BRP Evinrude E-TEC User manual

Printed in the United States.
© 2017 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
BRP US Inc.
Technical Publications
P.O. Box 597
Sturtevant, Wisconsin 53177 United States
www.evinrude.com or www.johnson.com
† AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II
are registered trademarks of Tyco International, Ltd.
† Amphenol is a registered trademark of The Amphenol Corporation.
† BEP is a registered trademark of Actuant Corporation.
† Champion is a registered trademark of Federal-Mogul Corporation.
† Deutsch is a registered trademark of The Deutsch Company.
† Dexron is a registered trademark of The General Motors Corporation.
† Fluke is a registered trademark of The Fluke Corporation
† GE is a registered trademark of The General Electric Company.
† GM is a registered trademark of The General Motors Corporation.
† Locquic and Loctite are registered trademarks of The Henkel Group.
† Lubriplate is a registered trademark of Fiske Brothers Refining Company.
† NMEA is a registered trademark of the National Marine Electronics Association.
† Oetiker is a registered trademark of Hans Oetiker AG Maschinen.
† Packard is a registered trademark of Delphi Automotive Systems.
† Permatex is a registered trademark of Permatex.
† STP is a registered trademark of STP Products Company.
† Snap-on is a registered trademark of Snap-on Technologies, Inc.
The following trademarks are the property of BRP US Inc. or its affiliates:
Original Instructions
Evinrude ® Twist Grip™
Johnson ® Nut Lock™
Evinrude ® E-TEC ® Screw Lock™
FasTrak™ Ultra Lock™
S.A.F.E.™ Moly Lube™
SystemCheck™ Triple-Guard ® Grease
I-Command™ DPL™ Lubricant
Evinrude ® ICON™ 2+4 ® Fuel Conditioner
Evinrude ® / Johnson ® XD30™ Outboard Oil Carbon Guard™
Evinrude ® / Johnson ® XD50™ Outboard Oil Gel-Seal II™
Evinrude ® / Johnson ® XD100™ Outboard Oil HPF PRO™ Gearcase Lubricant

2
Service Manual
Contents
Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page
1 Reference Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Routine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Engine Cover Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4 Engine Management Module (EMM) . . . . . . . . . . . . . . . . 59
5 System Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6 Electrical and Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
8 Oiling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
10 Powerhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
11 Midsection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
12 Trim and Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
13 Manual Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S–325
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I–349
Trouble Check Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . T–357
Diagrams
IMPORTANT: For complete outboard rigging and control installation information, refer to the current
Installation and Predelivery Guide included with the service manual set.
All special tools referenced in this manual can be found in the current Special Tools Guide, included
with the service manual set.

Reference Information
3
1
Reference Information
Table of Contents
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Abbreviations Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product Reference and Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Emission-Related Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Manufacturer’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dealer’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Owner’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EPA Emission Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Model Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service Specifications, 40 – 60 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Service Specifications, 60 H.O. – 90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wire Size Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
American Wire Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Metric Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Safety Notice
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This publication is written for qualified, factory-
trained technicians who are already familiar with
the use of Evinrude/Johnson Special Tools. The
included information is not a substitute for work
experience. It is an organized guide for reference,
repair, and/or maintenance.
The following symbols and/or signal words
may be used in this document:
These safety alert signal words mean:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
IMPORTANT: Identifies information that controls
correct assembly and operation of the product.
DO NOT perform any work until you have read
and understood these instructions completely.
Torque wrench tightening specifications must
strictly be adhered to.
Should removal of any locking fastener (lock tabs,
locknuts, or patch screws) be required, always
replace with a new one.
When replacement parts are required, use Evin-
rude/Johnson Genuine Parts or parts with equiva-
lent characteristics, including type, strength and
material. Use of substandard parts could result in
injury or product malfunction.
Always wear EYE PROTECTION AND APPRO-
PRIATE GLOVES when using power tools.
Unless otherwise specified, engine must be OFF
when performing this work.
Always be aware of parts that can move, such as
flywheels, propellers, etc.
Some components may be HOT. Always wait for
engine to cool down before performing work.
If you use procedures or service tools that are not
recommended in this manual, YOU ALONE must
decide if your actions might injure people or dam-
age the outboard.
This document may be translated into other lan-
guages. In the event of any discrepancy, the
English version shall prevail.
DANGER
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not
avoided, could result in death or serious
injury.
CAUTION
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate
personal injury.
NOTICE
Indicates an instruction which, if not fol-
lowed, could severely damage engine com-
ponents or other property.
ENVIRONMENTAL NOTE
A note which provides tips and behaviors related
to protecting the environment.

1
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 propel-
ler can continue to turn even after the engine is off. Remove propeller before servicing and when
running the outboard on a flushing device.
DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to
accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can
cause serious brain damage or death.
WARNING
Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172
kPa).
The motor cover and flywheel cover are machinery guards. Use caution when conducting tests
on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and clothing
away from rotating parts.
During service, the outboard may drop unexpectedly. Avoid personal injury; always support the
outboard’s weight with a suitable hoist or the tilt support bracket during service.
To prevent accidental starting while servicing, disconnect the battery cables at the battery. Twist
and remove all spark plug leads.
The electrical system presents a serious shock hazard. DO NOT handle primary or secondary
ignition components while outboard is running or flywheel is turning.
Gasoline is extremely flammable and highly explosive under certain conditions. Use caution
when working on any part of the fuel system.
Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve
fuel system pressure.
Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular phones
in the vicinity of a fuel leak or while fueling.
Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and
causing an explosion.
Always work in a well ventilated area.
Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Defi-
nite resistance to tightening must be felt when reusing a locking fastener. If replacement is indi-
cated, use only authorized replacement or equivalent.

Reference Information
Abbreviations Used In This Manual
6
Abbreviations Used In This Manual
Units of Measurement List of Abbreviations
A Amperes
amp-hr Ampere hour
fl. oz. fluid ounce
ft. lbs. foot pounds
HP horsepower
in. inch
in. Hg inches of mercury
in. lbs. inch pounds
kPa kilopascals
ml milliliter
mm millimeter
N·m Newton meter
P/N part number
psi pounds per square inch
RPM revolutions per minute
°C degrees Celsius
°F degrees Fahrenheit
ms milliseconds
µs microseconds
ΩOhms
VVolts
VAC Volts Alternating Current
VDC Volts Direct Current
ABYC American Boat & Yacht Council
ATDC after top dead center
AT air temperature sensor
BPS barometric pressure sensor
BTDC before top dead center
CCA cold cranking amps
CFR Code of Federal Regulations
CPS crankshaft position sensor
EMM Engine Management Module
EPA Environmental Protection Agency
ICOMIA International Council of Marine
Industry Associations
ID Inside dimension
MCA marine cranking amps
MWS modular wiring system
NMEA National Marine Electronics Assoc.
ROM read only memory
S.A.F.E. speed adjusting failsafe electronics
SAC start assist circuit
SAE Society of Automotive Engineers
SYNC synchronization
TDC top dead center
TPS throttle position sensor
USCG United States Coast Guard
WOT wide open throttle
WTS water temperature sensor

7
Reference Information
Standard Torque Specifications
1
Standard Torque
Specifications Product Reference and Illustrations
BRP US Inc. reserves the right to make changes
at any time, without notice, in specifications and
models and also to discontinue models. The right
is also reserved to change any specifications or
parts, at any time, without incurring any obligation
to equip same on models manufactured prior to
date of such change. Specifications used are
based on the latest product information available
at the time of publication.
The continuing accuracy of this manual cannot be
guaranteed.
All photographs and illustrations used in this man-
ual may not depict actual models or equipment,
but are intended as representative views for refer-
ence only.
Certain features or systems discussed in this
manual might not be found on all models in all
marketing areas.
All service technicians must be familiar with nauti-
cal orientation. This manual often identifies parts
and procedures using these terms.
Size In. Lbs. Ft. Lbs. N·m
No. 6 7–10 0.58–0.83 0.8–1.1
No. 8 15–22 1.25–1.83 1.7–2.5
No. 10 24–36 2–3 2.7–4.0
No. 12 36–48 3–4 4.0–5.4
1/4 in. 60–84 5–7 7-9.5
5/16 in. 120–144 10–12 13.5–16.5
3/8 in. 216–240 18–20 24.5–27
7/16 in. 336–384 28–32 38–43.5
M3 15–22 1.25–1.83 1.7–2.5
M4 24–35 2–2.9 2.7–4.0
M5 35–60 2.9–5 4.0–6.8
M6 84–106 7–8.8 9.5–12
M8 177–204 14.7–17 20–23
M10 310–336 25.8–28 35–38
IMPORTANT: These values apply only when
a specific torque for a specific fastener is not list-
ed in the appropriate section. When tightening
two or more screws on the same part, DO NOT
tighten screws completely, one at a time.
WARNING
Torque wrench tightening specifications
must be strictly adhered to. Replace any lock-
ing fastener (locknut or patch screw) if its
locking feature becomes weak. Definite resis-
tance to turning must be felt when reusing a
locking fastener.
If replacement is specified or required
because the locking fastener has become
weak, use only authorized Evinrude Genuine
Parts.
Nautical Orientation 006411

8
Reference Information
Emission-Related Installation Instructions
Emission-Related Installation
Instructions
Failing to follow these instructions when installing a certified engine in a vessel violates federal
law (40 CFR 1068.105 (b)), subject to fines or other penalties as described in the Clean Air Act.
A repair shop or person of the owner's choosing may maintain, replace, or repair emission control
devices and systems. These instructions do not require components or service by BRP or authorized
Evinrude dealers. Although an authorized Evinrude dealer has the in-depth technical knowledge and
tools to service Evinrude outboard engines, the emission-related warranty is not conditioned on the use
of an authorized Evinrude dealer or any other establishment with which BRP has a commercial relation-
ship.
For emission-related warranty claims, BRP is limiting the diagnosis and repair of emission-related parts
to authorized Evinrude dealers. For more information, please refer to the US EPA EMISSION-RELATED
WARRANTY contained in the Operator’s Guide. Proper maintenance is the owner's responsibility. A
warranty claim may be denied if, among other things, the owner or operator caused the problem through
improper maintenance or use.
You must follow the instructions for fuel requirements in the FUEL REQUIREMENTS section of this man-
ual. Even if gasoline containing greater than ten volume percent ethanol is readily available, the US EPA
has issued a prohibition against the use of gasoline containing greater than 10 vol% ethanol that applies
to this engine. The use of gasoline containing greater than 10 vol% ethanol with this engine may harm
the emission control system.
Manufacturer’s Responsibility
Beginning with 1999 model year outboards, manufacturers of marine outboards must determine the
exhaust emission levels for each outboard horsepower family and certify these outboards with the
United States of America Environmental Protection Agency (EPA). An emissions control information
label, showing emission levels and outboard specifications, must be placed on each outboard at the time
of manufacture.
Dealer’s Responsibility
When performing service on all 1999 and more recent Evinrude outboards that carry an emissions con-
trol information label, adjustments must be kept within published factory specifications.
Replacement or repair of any emission related component must be executed in a manner that maintains
emission levels within the prescribed certification standards.
Dealers are not to modify the outboard in any manner that would alter the horsepower or allow emission
levels to exceed their predetermined factory specifications.
Exceptions include manufacturer’s prescribed changes, such as altitude adjustments, for example.
Owner’s Responsibility
The owner/operator is required to have outboard maintenance performed to maintain emission levels
within prescribed certification standards.

Reference Information
Emission-Related Installation Instructions
9
1
The owner/operator is not to, and should not allow anyone to, modify the outboard in any manner that
would alter the horsepower or allow emissions levels to exceed their predetermined factory specifica-
tions.
Tampering with the fuel system to change horsepower or modify emission levels beyond factory settings
or specifications will void the product warranty.
EPA Emission Regulations
All new 1999 and more recent Evinrude outboards are certified to the EPA as conforming to the require-
ments of the regulations for the control of air pollution from new watercraft marine spark ignition out-
boards. This certification is contingent on certain adjustments being set to factory standards. For this
reason, the factory procedure for servicing the product must be strictly followed and, whenever practical,
returned to the original intent of the design. The responsibilities listed above are general and in no way a
complete listing of the rules and regulations pertaining to the EPA requirements on exhaust emissions
for marine products. For more detailed information on this subject, you may contact the following loca-
tions:
U.S. Environmental Protection Agency
Office of Transportation and Air Quality
Certification Division
Gasoline Engine Compliance Center
2000 Traverwood Drive
Ann Arbor, MI 48105
EPA Internet Web Site:
www.epa.gov/otaq

10
Reference Information
Model Designation
Model Designation
Engine Identification
Model and serial numbers are located on the swivel bracket and on the powerhead.
1. Model and serial number
2. Serial number 010518
010519
B E 90 DG X AF A
STYLE:
AAlternate
Feature
JJohnson
EEvinrude
HORSEPOWER SHAFT LENGTH:
15 in. Std.
L20 in. Long
X25 in. X-long
Z30 in. XX-long
MODEL IDENTIFICATION *
The first two characters identify
Model Version:
AA A First major variant
AB A Second major variant
AF A Third major variant
Outboards built after April 2012:
• follow the model identification shown
above.
• subsequent versions continue through
the alphabet as AG, AH etc.
• will not use letters from the word
INTRODUCES to identify models.
*Refer to Administrative Bulletin 2012-03(A)
for additional information.
DESIGN FEATURES:
CCounter Rotation
DEvinrude E-TEC
EElectric Start w/Remote Steering
GGraphite Paint
HHigh Output
JJet Drive
MMilitary
NPontoon Series, No Oil Tank
PPower Trim and Tilt
RRope Start w/Tiller Steering
SSaltwater Approved
TTiller Steering
PREFIX:
BBodensee model
DICON model
The third character identifies
Model Revision:
AA A First revision
AA B Second revision
Subsequent revisions continue
through the alphabet in order
(A through Z).
12

Reference Information
Model Designation
11
1
Models Covered
This manual covers service information on the following Evinrude E-TEC models:
•52.7 cubic inch (.86 L), 2-Cylinder starting with serial number 5409508.
•79 cubic inch (1.29 L), 3-Cylinder starting with serial number 5409506.
Model Shaft
Number Length Type Gear Ratio
40 E40DRLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Tiller Rope Manual
E40DRGLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Tiller Rope Manual
E40DRMLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Tiller Rope Manual
E40DPLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Remote Electric Power Tilt
E40DPGLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Remote Electric Power Tilt
E40DSLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Remote Electric Power Tilt
E40DTLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Tiller Electric Power Tilt
E40DGTLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Tiller Electric Power Tilt
E40DHLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Remote Electric Power Tilt
E40DHGLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Remote Electric Power Tilt
E40DHSLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Remote Electric Power Tilt
E40DPJLAG_ 25 I2 Jet N/A Remote Electric Power Tilt
50 E50DPLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Remote Electric Power Tilt
E50DPGLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Remote Electric Power Tilt
E50DSLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Remote Electric Power Tilt
E50DTLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Tiller Electric Power Tilt
E50DGTLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Tiller Electric Power Tilt
60 E60DPLAGA 20 I2 F 11:32, 0.34, 2.90:1 Remote Electric Power Tilt
E60DPGLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Remote Electric Power Tilt
E60DSLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Remote Electric Power Tilt
E60DTLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Tiller Electric Power Tilt
E60DGTLAG_ 20 I2 F 11:32, 0.34, 2.90:1 Tiller Electric Power Tilt
E60HGLAF_ 20 I3 S2 11:26, 0.42, 2.36:1 Remote Electric Power Trim/Tilt
E60HGXAF_ 25 I3 S2 11:26, 0.42, 2.36:1 Remote Electric Power Trim/Tilt
E60DPJLAF_ 25 I3 Jet N/A Remote Electric Power Trim/Tilt
65 E65SLAF_ 120 I3 S2 11:26, 0.42, 2.36:1 Remote Electric Power Trim/Tilt
E65GLAF_ 120 I3 S2 11:26, 0.42, 2.36:1 Remote Electric Power Trim/Tilt
E65SNLAF_ 120 I3 S2 11:26, 0.42, 2.36:1 Remote Electric Power Trim/Tilt
E65GNLAF_ 120 I3 S2 11:26, 0.42, 2.36:1 Remote Electric Power Trim/Tilt
75 E75DPLAF_ 20 I3 S 13:26, 0.50, 2.0:1 Remote Electric Power Trim/Tilt
E75DPGLAF_ 20 I3 S 13:26, 0.50, 2.0:1 Remote Electric Power Trim/Tilt
E75DSLAF_ 20 I3 S 13:26, 0.50, 2.0:1 Remote Electric Power Trim/Tilt
90 E90DPLAF_ 20 I3 S 13:26, 0.50, 2.0:1 Remote Electric Power Trim/Tilt
E90DPGLAF_ 20 I3 S2 11:26, 0.42, 2.36:1 Remote Electric Power Trim/Tilt
E90DPXAF_ 25 I3 O 12:27, 0.444, 2.25:1 Remote Electric Power Trim/Tilt
E90DGXAF_ 25 I3 O 12:27, 0.444, 2.25:1 Remote Electric Power Trim/Tilt
E90DSLAF_ 20 I3 S2 11:26, 0.42, 2.36:1 Remote Electric Power Trim/Tilt
E90SLAF_ 120 I3 S2 11:26, 0.42, 2.36:1 Remote Electric Power Trim/Tilt
E90SLAF_ 120 I3 S2 11:26, 0.42, 2.36:1 Remote Electric Power Trim/Tilt
E90GLAF_ 120 I3 S2 11:26, 0.42, 2.36:1 Remote Electric Power Trim/Tilt
E90SNLAF_ 120 I3 S2 11:26, 0.42, 2.36:1 Remote Electric Power Trim/Tilt
E90GNLAF_ 120 I3 S2 11:26, 0.42, 2.36:1 Remote Electric Power Trim/Tilt
1. Pontoon Series
60
H.O.
Engine Gearcase MidsectionSteering StartingHP

12
Reference Information
Service Specifications, 40 – 60 HP
Service Specifications, 40 – 60 HP
Service Specifications
HP 40 40 H.O. 50 60
Engine
Full Throttle Operating Range 5000-6000 RPM 5000-6000 RPM 5500-6000 RPM 5500-6000 RPM
Power 40HP(29.4kw)@
5500 RPM 40 HP (29.4 kw) @ 5500 RPM 50 HP (36.8 kw) @ 5750 RPM 60 HP (44.1 kw) @ 5750 RPM
Idle RPM in NEUTRAL 750 ± 50 EMM Controlled
Idle RPM in Gear 800 ± 50 EMM Controlled
Weight
(may vary depending on model) (RL) Models: 232 lbs. (105 kg) (HL, PL, SL, TL) Models: 240 lbs. (109 kg)
Engine Type In-line, 2 Cylinder, Two-Cycle
Displacement 52.7 cu. in. (864 cc)
Bore 3.601 in (91.47 mm)
Stroke 2.588 in. (65.74 mm)
Standard Bore 3.6005 to 3.6015 in. (91.45 to 91.48 mm)
To bore oversize, add piston oversize dimension to standard bore
Top Crankshaft Journal 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Center Crankshaft Journal 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Bottom Crankshaft Journal 1.5747 to 1.5752 in. (40.0 to 40.01 mm)
Rod Crankpin 1.3757 to 1.3762 in. (34.94 to 34.96 mm)
Piston Ring End Gap, Both 0.011 to 0.023 in. (0.28 to 0.58 mm)
Fuel System
Fuel/Oil Control EMM Controlled
Starting Enrichment EMM Controlled
Preferred Fuel Regular unleaded gasoline
Acceptable Fuel
Use unleaded regular gasoline. The use of unleaded gasoline containing alcohol
above the percentage specified by government regulations is not recommended. Do
NOT use Fuel labeled "E85." Use of fuel labeled E15 is prohibited by U.S. EPA Reg-
ulations.
Minimum Octane 87 AKI (R+M)/2 or 90 RON
Additives 2+4 ®Fuel Conditioner, Fuel System Cleaner
Use of other additives may result in engine damage.
Minimum (High) Fuel Pressure 24 to 28 psi (165 to 193 kPa)
Minimum Fuel Lift Pump Pressure 3 psi (21 kPa)
Maximum Fuel Inlet Vacuum 4 in. Hg.

Reference Information
Service Specifications
13
1
HP 40 40 H.O. 50 60
Oil System
Lubricant – Preferred Lubricant
–Acceptable Lubricant Evinrude/Johnson XD100, XD50, XD30; or NMMA TC-W3 certified
Capacity 2 qt. (1.9 l)
Cooling System
Thermostat 143°F (62°C)
Maximum Temperature 212°F (100°C)
Water pressure 12 to 14 psi @ 5000 RPM
Electrical System
Minimum Battery Requirements 640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C)
Alternator 25-Amp fully regulated. Refer to Installation and Predelivery Guide for multiple bat-
tery applications.
Tachometer Setting 6 pulse (12 pole)
Engine Fuse P/N 967545 – 10 A
Ignition System
Type Capacitor Discharge
Firing Order 1-2
Ignition Timing EMM Controlled
RPM Limit in Gear 6250
RPM Limit in Neutral 1800
Crankshaft Position Sensor Air
Gap Fixed
Spark Plug Refer to Emission Control Information Label
Champion†QC10WEP @ 0.028 ± 0.003 in. (0.71 mm)
Gearcase
Gear Ratio 11:32, 0.34, 2.90:1
Lubricant
– Capacity Evinrude HPF Pro Lubricant 22 fl. oz. (650 ml)
Shift Rod Height 20 in. (L) Models: 21.38 (543 mm) ± one-half turn
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD
Trim & Tilt System (Full Featured)
Lubrication Evinrude/Johnson Power Trim & Tilt Fluid, P/N 775612
Fluid Capacity 15.2 fl. oz. (450 ml)
Trim Range 0° to 15°
Tilt Range 16° to 65°

14
Reference Information
Service Specifications, 60 H.O. – 90 HP
Service Specifications, 60 H.O. – 90 HP
Service Specifications
HP 60 H.O. 65 75 90
Engine
Full Throttle Operating Range 5000-5500 RPM 4500-5500 RPM 4500-5500 RPM 4500-5500 RPM
Power 60 HP (44.1 kw)
@ 5000 RPM 65 HP (47.8 kw) @ 5000 RPM 75 HP (56 kw)
@ 5000 RPM 90 HP (67.1 kw) @ 5000 RPM
Idle RPM in NEUTRAL 600 ± 50 EMM Controlled
Idle RPM in Gear 700 ± 50 EMM Controlled
Weight
(may vary depending on model) (L) Models: 320 lbs. (145 kg)
(X) Models: 335 lbs. (152 kg)
Engine Type In-line, 3 Cylinder, Two-Cycle
Displacement 79.1 cu. in. (1296 cc)
Bore 3.601 in (91.47 mm)
Stroke 2.588 in. (65.74 mm)
Standard Bore 3.6005 to 3.6015 in. (91.45 to 91.48 mm)
To bore oversize, add piston oversize dimension to standard bore
Top Crankshaft Journal 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Center Crankshaft Journal 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Bottom Crankshaft Journal 1.5747 to 1.5752 in. (40.0 to 40.01 mm)
Rod Crankpin 1.3757 to 1.3762 in. (34.94 to 34.96 mm)
Piston Ring End Gap, Both 0.011 to 0.023 in. (0.28 to 0.58 mm)
Fuel System
Fuel/Oil Control EMM Controlled
Starting Enrichment EMM Controlled
Preferred Fuel Regular unleaded gasoline
Acceptable Fuel
Unleaded regular gasoline. The use of unleaded gasoline containing alcohol above
the percentage specified by government regulations is not recommended. Do NOT
use Fuel labeled "E85." Use of fuel labeled E15 is prohibited by U.S. EPA Regula-
tions.
Minimum Octane 87 AKI (R+M)/2 or 90 RON
Additives 2+4 ®Fuel Conditioner, Fuel System Cleaner
Use of other additives may result in engine damage.
Minimum (High) Fuel Pressure 24 to 28 psi (165 to 193 kPa)
Minimum Fuel Lift Pump Pressure 3 psi (21 kPa)
Maximum Fuel Inlet Vacuum 4 in. Hg.

Reference Information
Service Specifications
15
1
HP 60 H.O. 65 75 90
Oil System
Lubricant – Preferred Lubricant
–Acceptable Lubricant Evinrude/Johnson XD100, XD50, XD30; or NMMA TC-W3 certified
Capacity 2.4 qt. (2.3 l)
Cooling System
Thermostat 143°F (62°C)
Maximum Temperature 212°F (100°C)
Water pressure 19 to 21 psi @ 5000 RPM
Electrical System
Minimum Battery Requirements 640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C)
Alternator 25-Amp fully regulated. Refer to Installation and Predelivery Guide for multiple bat-
tery applications.
Tachometer Setting 6 pulse (12 pole)
Engine Fuse P/N 967545 – 10 A
Ignition System
Type Capacitor Discharge
Firing Order 1-2-3
Ignition Timing EMM Controlled
RPM Limit in Gear 6250
RPM Limit in Neutral 1800
Crankshaft Position Sensor Air Gap Fixed
Spark Plug Refer to Emission Control Information Label
Champion†QC10WEP @ 0.028 ± 0.003 in. (0.71 mm)
Gearcase
Gear Ratio Refer to Models Covered on p. 11.
Lubricant
– Capacity
Evinrude HPF Pro Lubricant
20 in. (L) Models: 31.6 fl. oz. (935 ml)
25 in. (X) Models: 32.8 fl. oz. (970 ml)
Shift Rod Height 20 in. (L) Models: 21.25 (539.75 mm) ± one-half turn
25 in. (X) Models: 26.25 (666.75 mm) ± one-half turn
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD
Trim & Tilt System
Lubrication Evinrude/Johnson Biodegradable TNT Fluid, P/N 763439
Fluid Capacity 21 fl. oz. (620 ml)
Trim Range 0° to 15°
Tilt Range 16° to 65°

Reference Information
Wire Size Table
16
Wire Size Table
This table provides closest equivalent size cross references between American and metric wire sizes.
American Wire Gauge
American Wire Gauge (AWG) is a standardized
wire gauge system used in North America to iden-
tify the diameter of round, electrically conducting
wire. Increasing gauge numbers result in decreas-
ing wire diameters.
The AWG of a stranded wire is determined by the
total cross sectional area of the conductor.
Because there are small gaps between the
strands, stranded wire will always have a slightly
larger overall diameter than a solid wire of the
same AWG.
Metric Wire Size
Metric wire size is also standardized. Metric wire
size is determined by the number of strands of
wires expressed in millimeters (mm) and the total
cross sectional area of the conductor, expressed
as square millimeters (mm²).
Example: 41/1.63 means forty–one strands of
wire, each with a 1.63 mm diameter. This example
has a cross sectional area of 2.08 mm².
Cross
Section (3) Cross Section (3)
(
in.
)
(
mm
)
(
mm²
)
(
in.
)
(
mm
)
(
mm²
)
6/0 3335 0.58 14.73 170.3 12 65 0.0808 2.05 3.31
5/0 2646 0.517 13.12 135.1 13 52 0.072 1.83 2.62
4/0 2109 0.46 11.7 107 14 41 0.0641 1.63 2.08
3/0 1665 0.41 10.4 85 15 32 0.0571 1.45 1.65
2/0 1330 0.365 9.26 67.4 16 26 0.0508 1.29 1.31
1/0 1064 0.325 8.25 53.5 17 21 0.0453 1.15 1.04
1 836 0.289 7.35 42.4 18 16 0.0403 1.02 0.823
2 664 0.258 6.54 33.6 19 13 0.0359 0.912 0.653
3 523 0.229 5.83 26.7 20 10 0.032 0.812 0.518
4 420 0.204 5.19 21.1 21 8 0.0285 0.723 0.41
5 329 0.182 4.62 16.8 22 6 0.0253 0.644 0.326
6 266 0.162 4.11 13.3 23 5 0.0226 0.573 0.258
7 206 0.144 3.66 10.5 24 4 0.0201 0.511 0.205
8 168 0.128 3.26 8.36 25 3 0.0179 0.455 0.162
9 130 0.114 2.91 6.63 27 2 0.0142 0.361 0.102
10 105 0.102 2.59 5.26 30 1 0.01 0.255 0.0509
11 82 0.0907 2.3 4.17
Notes: (1) 30 AWG (0.255 mm) conductor diameter
(2) Single wire strand diameter
(3) Total area cross section of all wire strands
Number
of Wire
Strands (1)
Conductor
Wire Strand
Diameter (2)
AWG
Number
of Wire
Strands (1)
Conductor
Wire Strand
Diameter (2) AWG

Routine Service
17
2
Routine Service
Table of Contents
Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lifting the Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Outboard Rigging Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Oetiker Clamp Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Steering Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Throttle Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Tilt Limit Switch Adjustment (3-Cylinder Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Trim Sending Unit Adjustment (2-Cylinder Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Trim Sending Unit Adjustment (3-Cylinder Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Dual-Outboard Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Water Intake Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Engine Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Running the Outboard Using a Hose and Flushing Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Tiller Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Swivel Bracket and Trailering Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Tilt Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Throttle and Shift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Gearcase Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Trim and Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Indexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Fuel and Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Oil Filters and Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Hoses and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Anti-Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Gearcase Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Pre-Season Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Submerged Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Oetiker Clamp Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

18
Routine Service
Inspection and Maintenance Schedule
Inspection and Maintenance Schedule
Routine inspection and maintenance is necessary to prolong outboard life. The following chart provides
guidelines for inspection and maintenance to be performed by an authorized Dealer.
IMPORTANT: Outboards used in rental, commercial, or other high hour applications require more fre-
quent inspections and maintenance. Adjust schedule for operating and environmental conditions.
Description of Service
Every 300 hours or every 3 years(1)
(1) Commercial use, heavy use, or use in salt or polluted water requires more frequent inspection and maintenance.
Routine Inspection
Engine Care Product
Anodes (anti–corrosion), check condition  
Back pressure probe, replace 
Batteries, check connections and condition  
Control cables, inspect and adjust 
Cooling system; check water pump indicator / water pressure  
Displays & gauges, self-test/warning horn, check operation  
Electrical and ignition wires, inspect for wear or chafing 
Emergency cut–off switch(es) and tether cord, check operation  
EMM, access EMM information, resolve any service codes 
Engine Monitor self-test and warning horn, check 
Engine to transom mounting hardware, re-tighten (40 ft. lbs.) 
Fuel and oil systems, inspect and repair leaks (2)
(2) Emission-related component
 
Fuel filters, replace 
Gearcase and water inlet screens, check condition  
Gearcase lubricant, replace A
Grease fittings, lubricate (3)
(3) Annually in salt water applications
C
Oil filter, replace 
Power tilt or power trim and tilt system, check operation B
Propeller, check condition  
Propeller shaft splines, inspect and lubricate (3) C
Remote control system and switches (START/STOP, Trim etc.) check operation 
Fault codes, access EMM information, resolve any fault codes 
Spark plugs, replace (2) 
Starter pinion shaft, inspect and lubricate (3) 
Steering: Cable systems, inspect and lubricate C
Steering: Hydraulic systems, inspect fluid level, check hydraulic hose condition, check operation E
Thermostats, inspect and check operation (2) 
Water pump, replace (more frequent if water pressure loss or overheating occurs) 

19
Routine Service
Lifting the Outboard
2
Engine Care Products
The engine care products listed in the table below are referenced in this service manual, and are recom-
mended for use with Evinrude E-TEC outboards.
Lifting the Outboard
Use correct Lifting Fixture to lift outboard:
With recoil starter removed, Place lifting tool on
flywheel and seat the three screws completely.
Refer to Recoil Starter Removal on p. 317.
Fasten appropriate chain hook to eye of tool.
Carefully hoist outboard with chain and unbolt out-
board mounting brackets from frame.
Engine Care Product Notes
AHPF Pro Gearcase Lubricant Containers available in various sizes, see PAC Catalog
B Biodegradable TNT Fluid, P/N 763439 Use only in Power Trim & Tilt System of 3-cylinder models
B Power Trim/Tilt Fluid, P/N 775612 Use only in Power Tilt System of 2-cylinder models
CTriple-Guard Grease, P/N 508298
D Starter Bendix Lube, P/N 337016 IMPORTANT: Use no other products
E Hydraulic Fluid, P/N 770891
Anti-Corrosion Spray
“6 in 1” Multi-Purpose Lubricant
WARNING
To avoid personal injury, make sure the lifting
capacity of the hoist is at least twice the
weight of the outboard.
DO NOT allow the lift hook or chain from the
hoist to come in contact with any part of the
engine during lifting.
NOTICE
Use only the 1 1/8 in. (short) screws,
P/N 398067, included with the tool to avoid
damage to electronic components under the
flywheel.
Model Lifting Fixture
40–90 HP P/N 396748 with
1 1/8 in. screws
1. Lifting fixture
2. 1 1/8 in. screws 002098
1
2

20
Routine Service
Outboard Rigging Connections
Outboard Rigging Con-
nections
IMPORTANT: For complete outboard rigging
and remote control installation information, refer to
the Predelivery and Installation Guide included
with the service manual set.
Common Practices – All Models
Control Cable Identification
IMPORTANT: Identify control cable function be-
fore rigging outboard.
Identify each control cable:
•Put the control handle into NEUTRAL position.
The throttle cable casing guide will retract com-
pletely and the shift cable casing guide will go to
the midpoint of its travel.
Extend the control cables and lubricate them with
Triple-Guard grease.
Cable Retainer Clip Installation
When installing retainer clips on control arm link-
age pins, clips should be locked and must not be
bent or deformed.
For proper installation, review the following steps:
•Place washer on pin.
•Position retainer clip with straight section on the
bottom and angled section on the top.
•Use long nose pliers to insert straight section of
clip into linkage pin hole.
•Push the clip towards the hole while lifting on
the curved end with the pliers.
•Be sure retainer clip fully engages the pin.
•Lock the retainer by moving the angled section
behind the straight section.
1. Shift cable casing guide extended to midpoint
2. Throttle cable casing guide retracted DP0811
30501
2
1
1. Straight section
2. Angled section 010302
Locked Retainer Clip
1. Angled section behind straight section 010303
1
2
1