Evinrude e-tec 2005 User Manual

2005

40 HORSEPOWER

RL

™™

!

Read this Operator Guide thoroughly. It contains important

safety information. When operating your boat, always

have this Operator Guide onboard.

WARNING

!

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

• E-Start System (not battery dependent)

• Digital Engine Management

• Self Flushing Cooling System

• Long Term Storage Design

• Simplified Winterization Procedure

• 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

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 Recreational Products Inc. or its affiliates:

Evinrude® Evinrude®/Johnson® XD30

Evinrude® E-TEC

Evinrude®/Johnson® Genuine Parts S.A.F.E.

Evinrude®/Johnson® XD100

Evinrude®/Johnson® XD50

© 2004 Bombardier Motor Corporation of America. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

™

™

™

2+4® fuel conditioner

™

Triple-Guard® grease

Twist Grip

™

™



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 Recreational Products 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

E-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

E-TEC

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

of enjoyable use.

Evinrude

Happy Boating,

Roch Lambert
Executive Vice-President

Product Development, Sales and Marketing
North America

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Routine Inspection Checklist . . . . . . . . . . . . . . . 25

E

VINRUDE

E-TEC

OUTBOARD

2

MAINTENANCE

Engine Emissions Information . . . . . . . . . . . . . . 28

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . 29

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 33



PRODUCT INFORMATION

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Product Warranty Information . . . . . . . . . . . . . . 40

California Emission Control Warranty . . . . . . . . 42

Readiness Test . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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

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.

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.

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 Motor Corporation

of America (BMCA) has identified key infor­mation 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

Parts

istics, 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 29.

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.

Evinrude®/Johnson® Genuine

or parts with equivalent character-

Dealer. In many in-

6



PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS

BMCA 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 Recreational Prod­ucts distributor where the outboard was registered.

Technical Literature

BMCA 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

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

7

Bombardier Recreational Products

USING YOUR

EVINRUDE E-TEC

OUTBOARD

USING YOUR E-TEC

OUTBOARD



9

Using Your E-TEC Outboard

COMPONENT IDENTIFICATION

1

2

5

4

3

6

7

8

Item Description Item Description

1 Air Inlet, Tilt Handle 5 Stop Button / Emergency Stop

2 Water Pump Indicator, Flushing Port 6 Tilt Support

3 Engine Cover Latch 7 Clip and Lanyard Assembly

4 Anti-Corrosion Anodes 8 Water Intake Screens

10

Switch



COMPONENT IDENTIFICATION

Starboard

10

Port

9

11

12

13

14

15

Item Description Item Description

9 Fuel Filter 14 Steering Handle and

Throttle

10 Spark Plugs 15 Air Silencer

16

17

18

Twist Grip

™

11 Throttle Friction Screw 16 Oil Fill Cap

12 Shift Lever 17 Oil Tank

13 Starter Handle 18

EMM

(Engine Management Module)

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 25 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
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

12

3

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.

1. Clip

2. Emergency stop clip / key switch

3. Lanyard

IMPORTANT: The operator should always
use the clip and lanyard anytime the engine is
running. Refer to Emergency Stop Switch
on page 20.

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.

12



STARTING, STOPPING, SHIFTING

Move the shift lever to NEUTRAL. Refer to

Shifting and Speed Control on page 14.

1

1. NEUTRAL

WARNING

Always shift to NEUTRAL before start­ing the outboard to prevent sudden
boat movement, which can cause
injury.

Twist throttle grip to SHIFT or slower.

While seated, grasp the starter handle and
pull slowly until the starter engages, then pull
hard. Repeat, if needed, until outboard starts.
To prevent damage to starter assembly, allow
starter cord to rewind before releasing starter
handle.

1

2

1. Starter handle

2. NEUTRAL

If your outboard does not react normally to
this starting procedure or if it fails to start, re­fer to Troubleshooting on page 33.

1

1

1. SHIFT

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.

If the outboard is started at wide open throt­tle, twist the throttle grip back to SHIFT be­fore shifting.

EMM

) au-

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 21.

13

Using Your E-TEC Outboard

ENGINE STOPPING

Twist the throttle grip to SHIFT position or
slower.

Move shift lever to NEUTRAL.
Press the STOP button until the outboard

stops running. If equipped, close the vent
screw on the fuel tank’s filler cap.

1

WARNING

Do not operate the outboard in
REVERSE with the tilt/run lever in TILT.
The outboard may tilt out of the water,
resulting in loss of control.

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

With the outboard running, twist throttle grip:

• Clockwise to decrease speed; or

• Counterclockwise to increase speed.

1. STOP button

SHIFTING AND SPEED CONTROL

IMPORTANT: Carefully check the function of

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

Shifting

With engine running, twist the trottle grip to
SHIFT or slower.

Move the shift lever briskly and decisively to
FORWARD or REVERSE.

32

1

2

1. Decrease speed

2. Increase speed

FUEL SYSTEM PRIMING

If the outboard is run out of fuel, refill the fuel
tank and squeeze the primer bulb until firm.
Prime the electric fuel pump by first removing
the emergency stop switch clip and then pull­ing the rope at least two times. This will cause
the fuel pump to fill the injectors. Replace the
emergency stop switch clip and follow the
normal starting procedure.

1. Shift lever

2. FORWARD

3. REVERSE

14

1

FUEL ECONOMY

The economy throttle position can save fuel,
depending on boat load and hull design.
When boat reaches top speed, throttle back
from FULL SPEED. You will save fuel with a
minimal loss of speed.

OIL AND FUEL



OIL AND FUEL

OILING SYSTEM

Your outboard is designed to run in “get
home” mode in the event your oil tank runs
low. You will have approximately five hours of
normal operation before running out of oil
when using TC-W3RL oil. If you are using

Evinrude/Johnson XD100

proximately ten hours of normal operation re­maining. Refill the onboard oil tank as soon
as possible. Refer to Priming the Oiling

System on page 15.

IMPORTANT: Always “top off” your oil tank

prior to prolonged usage or long trips.

™ oil, you have ap-

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 2.0
quarts (1.9 liters).

PRIMING THE OILING SYSTEM

The oiling system must be primed before re­using the outboard if:

• You run completely out of oil; or

• The outboard is laid down for transportation
or storage.

Prime the oiling system by performing winter­ization. Refer to Long-Term (Winterization)
on page 31.

15

Using Your E-TEC Outboard

OIL REQUIREMENTS FUEL REQUIREMENTS

WARNING

The following outboard oils are recommend­ed for use in your

•

Evinrude/Johnson XD100
Evinrude/Johnson XD50

•

•

Evinrude/Johnson XD30

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 XD100

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

oil. Only an authorized

can program your outboard for this bene­fit.

If

Evinrude/Johnson

able, you must use an oil that meets NMMA
TC-W3RL 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-W3RL certification
standards is allowed. If you discontinue using

Evinrude E-TEC

outboard

as compared to using a conventional

Evinrude/Johnson XD100

Evinrude/Johnson XD100

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.

Evinrude E-TEC

;
™; or
™.

brand oils are formulated

oil is preferred

outboard. It is for-

outboard:

Evinrude

EMM

to cut normal oil con-

Evinrude/Johnson

Evinrude

brand oils are not avail-

EMM

has been pro-

dealer

Evinrude/Johnson XD100

is tempo-

, you MUST first re-

EMM

repro-

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



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.

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.

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

BMCA approves only
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®

fuel

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

17

Using Your E-TEC Outboard

WARNING

OPERATION

TILTING

Boat stability and steering torque can
vary due to changing water conditions.
If any adverse conditions occur, reduce
throttle and/or adjust tilt angle to main­tain control. If you experience boat
instability and/or high steering torque,
see your Dealer to correct these condi­tions.

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.

TRAILERING

Trailer your boat with the outboard in a verti­cal position. If your trailer does not provide ad­equate road clearance, the outboard can be
trailered by using the tilt support or an acces­sory trailering bracket. Refer to Tilt Support
on page 20.

IMPORTANT: Whenever using the tilt sup­port or an accessory trailering bracket, the
outboard must be restrained. Bouncing during
transport will damage the outboard and boat’s
transom.

WARNING

If you tilt the outboard and leave it
tilted, close the fuel tank vent screw
(turn clockwise) and close the fuel
shut-off valve (turn so handle is hori­zontal). Failure to do so might allow
fuel leakage which could lead to an
explosion or fire.

IMPORTANT: Use the tilt grip to tilt your out-

board.

Outboard Angle Adjustment

The outboard should be perpendicular to the
water when the boat is underway at full
speed. This adjustment can only be deter­mined by water testing the boat. Set angle ad­justment for your normal load.

Place the outboard in full TILT position. Refer
to Tilt Support on page 20.

• Turn the angle adjusting rod handle up.
Push in against spring so retainer will re­lease, then slide rod assembly all the way
out.

• Insert rod in desired position. Make sure rod
passes through both stern brackets.

• Push in against spring and turn rod handle
down. Make sure the retainer dropped into
lock position.

18



OPERATION

Tilt UP

Move tilt/run lever to TILT position.

1

1. TILT position

Grasp tilt grip on engine cover and tilt out­board to the full tilt position.

Tilt DOWN

Move tilt/run lever to RUN position.

1

1. RUN position

Grasp tilt grip on engine cover and raise out­board slightly.

1

1. Tilt grip

Tilt support will automatically engage.

WARNING

While outboard is tilted, leave tilt lever
in the TILT position. When the tilt/run
lever is in the RUN position, tilt support
can release unexpectedly and allow
outboard to drop, creating a risk of
serious personal injury or loss of con­trol.

1

1. Tilt grip

Tilt support will automatically disengage.
Slowly lower outboard to its normal operating

position.

19

Using Your E-TEC Outboard

TILT SUPPORT

Engage

Raise the outboard to full TILT position. Refer
to Tilting on page 18. After initial engage­ment of tilt support, tilt outboard fully and push
tilt support bracket to “lock” position.

1

1. Tilt support bracket – lock position

EMERGENCY STOP SWITCH

The emergency stop switch is on the steering
handle. Use of the emergency stop feature is
highly recommended on all boats.

Connect the clip to the emergency stop
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.

12

Disengage

Tilt outboard fully and pull tilt support bracket
to “unlock” position.

1

1. Tilt support lever – unlock position

Move tilt/run lever to RUN position and gently
lower outboard to RUN position.

3

1. Clip

2. Emergency stop clip / key switch

3. Lanyard

An extra clip is provided. Another person can
insert it in the stop switch and start the out­board in an emergency.

1

20

1. Extra clip



OPERATION

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.
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.

ENGINE OVERHEATING

If the engine overheats, the
Adjusting Failsafe Electronics) mode will im­mediately limit the engine’s speed to 1200
RPM. If the engine was running faster than
1200 RPM when the
ed, it will shake noticeably. The protection
system must be RESET before the engine will
operate at speeds over 1200 RPM. Under
certain conditions the
engine.

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.

S.A.F.E.

EMM

mode activates and the

S.A.F.E.

mode activat-

will shut off the

(Speed

IMPORTANT: Do not run your outboard—
even for a brief start-up—without supplying
water to it. Refer to Flushing on page 30.

While boating, the outboard’s water intakes
must stay completely submerged and unob­structed. Observe proper transom height and
tilt 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, muddy and debris-laden water, and at
extreme trim angles.

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.

IMPORTANT: If cooling is not restored, the

EMM

will identify a progressive overheating
condition and shut off the engine. 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

1. Water intake screens

2. Water pump indicator

21

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!

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.

If you hit any object:

• STOP immediately and examine the out­board 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.

22



OPERATION

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 30.

Salt Water Lubrication Points

1

1. Tilt lever, tilt lever shaft, and swivel bracket lu­brication points (annually)

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.

1

1. Tilt tube lubrication points (annually)

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

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.

23

Using Your E-TEC Outboard

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. After the system drains,
slowly pull the rope handle once so the fly­wheel turns briefly, forcing any remaining wa­ter from the water pump impeller.

Evinrude/Johnson XD100

Evinrude E-TEC

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

On outboards equipped with an accesso­ry electric starter, a blown fuse will not allow

the engine to start. 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-

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 30.

SHALLOW WATER

IMPORTANT: Gearcase damage can occur if

the gearcase is allowed to drag on the water­way bottom.

1

2

1. Fuse

2. Spare fuse

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

24



ROUTINE INSPECTION CHECKLIST

ROUTINE INSPECTION CHECKLIST

Common Sense Pre-launch Checks (Each Use)

Check fuel level.



Check oil level.



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



Check condition of propeller.



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

Evinrude

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

25

Using Your E-TEC Outboard

Bombardier Recreational Products

26

MAINTENANCE



27

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

EPA Emission Regulations

All new 1999 and more recent
boards manufactured by BMCA 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

Evinrude

out-

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.

28

EPA INTERNET WEB SITE:

www.epa.gov



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.

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

Propeller shaft splines, inspect and lubricate

Spark plugs, inspect and replace if necessary

Steering handle, inspect and lubricate

Thermostats, inspect

Throttle cable, inspect and re-tension

Water pump, inspect or replace if necessary

(3)

(3)

(2)

(2)

(2)

Engine

Care

Product

A

B

B

Every 300

Hours or

Three Years
















(1)

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

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 23

A.

Ultra-HPF

Triple Guard

B.

gearcase lubricant

grease

Evinrude E-TEC

29

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.

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.

WARNING

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.

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.

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.

30

LONG-TERM (WINTERIZATION) TRANSPORTATION

WARNING

If the outboard is laid down for transportation

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.

or storage, the oiling system must be primed
before reusing the outboard. Prime the oiling
system by performing winterization. Refer to

Long-Term (Winterization) on page 31.

PRE-SEASON CHECK

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). Throttle 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 water (if winterizing on a trailer).

4) Advance throttle to 1/2 throttle position
and start the outboard.

5) After approximately 15 seconds, move
throttle to IDLE position. Run the outboard
at idle for another 15 seconds, then ad­vance throttle again to 1/2 throttle position.

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 off
water and detach garden hose (if used).

8) Remove engine cover. Top off oil reservoir
and 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, then install propeller.

IMPORTANT: When finished, leave the out­board in vertical position long enough to com­pletely drain the powerhead.

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.

2+4

fuel

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

23.

IMPORTANT: Do not run your outboard—
even for a brief start-up—without supplying
water to it. Refer to Flushing on page 30.

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 33 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 21.

Stop the outboard and check the fuel system
for leaks.

WARNING



STORAGE

or equiva-

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

31

Maintenance

OUTBOARD EXTERNAL FINISH

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.

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.

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).

Evinrude

anti-

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.

IMPORTANT: The spark plugs should be ser-

viced by an
spark plug maintenance can lead to engine
damage.

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.

Evinrude E-TEC

Dealer. Incorrect

32



TROUBLESHOOTING

TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSE

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

• Fuse blown.

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

ing, Stopping, Shifting

• Fuel tank empty.

• Fuel hose kinked.

• Fuel system contaminated with water or dirt.

• Fuel system not primed after running out of fuel.
Refer to

Fuel System Priming on page 14.

• Fuel filter obstructed.

• Throttle not at IDLE. Return throttle to IDLE.

• Spark plugs incorrect. Refer to Specifications on
page 39.

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

• Fuse blown.

on page 12.

Engine will not idle properly • Debris on propeller.

• Spark plugs damaged or incorrect. Refer to

Specifications on page 39.

• Fuel system contaminated with water or dirt.

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

Specifications on page 39.

• 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 21.

• Oiling system malfunction.

•

Engine runs, but makes little or
no progress

S.A.F.E.

gine Overheating

• Propeller hub loose, slipping.

• Propeller blades bent or missing.

protection mode activated. Refer to En-

on page 21.

• Propeller shaft bent.

• Propeller debris.

Warning system activates • Refer to Engine Overheating on page 21.

33

PRODUCT INFORMATION

INSTALLATION

WARNING

Your outboard must not exceed the
maximum horsepower indicated on the
boat’s capacity plate. Such overpower­ing can cause loss of control. Contact
your Dealer or the boat’s manufacturer
if your boat lacks a capacity plate.

Boats designed for remote-steered out­boards might be overpowered by a
tiller-steered outboard of the maximum
rated horsepower. Ask your Dealer or
boat manufacturer if you are unsure
about your boat’s suitability.

Incorrectly matched boat and outboard
transom heights can cause boat insta­bility and loss of control. Refer to Tran­som Height and Shaft Length.



INSTALLATION

On a specialty hull, non-planing hull, or on a
boat with a curved transom, these guidelines
might not apply. See your Dealer for special
installation information.

Transom Height and Shaft Length

The transom height dimension listed in Spec­ifications on page 39 is the height of the boat

transom your outboard needs. This dimen­sion is measured at the transom centerline,
perpendicular to the bottom of the boat. Use
this procedure to determine whether or not
the boat’s transom height is correct for the
outboard’s shaft length

Prevent lateral movement and possible
outboard loss by using the mounting
hardware supplied or hardware of suf­ficient size, strength, and quality. Refer
to Installing the Outboard on page 36.

A mounting surface that is damaged or
too thin to support your outboard while
underway might fail during operation,
causing a loss of control. Be sure the
boat’s transom or mounting bracket is
structurally sound and between 1 5/8
in. (41 mm) and 2 3/4 in. (70 mm) in
thickness.

IMPORTANT: If you need a hoist to lift the en-

gine, first refer to Specifications on page 39
for engine weight and choose a hoist accord­ingly.

If you install and operate the engine:

• Lower than recommended — Serious pow­erhead damage could result from water en­try into the lower engine cover or
overloading from an under-revving propeller
at wide open throttle.

• Higher than recommended — Serious pow­erhead damage could result from inade­quate cooling or an over-revving propeller.
Propeller ventilation (slippage) often oc­curs, resulting in poor boat performance.

1

2

1. Transom height

2. Antiventilation plate

3. Final position – 0 to 2 in. (0 to 51 mm)

Refer to Outboard Angle Adjustment on
page 18. The antiventilation plate must be
parallel with the boat bottom.

The resulting position of the antiventilation
plate must be no higher than the boat’s bot­tom and no lower than 2 in. (51 mm) below it.

If the resulting position of the antiventilation
plate is above or below the 0 to 2 in. (0 to 51
mm) range, the outboard shaft length must be
changed or the boat’s transom must be mod-
ified.

Vent Line Clamp

In compliance with Federal regulations, this
outboard was shipped with a vent line clamp
installed. This clamp must be removed prior to
attempting to prime the fuel system or start
the outboard for the first time.

IMPORTANT: Failure to remove the clamp
may cause fuel starvation issues and undesir­able running qualities.

3

35

Product Information

Installing the Outboard

WARNING

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.

IMPORTANT: Follow all directions carefully.

The outboard’s warranty will not cover prod­uct damage or failure that results from incor­rect outboard installation.

WARNING

Even if equipped with clamp screws,
your outboard must be bolted to the
boat to prevent it from “working off the
transom” during operation.

Use

Evinrude/Johnson Genuine Parts

ing hardware to ensure proper installation. In­structions are packed with the mounting kit
and are repeated here.

mount-

1. Drilled transom holes

Apply a good waterproof caulk to bolt shanks.
Insert the bolts through the stern bracket and
transom. Loosen clamp screws and apply
caulk on and around bolts between stern
brackets and transom to keep water out of the
drilled holes.

Retighten clamp screws. Install the large
washers and two of the locknuts on the bot­tom bolts. Install the small washers and the
other two locknuts on the top bolts. Tighten all
nuts securely.

2

1

2

Mounting hardware

Center the outboard on the boat’s transom
and over the transom plate if one is used.
Tighten the clamp screws by hand only.

Drill two 11/32 in. (8,7 mm) holes through the
boat’s transom on each side of the outboard
using the stern bracket holes as guides.

36

3

1. Clamp screws

2. Small washers

3. Large washers

After 30 minutes of operation, retighten clamp
screws by hand. DO NOT use tools to tighten
clamp screws. Check clamp screws regularly.

WARNING

When replacing bolts, screws, or other
fasteners, use
or parts of equivalent strength and
material.

Evinrude/Johnson

parts

ACCESSORIES

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.



ACCESSORIES

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.

1

1. Water pressure port (behind fuel filter)

2. Fuel filter

2

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 39.

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

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.

37

Product Information

ADJUSTMENTS

Idle RPM in Gear

The idle RPM in gear setting can be adjusted,
if desired, to provide more idle control, steer­ing, and quietness in certain applications.

IMPORTANT: Only your Dealer can adjust
the idle RPM in gear setting.

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.

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

Friction

1

2

1. Throttle friction screw

2. Steering friction screw

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.

38

Throttle Friction — Adjust until a slight
drag is felt when accelerating or decelerating
only. DO NOT overtighten.

Steering Friction — The steering friction
was set on your outboard at the factory. A
slight drag should be felt when turning the out­board with the steering handle. If adjustment
is necessary, turn the adjustment screw:

• Clockwise to increase friction; or

• Counterclockwise to decrease friction.

WARNING

DO NOT overtighten for “hands-off”
steering. Reduced steering control
could result.

SPECIFICATIONS

40 Models

Displacement 52.7 cu. in. (864 cc)



SPECIFICATIONS

Engine Type In-line, 2 Cylinder, Two-Cycle,

Full Throttle

5000 to 6000 RPM

Operating Range

Power

Idle RPM in Gear

Idle RPM in Neutral

Ignition Timing

Emission Control System:
per SAE J1930

Fuel Requirements

(1)

(2)

(2)

(2)

(2)

(2)

40 HP (29.8 kw) @ 5500 RPM

850 ± 50

750 ± 50

Not Adjustable

ECM (Engine Control Module),

87 Pump Posted AKI (90 RON) – Refer to Oil and Fuel on
page 15

Oil – Lubricant

TC-W3RL NMMA-certified oil or
– Refer to Oil and Fuel on page 15

– Capacity

Spark Plug

(2)

2.0 qt. (1.9 l)

Refer to ECI Label

Fuses Refer to Fuse on page 24

Fuel Filter In-line Replaceable

Gearcase – Lubricant

– Capacity

Evinrude Ultra-HPF

22 fl. oz. (650 ml)

™

Evinrude E-TEC

Evinrude E-TEC

Evinrude/Johnson XD100

oil

Propeller Refer to Propeller Selection on page 37

Weight 232 lbs. (105 kg)

Sound at Driver’s Ear

76.8 dB(A)

(LpA) ICOMIA 39.94

Vibration at Tiller (arms) Less than 2.5 m/s

2

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

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

(2) Emission Control Information.

39

Product Information

PRODUCT WARRANTY INFORMATION

BOMBARDIER MOTOR CORPORATION OF AMERICA

LIMITED WARRANTY FOR 2005

EVINRUDE

OUTBOARD ENGINES

SOLD IN THE UNITED STATES AND CANADA

1. SCOPE OF THE LIMITED WARRANTY

Bombardier Motor Corporation of America* (“BMCA”) warrants its 2005

Evinrude

and under the conditions described below.

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

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 BMCA parts
and accessories one-year limited warranty.

California residents who purchased or warranty-registered a Product in California should refer to BMCA'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
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 BMCA 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. BMCA 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 BMCA

Evinrude

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

Evinrude

® outboard engines sold by authorized

and accessories in-

4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE

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

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

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

5. WHAT BOMBARDIER MOTOR CORPORATION OF AMERICA WILL DO

BMCA'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 BMCA. Such repair or replacement of parts
will be done without charge for parts and labor, at any authorized Dealer. BMCA's responsibility is limited to making the
required repairs or replacements of parts with new or BMCA-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.

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

40



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 BMCA, 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 BMCA. BMCA
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 BMCA 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 BMCA limited warranty, BMCA 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 Motor Corporation of America Customer Support Ser­vices, 250 Sea Horse Drive, Waukegan, IL 60085, 1-847-689-7090.

BOMBARDIER MOTOR CORPORATION OF AMERICA

LIMITED WARRANTY FOR 2004

SOLD OUTSIDE THE UNITED STATES AND CANADA

For a copy of the Limited Warranty, see your Bombardier Motor Corporation of America (“BMCA”) distributor/dealer au­thorized to distribute

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

* Engines sold in Canada are distributed and serviced by Bombardier Recreational Products Inc.
Limited Warranty Revision February 2004

Evinrude

products in the country in which the sale occurs.

EVINRUDE

OUTBOARD ENGINES

41

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.

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

The Star Label Means Cleaner Marine Engines

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

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

42



CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR EMISSION CONTROL WARRANTY RIGHTS AND OBLIGATION

The California Air Resources Board and Bombardier Motor Corporation of America (“BMCA”) are pleased
to explain the emission control system warranty on your 2004
new outboard engines must be designed, built, and equipped to meet the State's stringent anti-smog stan­dards. BMCA 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, BMCA will repair your outboard at no cost to you including diagno­sis, parts, and labor provided that such work is performed by an authorized BMCA dealer.

Evinrude E-TEC

outboard. In California,

Manufacturer's Limited Warranty Coverage

This emission limited warranty covers
ifornia, that are originally sold in California to a California resident, or subsequently warranty-registered to
a California resident. The BMCA U.S. and Canada limited warranty conditions for
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 BMCA.

Parts covered are:

Evinrude

outboards certified and produced by BMCA for sale in Cal-

Evinrude E-TEC

Evinrude

outboard are warranted from the date of purchase

outboards are

1. Electrical System 4. Air Induction System

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

A. Oil Injector

6. Sensors

3. Fuel System

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

A. Air Temperature Sensor

7. Gaskets

A. All Emission Component Gaskets

43

Product Information

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

The BMCA Operator's Guide provided contains written instructions for the proper maintenance and use
of your outboard. All emission warranty parts are warranted by BMCA 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
BMCA 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 BMCA 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 BMCA for the remainder of the warranty period of the
original part. All parts replaced under this limited warranty become the property of BMCA.

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. BMCA recommends that you retain all receipts covering maintenance on your out­board, but BMCA 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 BMCA 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 BMCA 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 BMCA dealer, contact Bombardier Motor Corporation of America Customer Support
Services, 250 Sea Horse Drive, Waukegan, IL 60085, 1-847-689-7090 or visit www.evinrude.com.

44



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 BMCA 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
Recreational Products 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

45

Product Information

Bombardier Motor Corporation of America

46

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:

Evinrude/Johnson

outboard. I have also received a

Date:

47

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.

48

FREQUENTLY ASKED QUESTIONS

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

• Yes! Bombardier Motor Corporation of America knows you want to spend your time on the
water, not servicing your
service, chains to replace, 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.

Evinrude E-TEC

outboard. There are no valves to adjust, belts to

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-W3RL oil may be used. The outboard can be programmed by your Dealer to run on

Evinrude/Johnson XD100

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

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

Evinrude E-TEC

outboard?

outboard require?

Do I need to mix oil into my fuel?

•No.

Where should I take my

• For repairs covered under warranty, you must take your

Can I order replacement parts and accessories for my

• Yes. When replacement parts are required, use

Evinrude E-TEC

thorized dealer. Bombardier Motor Corporation of America-approved dealers and distribu­tors have received the necessary training to properly service your outboard. Contact
Bombardier Motor Corporation of America for an authorized
you.

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.

outboards do not require any mixing of oil and fuel.

Evinrude E-TEC

outboard for service?

Evinrude E-TEC

Evinrude E-TEC

Evinrude E-TEC

Evinrude/Johnson

outboard?

Genuine Parts or parts

outboard to an au-

dealer near

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

• Yes. In order to maintain contact with you or the new
Motor Corporation of America requests you complete the form outlining Change of Address
/ Change of Ownership on page 45. This will ensure you or the new owner is made aware
of any product announcements and keep the warranty coverage up-to-date.

What do I need to do before storing my

• Winterization is minimal. Refer to Storage on page 30 for step-by-step instructions to store
your

Evinrude E-TEC

outboard for the off-season.

Evinrude E-TEC

Evinrude E-TEC

Evinrude E-TEC

owner, Bombardier

outboard?

outboard for the winter?

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