Evinrude 90 E-TEC, 75 E-TEC, 2004 90 E-TEC, 2004 75 E-TEC User Manual

™

2004

75/90 HORSEPOWER

PL, PX, SL

!

Read this Operator Guide thoroughly. It contains important

safety information. When operating your boat, always

WARNING

have this Operator Guide onboard.

!

FEATURES AT A GLANCE

Easy to Own and Operate

• Three-Year Limited Warranty

• No Scheduled Dealer Maintenance for
Three Years of Normal Recreational Use

• No Break-In Period

Sure Start System

•

• Digital Engine Management

• Self Flushing Cooling System

• Long Term Storage Design

• Simplified Winterization Procedure

• No Electrical Current Draw in Key Off Mode

• Digital Diagnostics

• Ultra Low Oil Usage

Durable and Reliable

• Full Corrosion Protection

Evinrude E-TEC

•

• Auto-Calibrated Linkage

• Heavy-Duty Use Design

• Posi-Lock Latches

• Digital Diagnostics

• Extra Capacity Water Pump

• High Thrust, Large Gearcase

• Dual Platinum Spark Plugs

• Vibration Isolated Electronics

• Beltless 25 Amp Charging System

• Stainless Steel Thermostats

• Nickel/Chrome-Faced Piston Rings

• Micro Finished Connecting Rods/Crankshaft

(not battery dependent)

Lubrication System

Cleaner and Quieter

• EPA 2006 and Beyond Compliance

• European Union 2006 and Beyond
Emissions Compliance

• California 3-Star Emissions Compliance

• Sealed Fuel System

• Low Friction Design (No powerhead
gears, belts, cams, oil scraping rings,
or mechanical oil pump)

• Full Length Insulated Lower Pans

• Quiet Signature Sound

• Air Intake/Silencer

• Idle Air Bypass

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

Evinrude® 2+4® fuel conditioner

Evinrude® E-TEC

Evinrude®/Johnson® Genuine Parts System Check®

Evinrude®/Johnson® XD100

Evinrude®/Johnson® XD25

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

™

™

™

S.A.F.E.

™

Sure Start® System

Triple-Guard® grease

Dear Boating Enthusiast,

®

Congratulations on your purchase of our industry-leading

Evinrude

E-TEC

™ out­board! Your purchase comes with the full commitment and backing of the Bombar­dier Outboard Engine team. We know your

Evinrude E-TEC

outboard will provide
you with years of reliable use, and we hope you will enjoy using it as much as we
enjoyed designing and building this innovative product.



You can be proud you purchased an

Evinrude E-TEC

outboard with the following

benefits.

• Easy to Own and Operate – This means fewer time-consuming and expensive

maintenance requirements. Your

Evinrude E-TEC

outboard has a debris-resistant,
flow-through cooling system, and requires no break-in, oil changes, oil filter chang­es, or expensive winterizing. Best of all, there is no scheduled dealer maintenance
for three years of normal recreational use—only common sense pre-launch checks
and periodic checks for corrosion when used in salt-water applications.

• Cleaner and Quieter – Your

Evinrude
E-TEC

sound that rivals any competitive outboard. Additionally, this

outboard complies with the strictest EPA, European Union, and California

Evinrude E-TEC

outboard has the quieter signature

Evinrude

emissions regulations for outboard engines, and its sealed fuel system minimizes
evaporative emissions.

• Durability, Quality, and Reliability – Your

Evinrude E-TEC

outboard utilizes prov­en, extremely durable engine components, such as pistons made from material de­veloped by NASA, which are two-and-a-half times stronger than competitive
pistons. There are no belts, pulleys, powerhead gears, cams, oil scraping rings, or
mechanized oil pumps to cause problems. The

Evinrude E-TEC Sure Start

®

Sys­tem delivers easy, quick starts every time, and its full magneto electronics are not
dependant on a battery. All of this guarantees you getting out there on the water
and, most importantly, getting back.

• Exceptional Styling – We put a lot of thought into the styling as well as the tech­nology. We know form and function go hand in hand, so we made the hood ergo­nomically correct—should you ever need to lift it off. The packaging style you will
find under the hood is something that has never been seen in the outboard engine
industry. And with molded-in color, your

Evinrude E-TEC

outboard is more resistant
to fading, chipping, peeling, or cracking than any other outboard on the market, giv­ing you years of a great-looking outboard.

We, as a company, are proud you have purchased this technology-leading

outboard engine. We thank you for your business and wish you many years

E-TEC

Evinrude

of enjoyable use.

Happy Boating,

Roch Lambert
Vice-President and General Manager

1

Table of Contents

TABLE OF CONTENTS

About This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Important Safety Messages . . . . . . . . . . . . . . . . . . 5

USING YOUR

Component Identification . . . . . . . . . . . . . . . . . . 10

Starting, Stopping, Shifting . . . . . . . . . . . . . . . . . 12

Oil and Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Instruments and Controls . . . . . . . . . . . . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Routine Inspection Checklist . . . . . . . . . . . . . . . 30

E

VINRUDE

E-T

EC

OUTBOARD

2

MAINTENANCE

Engine Emissions Information . . . . . . . . . . . . . . 32

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . 33

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 37

PRODUCT INFORMATION

Rigging and Accessories . . . . . . . . . . . . . . . . . . 40

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43



Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Product Warranty Information . . . . . . . . . . . . . . 46

California Emission Control Warranty . . . . . . . . 48

Readiness Test . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3

ABOUT THIS GUIDE

This Operator’s Guide is an essential part of
your

Evinrude E-TEC

pertinent information which, if followed, will
provide you with a thorough understanding
needed for proper operation, maintenance,
care, and—above all—safety. Safety is our
first priority and it should be yours too. It is
strongly recommended you read this Guide
from cover to cover. The more you know and
understand about your
board, the greater the safety and pleasure
you will get from using it. Following this rec­ommendation will assure the completeness of
the information essential to your safety, the
safety of any passengers, and other water us­ers.

This Operator’s Guide identifies important
safety messages.

Although the mere reading of such informa­tion does not eliminate the hazard, the under­standing and application of the information
will promote the correct use of your outboard
engine.

outboard. It contains

Evinrude E-TEC

out-

Warning Symbols in this Guide

How can you reduce the risk of death, per­sonal injury, and possible property dam­age? This Operator’s Guide answers such
questions and are contained in boxes high­lighted by the Safety Alert Symbol. It is im­perative to read, understand, and follow
these comments.

This Guide should be kept in a waterproof bag
with the outboard at all times during opera­tion. If the product ownership is transferred,
this Guide should be forwarded to the new
owners.

A responsible, educated boater will fully ap­preciate the pleasures of boating and will be a
safe boater. Boating Safety Classes are con­ducted by the U.S. Coast Guard Auxiliary, the
U.S. Power Squadron and some Red Cross
Chapters. For information about classes, call
toll free 1-800-336-BOAT.

For additional information about boating safe­ty and regulations, call:

• U.S. Coast Guard Boating Safety Hotline
1-800-368-5647.

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

This Operator’s Guide uses the following sig­nal words identifying important safety mes­sages.

DANGER

Indicates 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.

These safety notices mean:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Additionally, Bombardier has identified key in-

formation that is essential to the operation of
your

Evinrude E-TEC

Key information appears throughout this
Guide in gray boxes with a key above the
text. This highlighted information is a vital ref­erence when using your outboard.

outboard.

4



IMPORTANT SAFETY MESSAGES

IMPORTANT SAFETY MESSAGES

This Operator’s Guide contains essential in­formation to help prevent personal injury and
damage to equipment. Safety messages ap­pear throughout this Guide in the applicable
section.

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, follow all safety warnings and rec­ommendations. Do not disregard any
of the safety precautions and instruc­tions.

Anyone operating your boat should
first read and understand this Guide
before they operate your boat and out­board.

SAFETY MEASURES — General

To fully appreciate the pleasures, enjoy­ment and excitement of boating there
are some basic rules that should be ob­served and followed by any boater.
Some rules may be new to you and oth­ers may be common sense or obvious...
irrespective, take them seriously!

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

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

Know the marine traffic laws and obey
them.

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

Remember, gasoline fumes are flamma­ble and explosive. Always adhere to the
fueling procedure contained in this Op­erator’s Guide and those given to you by
the fueling station. Always verify fuel
level before use and during the ride. Ap­ply the principle of 1/3 fuel to destina­tion, 1/3 back and 1/3 reserve fuel
supply. Do not carry spare fuel or flam­mable liquids in any storage or engine
compartments.

Whenever running the engine, assure
there is proper ventilation to avoid the
accumulation of carbon monoxide (CO),
which is odorless, colorless, and taste­less, and can lead to unconsciousness,
brain damage, or death if inhaled in suf­ficient concentrations. CO accumulation
can occur while docked, anchored, or
underway, and in many confined areas
such as the boat cabin, cockpit, swim
platform, and heads. It can be worsened
or caused by weather, mooring and op­erating conditions, and other boats.
Avoid exhaust fumes from your engine
or other boats, provide proper ventila­tion, shut off your engine when not
needed, and be aware of the risk of
backdrafting and conditions that create
CO accumulation. In high concentra­tions, CO can be fatal within minutes.
Lower concentrations are just as lethal
over long periods of time.

Avoid standing up or shifting weight sud­denly in light weight boats.

Keep your passengers seated in seats.
The boat’s bow, gunwale, transom and
seat backs are not intended for use as
seats.

5

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

Proceed with caution and at very low
speed in shallow water. Grounding or
abrupt stops may result in personal inju­ry or property damage. Also be alert for
debris and objects in the water.

Be familiar with the waters you are oper­ating in. The gearcase of this outboard
extends below the water surface and
could potentially come in contact with
underwater obstructions. Contact with
underwater obstructions may result in
loss of control and personal injury.

Respect no wake zones, rights of other
water users and the environment. As the
"skipper" and owner of a boat you are
responsible for damage to other boats
caused by the wake of your boat. Allow
no one to throw refuse overboard.

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

High performance boats have a high
power-to-weight ratio. If you are not ex­perienced in the operation of a high per­formance boat, do not attempt to
operate one at, or near, its top speed un­til you have gained that experience.

Become completely familiar with the
control and operation of your boat and
outboard before embarking on your first
trip or taking on a passenger(s). If you
have not had the opportunity to do so
with your Dealer, practice driving in a
suitable area and feel the response of
each control. Be familiar with all controls
before applying the throttle above idle
speed. As the operator, you are in con­trol and responsible for safe operation.

SAFETY MEASURES — Installation and Maintenance

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

Do not overpower your boat by using an
engine that exceeds the horsepower in­dicated on the boat’s capacity plate.
Overpowering could result in loss of
control. If your boat has no capacity
plate, contact your DEALER or the
boat’s manufacturer.

When replacement parts are required,
use

Evinrude®/Johnson® Genuine

Parts

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

Only perform service procedures which
are detailed in this Operator’s Guide. At­tempting to perform maintenance or re­pair on your outboard if you are not
familiar with the correct service and
safety procedure could cause personal
injury or death. Further information can
be obtained from your authorized

Evinrude/Johnson

stances proper tools and training are re­quired for certain service or repair
procedures.

Maintain your boat and engine in top
condition at all times. Adhere to the
Maintenance Schedule on page 33.

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 in-

6

PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS

Bombardier reserves the right to make changes at any time, without notice, to features, spec­ifications and model availability, and to change any specification or part at any time without
incurring any obligation to update older models. The information in the Guide is based on the
latest specifications available at the time of publication.

Photographs and illustrations used in this Guide might not depict actual models or equipment
but are intended as representative views for reference only.

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

Owner’s Identification

United States and Canada — At the time of purchase, your Dealer will complete your out-

board registration forms. Your portion provides proof of ownership and date of purchase.

Outside United States and Canada — See your Dealer or distributor for details.

Model and Serial Numbers

The model and serial numbers appear on a plate attached to the stern bracket or swivel brack­et. Record your outboard’s:

Model Number _______________________
Serial Number ________________________
Purchase Date _______________________
Ignition Key Number ___________________

Stolen Outboards

United States and Canada — Report your outboard as stolen to Customer and Dealer Sup-

port 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 United States and Canada — Report the theft to the Bombardier distributor where
the outboard was registered.



Technical Literature

Bombardier offers technical literature specifically for your outboard. A service manual, a parts
catalog, or an extra Operator’s Guide can be purchased from your selling Dealer. For the
name and location of the nearest
www.evinrude.com.

Evinrude

Dealer in the United States and Canada visit

Declaration of Conformity

Bombardier Motor Corporation of America

Manual applies conforms to the essential requirements outlined in CE Machinery Directive
98-37-EC, as amended.

declares that the outboard to which this Operator’s

7

USING YOUR

EVINRUDE E-TEC

OUTBOARD

USING YOUR E-TEC

OUTBOARD



9

Using Your E-TEC Outboard

COMPONENT IDENTIFICATION

1

5

2

7

6

3

8

9

4

Item Description Item Description

1 Air Inlet, Tilt Handle 6 Fuel Fitting

2 Water Pump Indicator, Flushing Port 7 Tilt Limiter Cam

3 Engine Cover Latch 8 Tilt Support

4 Anti-Corrosion Anodes 9 Water Intake Screens

5 Battery Cables

10



COMPONENT IDENTIFICATION

Starboard

11

Port

15

12

14

13

10

17

18

19

16

Item Description Item Description

10 Fuel Filter 16 Trailering Tilt Switch

11 Spark Plugs 17 Flywheel Guard

12 Engine Cover Latch 18 Oil Fill Cap

13 Fuse 19 Oil Tank

EMM

14 Spare Fuse 20

15 Air Silencer

(Engine Management Module)

20

11

Using Your E-TEC Outboard

STARTING, STOPPING, SHIFTING

SAFETY INFORMATION ENGINE STARTING

Refer to the Routine Inspection Checklist

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.

on page 30 for pre-launch checks before us­ing your

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

Be sure the water intake screens are below
the water surface.

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.

Evinrude E-TEC

outboard.

WARNING

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

Always shut off the outboard when your
boat is near people who are 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.

12

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.
The operator should always use the clip and
lanyard anytime the engine is running. Refer
to Emergency Stop/Key Switch on page 22.

WARNING

Always use the safety lanyard when
operating your boat to help prevent a
runaway boat and reduce the risk of
personal injury or death.



STARTING, STOPPING, SHIFTING

Move the remote control handle to NEU­TRAL.

12

1. Concealed side mount control

2. Binnacle mount control

WARNING

If you are using a remote control that
does not have start-in-gear prevention,
the outboard can be started while it is
in gear. Protect against unexpected
boat movement by always starting your
outboard in NEUTRAL.

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 (
tomatically increases idle speed slightly. Idle
speed will decrease as the engine warms up.
The

System Check

nate if the throttle is advanced.

Turn the key switch fully clockwise to the
START position. Crank the engine no longer
than 20 seconds.

gauge lights will illumi-

EMM

) au-

IMPORTANT: The starter motor can be dam­aged if operated continuously for more than
20 seconds.

Upon start-up, release the key.
If the engine did not start, release the key mo-

mentarily, then try again.
Each time the key switch is turned from OFF

to ON, the warning system will self-test. Refer
to Engine Monitoring on page 18. If the
warning system fails to self-test during start­up, see your Dealer.

If your outboard does not react normally to
this starting procedure or if it fails to start, re­fer to Troubleshooting on page 37.

After Engine Starts

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 on
page 20.

ENGINE STOPPING

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

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

13

Using Your E-TEC Outboard

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.

1

IMPORTANT: When shifting from FOR-

WARD 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 with a minimal loss of
speed.

1. NEUTRAL Lock Tab Hand Grip

Binnacle Mount Control

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

14

1. Concealed Side Mount Control

2. Binnacle Mount Control

OIL AND FUEL



OIL AND FUEL

OILING SYSTEM

If the “LOW OIL” warning light illuminates,
you have approximately five hours of normal
operation before running out of oil when us­ing TC-W3 oil. If using
XD100™ oil, you have approximately ten
hours of normal operation remaining. Refill
the onboard oil tank at next convenient op­portunity.

IMPORTANT: Always “top off” your oil tank
prior to prolonged usage or long trips.

Evinrude/Johnson

FILLING THE OIL TANK

Release the port and starboard engine cover
latches by turning each handle downward.

Remove the engine cover to access the oil
tank.

Remove the filler cap and fill the tank with the
recommended outboard lubricant, as speci­fied in Oil Requirements on page 16.

Pull up on the tilt handle to release the engine
cover seal on the engine cover.

1

1. Tilt handle

Replace the filler cap and tighten securely.
Reinstall the engine cover.

IMPORTANT: The oil tank capacity is 2.5
quarts (2.4 liters).

15

Using Your E-TEC Outboard

OIL REQUIREMENTS FUEL REQUIREMENTS

Evinrude/Johnson

Injection, or
board oils are recommended for use in your

Evinrude E-TEC
Evinrude/Johnson

to give best engine performance while con­trolling piston and combustion chamber de­posits, providing superior lubrication, and
ensuring maximum spark plug life.

Evinrude/Johnson

for your

mulated with special additives for cleaner
burning and lower consumption. This syn­thetic blend oil also provides superior lubrica­tion and maintains top performance.

For added protection and cost reduction, an
authorized dealer can program your

E-TEC

sumption in half using
XD100 as compared to using a conventional
oil. Only an authorized

can program your outboard for this bene­fit.

If
Injection, or
not available, you must use an oil that meets
NMMA TC-W3 certification standards.

IMPORTANT: If your
grammed for
DO NOT use any other oil unless in an emer-

gency. If
rarily unavailable, a one-time-only use of an
oil that meets NMMA TC-W3 certification
standards is allowed. If you discontinue using

Evinrude E-TEC

outboard

Evinrude/Johnson

Evinrude/Johnson

Evinrude/Johnson

turn to your Dealer to have the
grammed back to the original factory setting.

IMPORTANT: Failure to follow oil specifica­tions could void the engine warranty if a lubri­cation-related failure occurs.

XD100,

Evinrude

Evinrude/Johnson

outboard.

brand oils are formulated

XD100 oil is preferred

outboard. It is for-

EMM

to cut normal oil con-

Evinrude/Johnson

Evinrude

Evinrude/Johnson

XD100,

Evinrude

XD25 oils are

EMM

has been pro-

Evinrude/Johnson

XD100 is tempo-

XD100, you MUST first re-

Direct

XD25™ out-

Evinrude

dealer

Direct

XD100,

EMM

repro-

WARNING

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

Leaking fuel is a fire and explosion haz­ard. All parts in the fuel system should
be inspected frequently and replaced if
signs of deterioration or leakage are
found. Inspect the fuel system each
time you refuel, each time you remove
the engine cover and annually.

Follow these instructions to ensure
safety when handing fuel:

• Always turn off the engine before fuel­ing.

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

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

• Remove portable fuel tanks from the
boat before fueling.

• Always wipe off any fuel spillage.

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

• Always work in a well ventilated area.

IMPORTANT: Always use fresh gasoline.

Gasoline will oxidize; the result is loss of oc­tane, volatile compounds, and the production
of gum and varnish deposits which can de­grade the fuel system.

16

Minimum Octane

Your outboard is certified to operate on un­leaded automotive gasoline with an octane
rating equal to or higher than:

• 87 (R+M)/2 AKI — Inside the U.S.

• 90 RON — Outside the U.S.
Using unleaded gasoline that contains methyl
tertiary butyl ether (MTBE) is acceptable
ONLY if the MTBE content does not exceed
15% by volume.

Alcohol Fuels

Your outboard has been designed to operate
using the specified fuels; however, be aware
of the following:

• The boat’s fuel system may have different
requirements regarding the use of alcohol
fuels. Refer to the boat’s owner guide.

• Alcohol attracts and holds moisture that can
cause corrosion of metallic parts in the fuel
system.

• Alcohol blended fuel may cause engine per­formance problems.

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

• 10% ethanol by volume; or

• 5% methanol with 5% cosolvents by vol­ume.

FUEL SYSTEM OPERATION

Connecting the Fuel Hose

1) If the fuel hose is disconnected for any rea-

son, seal it to prevent spillage. Cap the fuel
fitting to prevent contamination.

2) 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.



OIL AND FUEL

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
does not drip.

IMPORTANT: Fuel distribution hoses in the

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

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.

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

FUEL ADDITIVES

Bombardier approves only
fuel conditioner fuel additive for use in your

Evinrude E-TEC

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

Evinrude 2+4

vent gum and varnish deposits from forming
in fuel system components and will remove
moisture from the fuel system.

It should be used during any period when your
engine is not being operated on a regular ba­sis. Its use will reduce fuel system icing and
fuel deterioration.

outboard.

fuel conditioner will help pre-

Evinrude 2+4®

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

17

Using Your E-TEC Outboard

INSTRUMENTS AND CONTROLS

ENGINE MONITORING

IMPORTANT: Your outboard must be

equipped with the
monitor. Operating your outboard without the

System Check

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 self­test by sounding a 1/2-second beep. The
gauge self-tests by turning the warning lights
on, then off in sequence. During engine start­up, 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

operator 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 (
senses 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
(Speed Adjusting Failsafe Electronics). If the
engine was running faster than 1200 RPM
when the
shake noticeably. Under certain operating
conditions the

S.A.F.E

System Check

engine monitor will void your

engine monitor alerts the

. mode activated, it will

EMM

will shut OFF the engine.

®

engine

System

EMM

S.A.F.E.

™

CAUTION

In the

S.A.F.E.

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

S.A.F.E.

If the
you 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.

)

1

1.

System Check

2.

System Check

mode, the engine speed

mode is activated and

2

gauge

gauge with tachometer

18



INSTRUMENTS AND CONTROLS

The following warnings may appear on the outboard’s indicator lights:

“LOW OIL”

Symptom Oil in the oil tank is at reserve level (about 1/4 full)

Result

Action

EMM

will activate light

• Fill the oil tank with recommended oil as soon as possible to avoid emptying
the tank. The outboard has approximately five hours (ten hours if using

Evinrude/Johnson

tion occurs. Refer to Filling the Oil Tank on page 15.

XD100 oil) of normal running time before “NO OIL” condi-

“NO OIL”

Symptom There is an oil delivery problem

Result

Action

Your outboard is designed to run in “get home” mode for up to five hours in the event you run
out of oil. Refill the onboard oil tank as soon as possible.

EMM

will activate

• 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.

S.A.F.E.*

mode

“WATER TEMP” or “HOT”

Symptom The engine is overheating

EMM

Result

Action

will activate

•A continuous light with
heating condition. Check the water pump indicator for a steady stream of wa­ter. Shut OFF the engine. Clear the water intake screens of any debris. If the
overheat condition still exists, the engine will operate in “get home” mode. Re­turn to harbor immediately.

•A flashing light — The
tion. The engine will not operate. Allow the engine to cool for 20 minutes and
return to harbor immediately. See your Dealer.

S.A.F.E.

mode

S.A.F.E.

EMM

mode — The

has identified a damaging overheating condi-

EMM

has identified an over-

“CHECK ENGINE” or “CHK ENG”

Symptom An abnormal operating condition

EMM

Result

Action

will activate light

•A flashing light — The
related to the fuel system. The engine will shut OFF and cannot be restarted.

•A continuous light with
with the outboard. Seek assistance and/or return to harbor. See your Dealer.

•A continuous light without
lem that should be addressed by your Dealer as soon as practical to avoid
operational difficulties.

EMM

has identified an abnormal operating condition

S.A.F.E.

mode — The

S.A.F.E.

EMM

mode — The

has identified a problem

EMM

has identified a prob-

WARNING

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

*Speed Adjusting Failsafe Electronics

19

Using Your E-TEC Outboard

ENGINE OVERHEATING

IMPORTANT: Do not run your outboard—

even for a brief start-up—without supplying
water to it. Refer to Flushing on page 34.

While boating, the outboard’s water intakes
must stay completely submerged and unob­structed. Observe proper transom height and
trim angle. While the outboard is running, the
outboard’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.

To RESET the system:

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

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

1) Shift to NEUTRAL.

2) SHUT OFF the engine.

3) Tilt the outboard up.

4) Clean the intake screens of any blockage.

5) Clean the water pump indicator of any

6) Lower the outboard.

7) Restart the engine and run at idle.

S.A.F.E.

blockage.

mode activates and the

1. Water intake screens

2. Water pump indicator

If the engine overheats, its
gine monitor will sound the warning horn and
turn on the “WATER TEMP” or “HOT” light. Al­so, the
Electronics) mode will immediately limit the
engine’s speed to 1200 RPM. If the engine
was running faster than 1200 RPM when the

S.A.F.E.

ably. The protection system must be RESET
before the engine will operate at speeds over
1200 RPM. Under certain conditions the
will shut off the engine.

S.A.F.E.

mode activated, it will shake notice-

(Speed Adjusting Failsafe

System Check

en-

EMM

IF cleaning the screens and indicator

not

restore the water pump indicator’s steady
discharge, the engine will operate only in “get
home” mode. Return to harbor immediately.
See your Dealer.

IF cleaning the screens and indicator
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.

IMPORTANT: If cooling is not restored, the

EMM

will identify a 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 causing engine shutdown,
see your Dealer for:

• Inspection of the water pump for excessive

wear or damage.

• Inspection of the thermostats.

IMPORTANT: Although the
can help prevent engine damage, it does not
guarantee you can run your engine indefinite­ly without engine damage.

S.A.F.E.

does

does

mode

20

REMOTE CONTROLS

WARNING



INSTRUMENTS AND CONTROLS

If you choose a non-

Evinrude

remote
control, it must have 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
components.

Evinrude

controls deliver the ca-

Evinrude

ble 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

Evinrude

modular

wiring system

Evinrude

1. Handle - shift and throttle

2. Trim/tilt switch (where equipped)

3. Neutral lock tab

4. Fast idle button (warm-up)

5. Throttle Friction Control

concealed side mount control

Evinrude

1. Handle - shift and throttle

2. Trim/tilt switch (where equipped)

3. Fast idle button (warm-up)

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 (warm-up)

5. Emergency stop clip and lanyard

binnacle mount control

side mount control

21

Using Your E-TEC Outboard

Emergency Stop/Key Switch

A combination emergency stop switch and
key switch is a feature of
remote controls and all
ing kits. Use of 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.

Evinrude

Evinrude

prewired

control wir-

WARNING

Always use the safety lanyard when
operating your boat to help prevent a
runaway boat and reduce the risk of
personal injury or death.

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.

1. Clip

2. Emergency stop / key switch

3. Lanyard

22

OPERATION



OPERATION

POWER TRIM AND TILT

WARNING

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.

Correct fluid level must be maintained
to ensure operation of the impact pro­tection on this unit.

Full Tilt

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

Tilting

If the tilted outboard’s cover contacts the
boat’s motor well, limit the maximum tilt by fol­lowing the procedures in Tilt Limiter Cam on
page 44.

Manually Tilting

If needed, the outboard will tilt up or down
manually, using the manual release screw.

WARNING

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

1) Turn the manual release screw counter­clockwise, slowly (about 3 1/2 turns), until
it lightly contacts its retaining ring.

2) Reposition the outboard.

3) Tighten the manual release screw to hold
the outboard in its new position.

1. Trim range

2. Tilt range

Trim

In most operating conditions, it is recom­mended to trim the outboard to the full down
position when accelerating. Once on plane,
trim the outboard up until the exhaust is
heard, then back down slightly.

Shallow Water Drive

You can tilt the outboard to any position with­in the tilt range but DO NOT run the engine
faster than idle speed. If idling a tilted out­board, keep its water intakes submerged at
all times.

1. Manual release screw

23

Using Your E-TEC Outboard

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
or otherwise seriously injuring occu­pants.

Some boat/motor/propeller combina­tions may encounter boat instability
and/or high steering torque when oper­ated at high speed at or near the out­board’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.

IMPORTANT: DO NOT use the tilt support le-

ver while trailering. Refer to Trailering on
page 25.

Engaging Tilt Support Lever

If you intend to leave the motor tilted for a pe­riod of time, engage the tilt support lever:

1) Tilt the motor UP using the trailering tilt
switch.

2) Flip the tilt support lever down.

3) Lower the motor until the tilt support lever
rests solidly on the stern brackets.

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 outboard 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 or
otherwise seriously injuring occupants.

24

Disengaging Tilt Support Lever

When you are finished tilting the motor, disen­gage the tilt support lever:

1) Tilt the motor UP.

2) Flip the tilt support lever up.

3) Lower the motor to operating position.

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 (on port side of engine).



OPERATION

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

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.

The motor is designed to be trailered in a ver­tical position or tilted, using the trailering
bracket. Use the position best suited for your
boat.

IMPORTANT: The motor MUST be in neutral
when trailering.

25

Using Your E-TEC Outboard

IMPACT DAMAGE

Your outboard has a shock absorption system
designed to help withstand damage from im­pact with underwater objects at low to moder­ate speeds. 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 outboard and injury to boat
occupants from the outboard 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!

If you hit any object:

• STOP immediately and examine the out-

board for loosening of attaching hardware.

• INSPECT for damage to swivel and stern

brackets, and steering components.

• 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 after an
accident or striking an object could
result in sudden, unexpected compo­nent failure, loss of boat control, and
personal injury. Unrepaired damage
could reduce your boat and outboard’s
ability to resist future impacts.

EMERGENCY STARTING

If the starter fails, your engine can be started
using a 1/4 in (6 mm) cord about 4 ft. (1.2 m)
long.

WARNING

The outboard’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 outboard can
be seriously damaged.

26

Move the shift lever to NEUTRAL
before performing emergency starting
procedures. Failure to do so may result
in unexpected boat movement.

The engine cover is a machinery guard.
To prevent injury from moving engine
components, keep hands, clothes, and
hair clear of powerhead.

Prevent electric shock by keeping clear
of the ignition coils and spark plug
leads when the motor is being started
or is running. Shock can cause serious
personal injury under certain condi­tions.

DO NOT turn flywheel by hand. Use
starter cord only.

Be sure:

• Key switch is OFF.

• Engine is in normal operating position.

• Shift lever is in NEUTRAL.



OPERATION

1) Release port and starboard side engine
cover latches downward. Pull up on the tilt
handle to release the engine cover seal
and remove the engine cover.

1

1. Engine cover latch

2. Tilt handle

2) Remove fuse holder from flywheel cover.

2

4) Holding the flywheel guard out of the way,
hook the knot of your emergency start cord
into the notch on the flywheel. Wind the
cord clockwise in the flywheel ridge, mak­ing one and a half full windings with the
cord.

2

3

1

1. NEUTRAL

2. Knot

3. Rope in flywheel ridge

5) Turn key switch ON.

6) From a secure position in the boat, pull
hard on emergency starting cord to start
engine.

CAUTION

1

1. Fuse

3) Raise flywheel guard from the fittings by
pulling up on the front two fastening tabs.

1

1. Fastening tabs

Keep everyone clear of your immediate
area when pulling on emergency start­ing cord, especially behind you.

Repeat procedure, if necessary, until engine
starts.

7) Refasten flywheel guard in place by push­ing the three fastening tabs back onto the
fittings.

1

1. Fastening tabs

27

Using Your E-TEC Outboard

DANGER

Contact with a rotating flywheel can
cause severe personal injury. Use
extreme care in re-fastening the fly­wheel guard on the fastening tabs.
Keep hands, hair, and clothing away
from coming in direct contact with
rotating parts.

If equipped, snap emergency stop switch lan­yard to secure place on clothing. Proceed im­mediately to nearest landing for service.

SALT WATER

Additional anodic protection for the outboard
has been provided for use in salt or brackish
water.

Upon removal from salt water, leave outboard
in a vertical position until its cooling system
has drained. During long periods of mooring,
tilt the gearcase out of the water, except in
freezing temperatures. Flush the outboard, if
desired. Refer to Flushing on page 34.

Salt Water Lubrication Points

Anti-Corrosion Anodes

Your outboard is equipped with one or more
anodes that protect it from galvanic corrosion.
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
outboard 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.

1. Trailering bracket and swivel bracket lubrica­tion points (annually)

1. Tilt tube lubrication points (annually)

28

WEEDY WATER

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

When operating in weedy water, 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.



OPERATION

HIGH ALTITUDE

Your outboard’s
pensate for changes in altitude. However, if
you 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

will automatically com-

FREEZING WEATHER

IMPORTANT: Use

oil when operating your
board in freezing weather. Refer to Oil Re-
quirements on page 16.

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

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

IMPORTANT: Store the outboard vertically.
Water remaining in the gearcase, 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 Storage
on page 34.

Evinrude/Johnson

Evinrude E-TEC

XD100

out-

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; and

• Keep speed slower than planing speed.

FUSE

A blown fuse will not allow the engine to
crank. Replace it with a fuse of the same rat­ing. A spare fuse is provided.

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

Fuse Replacement

IMPORTANT: Use only fuses of the same rat-

ing. Your
amp fuses.

Remove engine cover. Install spare fuse in
place of failed fuse.

Evinrude E-TEC

outboard uses 10-

1

SHALLOW WATER

IMPORTANT: Gearcase damage can occur if

the gearcase is allowed to drag on the water­way bottom.

DUAL OUTBOARD OPERATION

When in reverse above slow speed, be sure
both outboards are running, even if one is in
NEUTRAL.

If it is necessary to return to harbor with one
outboard not running, tilt the inoperative out­board high enough to keep its propeller out of
the water.

2

1. Fuse

2. Spare fuse

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

29

Using Your E-TEC Outboard

ROUTINE INSPECTION CHECKLIST

Common Sense Pre-launch Checks (Each Use)

Check fuel level.



Check function of steering, throttle, shift, and emergency stop circuit and lanyard.



Check condition of propeller.



Confirm operation of



Confirm the cooling system is operational (water intake screens and water pump



indicator).

Confirm this Operator’s Guide is onboard and readily accessible.



Periodic

Check condition of anti-corrosion anodes (annually or every 100 hours).



Check for debris on propeller.



Clean and wax upper and lower engine covers (annually or every 100 hours).



In salt water applications, check lubrication points and corrosion protection. Use

Evinrude



100 hours).

anti-corrosion spray or

System Check

Evinrude

self-test and warning horn.

“6 in 1” multi-purpose lubricant (annually or

30

MAINTENANCE



31

Maintenance

ENGINE EMISSIONS INFORMATION

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

Manufacturer’s Responsibility

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

Dealer’s Responsibility

When performing service on all 1999 and
more recent
emissions control information label, adjust­ments must be kept within published factory
specifications.

Replacement or repair of any emission relat­ed component must be executed in a manner
that maintains emission levels within the pre­scribed certification standards.

Dealers are not to modify the outboard in any
manner that would alter the horsepower or al­low emission levels to exceed their predeter­mined factory specifications.

Exceptions include manufacturer’s prescribed
changes, such as altitude adjustments, for ex­ample.

Evinrude

outboards that carry an

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.

EPA Emission Regulations

All new 1999 and more recent
boards 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 3rd St. NW
Washington, DC 20001

EPA INTERNET WEB SITE:

www.epa.gov

Evinrude

out-

32



MAINTENANCE SCHEDULE

MAINTENANCE 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 out­board maintenance and inspection scheduled to be performed 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.

Engine

(2)

Care

Product

A

B

C

D

C

Three Years

Description

Electrical and ignition wires, inspect for wear or chafing

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

Fasteners, inspect any loosened components

Fuel and oil system components, inspect and repair leaks

Fuel filter, replace

Gearcase lubricant, replace

Grease fittings, lubricate

Muffler foam, inspect and replace if necessary

Power trim/tilt system and fluid level, inspect

Propeller shaft splines, inspect and lubricate

Spark plugs, inspect and replace if necessary

Starter pinion shaft, inspect and lubricate

Steering system, inspect and lubricate

Thermostats, inspect

Throttle cable, inspect and re-tension

Water pump, inspect or replace if necessary

(1) When used in normal recreational use. Common sense dictates when using an Evinrude E-TEC

outboard for commercial or other heavy use that you check these items more frequently (annual
checks are recommended).

(2) Emission-related component

(3) Annually in salt water applications – Refer to Salt Water Lubrication Points on page 28

(3)

(3)

(2)

(2)

Every 300

Hours or


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













(1)

A.

Ultra-HPF

B. Power Trim/Tilt Fluid

C.

Triple Guard

D. Starter Bendix Lube Only P/N 337016

gearcase lubricant

grease

33

Maintenance

STORAGE

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.

You must protect against natural environmen­tal conditions that can be damaging to an out­board. Temperature and humidity changes
while your outboard is not in use can cause
corrosion of internal engine parts when they
are not protected. Fuel remaining in your fuel
tank can oxidize 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.

WARNING

FLUSHING

If desired, the outboard can be flushed after
each use on a trailer or at dockside while it is
vertical.

1) Place the outboard in an area with good
drainage.

2) Connect garden hose to flushing port.

3) Turn on the water. It is not necessary to
run the engine for a good flushing.

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

• Shift it to NEUTRAL.

• Keep hands, clothes, and hair clear of
powerhead.

• Remove the propeller.

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
does not drip.

34

IMPORTANT: The “CHECK ENGINE” or
“CHK ENG”
luminate if you are running the outboard dur-
ing the flushing procedure. This is normal.
The outboard will continue to run as long as it
is being supplied with water.

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

IMPORTANT: If you cannot store the out­board 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.

System Check

gauge light may il-

SHORT-TERM (BETWEEN USES)

If you must tilt the outboard 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 outboard in a verti­cal position.



STORAGE

LONG-TERM (WINTERIZATION)

WARNING

Outboard must be in NEUTRAL and the
propeller removed before performing
winterization. Failure to remove propel­ler or starting outboard in gear can
cause personal injury or death.

You can winterize your outboard in the water.
If you do so, do not remove the propeller and
make sure the water intake screens are com­pletely submerged. Do not start the outboard
again after winterization is completed.

Prepare your outboard for the off-season by
closely following these steps.

1) Remove the propeller (if winterizing on a
trailer). Outboard must be in NEUTRAL.

2) Following bottle directions, add
conditioner to fuel tank and fill it with fuel.

3) Attach garden hose to flushing port and
turn on the water (winterizing on a trailer).

4) Using fast idle lever/button, advance throt­tle to FULL fast idle warm-up position and
start the outboard.
will illuminate and the outboard will run at
idle speed. Refer to Remote Controls on
page 21 for location of fast idle lever/but­ton, depending on your remote control.

5) After the
(about 15 seconds), move throttle to IDLE
position.
Once the
again, using the fast idle lever/button,
advance throttle again to FULL fast idle
warm-up position.
will flash.

IMPORTANT: If the
not flash, you may not have used the fast idle
lever/button. If the lights are not flashing and
the outboard is not running at fast idle, imme­diately turn key switch OFF and re-start the
winterization procedure at step 4.

6) Outboard will automatically go to fast idle
and fog itself. Allow outboard to run until it
shuts OFF (about one minute).

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

8) With the engine cover removed, top off oil
reservoir, inspect the fuel filter. If there is
debris in the fuel filter, it must be replaced.
See your Dealer. Reinstall engine cover.

9) Grease propeller shaft splines with recom­mended lubricant and install propeller.

System Check

System Check

System Check

System Check

lights will re-light.

System Check

System Check

2+4

fuel

lights

lights turn off

lights turn off

lights

lights do

IMPORTANT: When finished, leave the out­board in vertical position long enough to com­pletely drain the powerhead. If equipped,
disconnect the speedometer pickup at the
upper connection and blow all water out of
the hose using air pressure of 25 psi or less.
Reconnect speedometer pickup after all the
water has been removed.

When using this winterization fogging proce­dure, engine oil may appear on the skeg be­low the gearcase area. This is normal.

Avoid potential oil stains by placing a shop
towel or suitable container under the propel­ler and skeg for the duration of the storage.

PRE-SEASON CHECK

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.
Replace damaged or missing parts with

Evinrude/Johnson Genuine Parts

lent. Check the gearcase for leakage. If leak­age is evident, the gearcase seals should be
replaced. See your Dealer.

IMPORTANT: Gearcase lubricant is thick
and clear. Do not confuse this with engine oil,

which may normally appear on the skeg after
performing the long-term (winterization) stor­age procedure.

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

28.

Battery — Charge fully. Refer to Battery on
page 41.

or equiva-

WARNING

Do not use a booster battery and
jumper cables to start the outboard.
Gasoline fumes can cause explosion
and fire, resulting in property damage,
personal injury or death.

Review your outboard’s warning system self­test routine. During your preseason start-up,
make sure the warning system self-tests
properly. If it does not, see your Dealer.

IMPORTANT: Do not run your outboard—
even for a brief start-up—without supplying
water to it. Refer to Flushing on page 34.

35

Maintenance

Following Starting, Stopping, Shifting on
page 12, start the outboard. If the outboard
was auto-winterized, it will emit a puff of
smoke on the first start of the season. Let it
idle while you:

Observe running quality. If poor, refer to
Troubleshooting on page 37 or see your
Dealer.

Confirm water pump operation. Water must
flow from the water pump indicator in a steady
stream. If it does not, shut off the outboard
and investigate. Refer to Engine Overheat-
ing on page 20.

Stop the outboard 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.

HULL FINISH

The condition of your boat’s bottom affects
performance. Marine growth or bottom paint­ing may reduce speed and fuel efficiency.

For maximum performance, keep the boat’s
running surface clean by rinsing it with fresh
water and wiping it dry. Apply
corrosion spray to any surface subject to cor­rosion, but avoid the anti-corrosion anode(s).

OUTBOARD EXTERNAL FINISH

Evinrude

anti-

SCRATCH REPAIR

Surface scratches on the upper and lower
engine covers can be polished out with buff­ing compound.

Treat affected areas using these steps:

1) Sand the affected area with 800-grit sand­paper.

2) Wet sand the area with 1200-grit sandpa­per.

3) Using a composite material buffing com­pound, polish the area, closely following
the product directions.

IMPORTANT: Your Dealer has the profes­sional materials to properly repair scratches.
Do not attempt to paint over marks or
scratches in the composite material. See
your Dealer to repair any deep scratches or
gouges.

SPARK PLUGS

WARNING

The ignition system presents a serious
shock hazard. The primary circuit oper­ates in excess of 200 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.

Your outboard’s upper and lower engine cov­ers use molded-in color technology, provid­ing a deep, durable gloss with maximum
ultraviolet (sunlight) protection.

The high gloss finish will show polish marks
when viewed closely in certain light condi­tions. This glossing is NORMAL.

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.

IMPORTANT: When trailering your outboard,
DO NOT cover the engine with canvas—it
will dull the finish of the outboard’s engine
covers.

36

IMPORTANT: The spark plugs should be ser­viced by an
spark plug maintenance can lead to engine
damage.

Evinrude E-TEC

Dealer. Incorrect

SUBMERGED OUTBOARD

If your outboard 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.

TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSE

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

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

Engine will not idle properly • Debris on propeller.

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

Engine runs, but makes little or
no progress

Warning system activates • Refer to Engine Monitoring on page 18.

• Fuse blown.

• Battery is dead.

ing, Stopping, Shifting

on page 12.

• Fuel tank empty.

• Fuel hose kinked.

• Fuel system contaminated with water or dirt.

• Fuel filter obstructed.

• Throttle not at IDLE. Return throttle to IDLE.

• Spark plugs incorrect. Refer to

Specifications on

page 45.

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

• Fuse blown.

• Flashing “Water Temp” or hot light, refer to

gine Monitoring
heating

on page 20.

on page 18 and Engine Over-

En-

• Flashing “Check Engine” or “Chk Eng” light, refer

Engine Monitoring on page 18.

to

• Spark plugs damaged or incorrect. Refer to

Specifications on page 45.

• Fuel system contaminated with water or dirt.

Specifications on page 45.

• Fuel filter obstructed.

• Fuel system contaminated with water or dirt.

• Water intakes obstructed and cooling system not
operating correctly. Refer to

Engine Overheating

on page 20.

• Oiling system malfunction.

•

S.A.F.E.

gine Monitoring

protection mode activated. Refer to En-

on page 18.

• Propeller hub loose, slipping.

• Propeller blades bent or missing.

• Propeller shaft bent.

• Propeller debris.



37

Maintenance

OWNER’S NOTES

38

PRODUCT INFORMATION



39

Product Information

RIGGING AND ACCESSORIES

PROPELLER

Propeller Selection

WARNING

Be alert of people in the water. Always
shift the outboard to NEUTRAL and
shut off the engine immediately when
your boat is in an area where there
might be people in the water. Serious
injury or death can result from contact­ing a rotating propeller or moving boat
and outboard.

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

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

Specifications on page 45.

WARNING

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

IMPORTANT: Apply

the entire 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

Standard vs. Counter Rotation

Right-hand propellers are considered stan­dard rotation propellers. When propelling a
boat forward, the propeller rotates in a right­hand (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)

WARNING

In dual-outboard installations, check to
make sure correct propellers are
installed on each outboard before
aggressively operating your boat. Shift
each engine 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 outboard being
checked.

40



RIGGING AND ACCESSORIES

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.

Install propeller nut and tighten to a torque of
120-144 in. lbs. (13.6-16.3 N·m).

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

Install new cotter pin and bend ends to se­cure.

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

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 out­board. 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.

BATTERY

Requirements

• 12-volt, heavy-duty, designated for "marine"
use;

• Vented/refillable or maintenance-free; and

• Rated according to the minimum require­ments in Specifications on page 45.

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.

Installation

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

IMPORTANT: 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.

1. Main cable

2. Starwasher

3. Accessory wires

41

Product Information

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. Main cable

2. Starwasher

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,
battery negative (–) 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.

WARNING

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

Do not use a booster battery and
jumper cables to start the outboard.
Gasoline fumes can cause explosion
and fire, resulting in property damage,
personal injury or death.

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.

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

1

1. Water pressure port (starboard side)

ADJUSTMENTS



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 outboard 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.

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.

43

Product Information

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.

44

SPECIFICATIONS

75, 90 Models

Displacement 79.1 cu. in. (1296 cc)

Engine Type In-line, 3 Cylinder, Two-Cycle,

Full Throttle Operating
Range

(1)

Power

75 HP – 4500 to 5500 RPM
90 HP – 4500 to 5500 RPM

75 HP – 75 HP (56 kw) @ 5000 RPM
90 HP – 90 HP (67.1 kw) @ 5000 RPM

(2)

(2)

(2)

(2)

(2)

700 ± 50

600 ± 50

Not Adjustable

ECM,

E-TEC

(Engine Control Module,

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

Idle RPM in Gear

Idle RPM in Neutral

Ignition Timing

Emission Control System:
per SAE J1930

Fuel Requirements

page 15

Oil – Lubricant

TC-W3 NMMA-certified oil or
Refer to Oil and Fuel on page 15

– Capacity

2.65 qt. (2.5 l)

Warning Signals Controlled by the outboard’s

Battery, Minimum 640 CCA (785 MCA) 12 volt

Spark Plug

(2)

Refer to ECI Label

Fuses Refer to Fuse on page 29

Fuel Filter In-line Replaceable

Battery Charging 25-Amp, Fully Regulated

Gearcase – Lubricant

– Capacity

Evinrude Ultra-HPF™

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

Power Trim/Tilt – Fluid

21 fl. oz. (622 ml)

Capacity

Propeller Refer to Propeller Selection on page 40

Weight L Models – 320 lbs. (145 kg)

X Models – 335 lbs. (152 kg)

Sound at Driver’s Ear

76.8 dB(A)

(LpA) ICOMIA 39.94

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

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

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

(2) Emission Control Information.

E-TEC

E-TEC

Evinrude/Johnson

EMM



SPECIFICATIONS

)

XD100 oil –

45

Product Information

PRODUCT WARRANTY 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 2004
rized

Evinrude

period and under the conditions described below.

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

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.

Evinrude/Johnson® Genuine Parts

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-

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.

Evinrude

® outboard engines sold by autho-

and accessories in-

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.

46



PRODUCT WARRANTY INFORMATION

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.

BOMBARDIER LIMITED WARRANTY FOR 2004

EVINRUDE

OUTBOARD

ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA

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.

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

Evinrude

products in

47

Product Information

CALIFORNIA EMISSION CONTROL

WARRANTY STATEMENT

Your

Evinrude E-TEC

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

For a healthier lifestyle and environment.

Better Fuel Economy

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

Longer Emission Warranty

Protects consumer for worry free operation.

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 identifies engines that meet the Air Resources Board's Personal Watercraft and Out­board marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003
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 emission than One Star
– Low Emission engines.

For more information: Cleaner Watercraft – Get the Facts

outboard has a special environmental label required by the California Air Resources

The Star Label Means Cleaner Marine Engines

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

48



CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

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 2004
ifornia, new outboard engines must be designed, built, and equipped to meet the State's stringent anti­smog standards. Bombardier must warrant the emission control system on your outboard for the periods
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
in California, that are originally sold in California to a California resident, or subsequently warranty-regis­tered to a California resident. The Bombardier U.S. and Canada limited warranty conditions for
outboards are still applicable to these models with the necessary modifications.

Select emission control parts of your
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
warranty, the part will be repaired or replaced by Bombardier.

Parts covered are:

Evinrude

Evinrude E-TEC

outboards certified and produced by Bombardier for sale

outboard are warranted from the date of purchase

Evinrude E-TEC

outboard. In Cal-

Evinrude

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. Intake Manifold
D. Wiring Harness

5. Oil System

2. Exhaust System

A. Inner Exhaust Housing B. Oil Lines, Fittings, and Clamps
B. Adaptor (Exhaust Manifold)
C. Megaphone (Inner Exhaust)

3. Fuel System

A. Fuel Lift Pump C. Throttle Position Sensor
B. Fuel Supply Pump D. Water Temperature Sensor
C. Fuel Injectors E. Thermostat
D. Vapor Separator
E. Fuel Lines, Fittings, and Clamps

A. Oil Injector

6. Sensors

A. Air Temperature Sensor
B. Crank Position Sensor

7. Gaskets

A. All Emission Component Gaskets

49

Product Information

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.

As the outboard owner, you should however 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.

50

CHANGE OF ADDRESS / CHANGE OF OWNERSHIP

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

51

Product Information

52

Your Dealer

Name:

Address:



CONFIRMATION OF RECEIPT

Upon delivery of your new

Evinrude/Johnson

outboard, complete and sign the form below.

Your Dealer will take receipt of the form for their records.

Receipt

Name:

Address:

Owner of Model No:

Serial No:

(To be completed by customer or selling Dealer)

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
copy of the Operator’s Guide.

Signature:

Date:

Evinrude/Johnson

outboard. I have also received a

53

Product Information

54

OWNER’S NOTES



55

Product Information

Readiness Test

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 outboard?

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 outboard?

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

7. Do you know your local marine traffic laws?

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

preoccupation, 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.

56

FREQUENTLY ASKED QUESTIONS

No dealer-scheduled maintenance for the first three years of normal recreational use? Really?

• Yes! Bombardier knows you want to spend your time on the water, not servicing your

Evinrude E-TEC

or oil to change. We do recommend pre-launch inspections of your outboard at each use and
at regular intervals. Salt water applications require minimal additional inspections and lubri­cation.

outboard. There are no valves to adjust, belts to service, chains to replace,

What fuel octane is recommended for my

•

Evinrude E-TEC

els is not harmful, but also not necessary.

What kind of oil does my

• Any TC-W3 oil may be used. The outboard can be programmed by your Dealer to run on

Evinrude/Johnson

Filling the Oil Tank on page 15; see also Oil Requirements on page 16.

outboards require a minimum octane of 87 (U.S.). Use of higher octane fu-

Evinrude E-TEC

XD100 oil for lower oil consumption and reduced operating cost. Refer to

Evinrude E-TEC

outboard require?

outboard?

Do I need to mix oil into my fuel?

•No.

Evinrude E-TEC

Where should I take my

• For repairs covered under warranty, you must take your
thorized dealer. Bombardier-approved dealers and distributors have received the necessary
training to properly service your outboard. Contact Bombardier for an authorized

E-TEC

dealer near you.

Can I order replacement parts and accessories for my

• Yes. When replacement parts are required, use
with equivalent characteristics, including type, strength, and material. Using substandard
parts could result in injury or product malfunction. Your dealer can order the parts and ac­cessories you desire.

Do I need to complete any paperwork when I move or sell my

• Yes. In order to maintain contact with you or the new
requests you complete the form outlining Change of Address / Change of Ownership on
page 51. This will ensure you or the new owner is made aware of any product announce­ments and keep the warranty coverage up-to-date.

outboards do not require any mixing of oil and fuel.

Evinrude E-TEC

outboard for service?

Evinrude E-TEC

Evinrude E-TEC

Evinrude/Johnson

Evinrude E-TEC

outboard?

Genuine Parts or parts

Evinrude E-TEC

outboard to an au-

Evinrude

outboard?

owner, Bombardier

What do I need to do before storing my

• Winterization is minimal. Refer to Storage on page 34 for step-by-step instructions to store
your

Evinrude E-TEC

outboard for the off-season.

Evinrude E-TEC

outboard for the winter?