1. Thrust Washer

2. Spacer

3. Propeller nut

4. Cotter pin

5. Keeper

Remove block of wood. Make sure engine is in
NEUTRAL; give propeller a spin. It must turn freely.

48 - Maintenance

Repair

If your propeller hits a solid object, the impact is par­tially absorbed by the rubber bushing in the hub to
help prevent damage to the engine. A strong impact
can damage the hub and propeller blades. Damage
to blades can cause unusual and excessive vibra­tion. Damage to the hub can cause excessive en­gine RPM with little forward movement.

IMPORTANT: Avoid or limit operation using a dam­aged propeller. Carry a spare propeller.

Keep your propeller in good condition. Use a file to
smooth slight damage to blade edges. See your
DEALER for repair of serious damage.

ANTI-CORROSION ANODES

Your motor is equipped with one or more anodes
that protect it from galvanic corrosion. Refer to Fea­tures section for anode location. Disintegration of
the anode is normal and indicates it is working.
Check each anode periodically. Replace anodes
smaller than 2/3 their original size. See your DEAL­ER for replacements.

Galvanic corrosion destroys underwater metal
parts and can occur in fresh or salt water; however,
salt, brackish and polluted waters will accelerate
corrosion.

Metal-based antifouling paint on the boat or motor
and the use of improperly installed shore power in
the area of your moored boat will also accelerate
corrosion.

IMPORTANT: NEVER paint the anode, its fasten­ers, or its mounting surface. Painting will reduce its
corrosion protection.

Maintenance - 49

TROUBLE CHECK CHART

IMPORTANT: If you are unable to identify or solve the problem, contact your DEALER.

SYMPTOM POSSIBLE CAUSE

Starter motor will not operate • Shift handle not in NEUTRAL.

Engine will not start • Not following starting instructions. Refer to Engine Starting Sec-

Engine will not idle properly • Motor angle excessive.

Engine loses power • Spark plugs damaged or incorrect. Refer to Engine Specifica-

Engine vibrates excessively • Propeller shaft bent.

Engine runs, but makes little or
no progress

Warning System Activates • Refer to Engine Monitoring.

• Battery and electrical connections loose or corroded.

• Fuse blown. Refer to Power Distribution Panel.

• Battery selector switch OFF.

tion.

• Battery voltage drops below 9.5 volts during cranking.

• Fuel tank empty.

• Fuel hose kinked.

• Fuel system contaminated with water or dirt.

• Fuel filter obstructed.

• Spark plugs incorrect. Refer to Engine Specifications.

• Spark plugs improperly gapped, carboned, burned, or wet.

• Ignition system component failure.

• Fuse blown. Refer to Power Distribution Panel.

• Fuse blown. Refer to Start Assist Circuit Fuse.

• Flashing "WATER temp" or hot light, refer to Engine Monitoring
and Engine Overheating.

• Flashing "check engine "chk eng" light, refer to Engine Monitor-
ing.

• Spark plugs damaged or incorrect. Refer to Engine Specifica-
tions.

• Fuel system contaminated with water or dirt.

• Fuse blown. Refer to Power Distribution Panel.

tions.

• Fuel filter obstructed.

• Fuel system contaminated with water or dirt.

• Water intakes obstructed and cooling system not operating cor­rectly. Refer to Operation Section, Engine Overheating.

• Oiling system malfunction.

• Fuse blown. Refer to Power Distribution Panel.

•

S.L.O.W.

ing.

• Propeller fouled and restricted, blades bent, or broken.

• Fuel system contaminated with water or dirt.

• Engine mounts(s) damaged.

•

S.L.O.W.

ing.

• Propeller hub loose, slipping.

• Propeller blades bent or missing.

• Propeller shaft bent.

• Propeller fouled and restricted.

protection mode activated. Refer to Engine Monitor-

protection mode activated. Refer to Engine Monitor-

50 - Maintenance

ENGINE MAINTENANCE AND INSPECTION SCHEDULE

Routine maintenance is necessary for all mechanized products. Periodic maintenance contributes to the
product’s life span. The following maintenance chart provides guidelines for engine maintenance and in­spection scheduled to be performed by you and/or by an authorized DEALER. The schedule should be
adjusted according to operating conditions and use.

The recommended lubricants have been formulated to protect bearings, gears and engine components.
They must be used to avoid damage caused by improper lubrication.

IMPORTANT: Schedules for rental operations, commercial applications or high hour use will require
greater frequency of inspection and maintenance.

Engine Maintenance and Inspection Schedule

Frequency

Engine

Description

Mechanical steering, lubricate

Tilt tube, inspect and lubricate

Swivel bracket / tilt support bracket, inspect and

(1)

lubricate

Throttle and shift linkage, inspect and lubricate

Remote control cables, lubricate

Starter pinion shaft, inspect and lubricate 200-250

(2)

models

Lubrication and corrosion protection for metallic
components

Battery connections and condition, verify 7 O D

SystemCheck self-test and warning horn, verify
operation

Anticorrosion anodes, verify operation O D

Water intake screens, verify condition O D

Overboard water pump indicator, verify operation O D

Steering system check, verify function O D

Throttle and shift operation, verify function O D

Emergency stop circuit and lanyard, verify function O D

Flush cooling system O

Operator’s Guide, onboard O

Engine upper and lower motor covers, clean and
wax

Operator’s Guide, review O

Fuel and oil system compon ents, inspect and repair

(3)

leaks

Fastener inspection, tighten loosened components D D

Air silencer, clean and inspect D D

Thermostat, inspect and verify operation

Power tilt/trim fluid, inspect fluid level 6 D D

(1)

(1)

(1)

(3)

Product

7 Every 60 days / Every 30 in Saltwater

7 Every 60 days / Every 30 in Saltwater

7 Every 60 days / Every 30 in Saltwater

(1)

7 Every 60 days / Every 30 in Saltwater

7 Every 60 days / Every 30 in Saltwater

9 Every 60 days / Every 30 in Saltwater

4 Every 60 days / Every 30 in Saltwater

Care

Each Use

10-Hour

Inspection

Every 50 Hours

or 6 months

Every 100 Hours

or Annually

OD

O

DD

DD

Every 200 Hours

or Biannually

Maintenance - 51

Engine Maintenance and Inspection Schedule

Frequency

Engine

Description

Engine to transom mounting hardware, re-torque
(40 ft. lbs.)

Electrical and ignition wires and connections,
inspect

Gearcase lubricant replace 5 D D

Powerhead synchronization and linkage, inspect

Access EMM information, resolve any service
codes

Fuel filter and oil filter(s) inspection, eliminate
contamination

Gearcase lubricant, inspect fill level and condition
of lube

Fuel and oil filter(s) replace D

Propeller shaft splines, inspect and lubricate 7 D

Starter pinion shaft, inspect and lubricate 100-175

(2)

models

Exhaust back- pressure nipple, decarbonize

Spark plugs, replace

Driveshaft splines, inspect and lubricate 8 D

Water pump, inspect and replace D

(1) Also recommended at 10-Hour Inspection

(2) Do not use light duty penetrating lubricants

(3) Emission-related component

(3)

(3)

(3)

Care

Product

7D D

5D

9D

Each Use

10-Hour

Inspection

Every 50 Hours

or 6 months

Every 100 Hours

or Annually

DD

DD

DD

D

D

D

Every 200 Hours

or Biannually

Dealer Performed Service

D

Operator Performed Service

O

4

Evinrude

anti-corrosion spray or

5

Ultra-HPF

6 Power Trim/Tilt Fluid

7

Triple-Guard

8

Evinrude Moly Lube

9 Starter Bendix Lube Only P/N 337016

gearcase lubricant

grease

P/N 175356

52 - Maintenance

Evinrude

“6 in 1” multi-purpose lubricant

CHANGE OF ADDRESS / CHANGE OF OWNERSHIP

3

If your address has changed or if there has been a change of ownership, be sure to fill out and mail the
card provided on this page.

Such notification is likewise necessary for your own safety even after expiration of the original warranty,
since Bombardier will be in a position to contact you if correction to your outboard becomes necessary.

Outside the U.S. and Canada, this card should be sent to the Bombardier division where the outboard was
registered. Please contact your Dealer or Distributor.

Change of address Change of ownership

Model number

Serial Number

Old address / Previous owner

Last name

First name M.I.

Address

City State

Zip code Country

Phone number

Signature Date

New address / New owner

Last name

First name M.I.

Address

City State

Zip code Country

Phone number

Signature Date

00006

Maintenance - 53

54 - Maintenance

Maintenance - 55

Your DEALER

Name:

Address:

Operator’s Guide

Confirmation of Receipt

Upon delivery of your new
will take receipt of the form for their records.

Receipt

Name:

Address:

Owner of model No:

The DEALER named on this document has instructed me on the operation, maintenance, safety features and
warranty policy, all of which I understand and agree to be bound with. I am also satisfied with the predelivery set-up
and inspection of my

Evinrude

Evinrude

Outboard. I have also received a copy of the Operator’s Guide.

® Outboard, complete and sign the form hereunder. Your DEALER

Serial No:

(To be completed by customer or selling DEALER)

Signature:

Date:

56 - Maintenance

Readiness Test and a Final Word to the Owner/Operator

The Operator’s Readiness Test....

1. Did you read this Guide from front cover to rear cover?

2. Are you ready to take responsibility for the safe operation of your boat and motor?

3. Do you understand all the safety precautions and instructions contained in this Guide?

4. Do you understand that this Guide contains essential information to help prevent personal injury and

damage to equipment?

5. Are you ready to follow the recommendations in this Guide and take a boating safety course before
you operate your boat and motor?

6. Do you know who to ask if you have any questions about your boat and motor?

7. Do you know your local marine traffic laws?

8. Do you understand that human error can be caused by carelessness, fatigue, overload, preoccupa-

tion, unfamiliarity of operator with the product, drugs and alcohol, just to name a few?

WARNING

It is impossible for this Guide to cover every hazardous situation you may encounter; how­ever, your understanding of and adherence to essential information contained in this Guide
will build good judgment when boating. Always be alert and careful: a good foundation for
safety.

*215564*