BRP EVINRUDE E-TEC BE225HGXABA 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
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are registered trademarks of Tyco International, Ltd.
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† BEP is a registered trademark of Actuant Corporation.
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† 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 Engine Management Module (EMM) . . . . . . . . . . . . . . . . 57
5 System Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6 Electrical and Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8 Oiling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
10 Evinrude ICON Remote Control System . . . . . . . . . . . . 201
11 Powerhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
12 Midsection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
13 Trim and Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S–321
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I–345
Trouble Check Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . T–353
Diagrams
IMPORTANT: For complete outboard rigging and control installation information, refer to the Predeliv-
ery and Installation Guide included with the service manual set.
All special tools referenced in this manual can be found in the 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
Model Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service Specifications 90° 3.3 L Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Service Specifications 90° 3.4 L Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wire Size Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
WOhms
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
manual. 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
006828
B E 225 HG X AB 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:
•200.1 cubic inch (3.3 L) 90° V6, starting with serial number 5370453.
•210 cubic inch (3.4 L), 90° V6, starting with serial number 5368446.
Type Gear Ratio
E200HSLAB_ White 20 in. M2 13:24 / .542 / 1.85:1 Standard H.O.
E200DHLAB_ Blue 20 in. M2 13:24 / .542 / 1.85:1 Standard H.O.
E200DHXAB_ White 25 in. M2 13:24 / .542 / 1.85:1 Standard H.O.
E200HGLAB_ Graphite 20 in. M2 13:24 / .542 / 1.85:1 H.O. H.O.
E200HCXAB_ White 25 in.
M2
113:24 / .542 / 1.85:1 Standard H.O.
DE200XCAB_ White 25 in.
M2
113:24 / .542 / 1.85:1 Standard
H.O., EST
2
DE200HXAB_ White 25 in. M2 13:24 / .542 / 1.85:1 Standard
H.O., EST
2
225 E225DPXAB_ White 25 in. M2 13:24 / .542 / 1.85:1 Standard
E225DCXAB_ White 25 in.
M2
113:24 / .542 / 1.85:1 Standard
E225HSLAB_ White 20 in. M2 13:24 / .542 / 1.85:1 H.O. H.O.
E225DHLAB_ Blue 20 in. M2 13:24 / .542 / 1.85:1 H.O. H.O.
E225GHLAB_ Graphite 25 in. M2 13:24 / .542 / 1.85:1 H.O. H.O.
E225DHXAB_ Blue 25 in. M2 13:24 / .542 / 1.85:1 H.O. H.O.
E225HGXAB_ Graphite 25 in. M2 13:24 / .542 / 1.85:1 Standard
DE225CXAB_ White 25 in.
M2
113:24 / .542 / 1.85:1 Standard
EST
2
DE225PXAB_ White 25 in. M2 13:24 / .542 / 1.85:1 Standard
EST
2
250 E250DPXAB_ White 25 in. M2 13:24 / .542 / 1.85:1 Standard
DE250PXAB_ White 25 in. M2 13:24 / .542 / 1.85:1 Standard
EST
2
E250DCXAB_ White 25 in.
M2
113:24 / .542 / 1.85:1 Standard
DE250CXAB_ White 25 in.
M2
113:24 / .542 / 1.85:1 Standard
EST
2
E250DPZAB_ White 30 in. M2 13:24 / .542 / 1.85:1 Standard
DE250PZAB_ White 30 in. M2 13:24 / .542 / 1.85:1 Standard
EST
2
E250DCZAB_ White 30 in.
M2
113:24 / .542 / 1.85:1 Standard
DE250CZAB_ White 30 in.
M2
113:24 / .542 / 1.85:1 Standard
EST
2
E250HSLAB_ White 20 in. M2 13:24 / .542 / 1.85:1 H.O. H.O.
E250DHLAB_ Blue 20 in. M2 13:24 / .542 / 1.85:1 H.O. H.O.
E250DHXAB_ Blue 25 in. M2 13:24 / .542 / 1.85:1 H.O. H.O.
E250HGLAB_ Graphite 20 in. M2 13:24 / .542 / 1.85:1 H.O. H.O.
E250HGXAB_ Graphite 25 in. M2 13:24 / .542 / 1.85:1 H.O. H.O.
300 DE300PXAB_ White 25 in. M2 13:24 / .542 / 1.85:1 Standard
EST
2
DE300CXAB_ White 25 in.
M2
113:24 / .542 / 1.85:1 Standard
EST
2
DE300PZAB_ White 30 in. M2 13:24 / .542 / 1.85:1 Standard
EST
2
DE300CZAB_ White 30 in.
M2
113:24 / .542 / 1.85:1 Standard
EST
2
E300DSLAB_ White 20 in. M2 13:24 / .542 / 1.85:1 Standard
E300DPXAB_ White 25 in. M2 13:24 / .542 / 1.85:1 Standard
E300DGXAB_ Graphite 25 in. M2 13:24 / .542 / 1.85:1 Standard
E300DCXAB_ White 25 in.
M2
113:24 / .542 / 1.85:1 Standard
E300DPZAB_ White 30 in. M2 13:24 / .542 / 1.85:1 Standard
E300DCZAB_ White 30 in.
M2
113:24 / .542 / 1.85:1 Standard
1. Counter Rotation 2. Electronic Shift & Throttle
Special Features
200
H.O.
250
H.O.
HP Model Number Color Shaft
Length Gearcase Styling

Reference Information
Service Specifications 90° 3.3 L Models
12
Service Specifications 90° 3.3 L Models
ENGINE
HP 200, 225, 250
Full Throttle Operating Range 5250–6000 RPM
Power 200 HP: (147.1 kw) @ 5700 RPM
225 HP: (165.5 kw) @ 5700 RPM
250 HP: (183.9 kw) @ 5700 RPM
Idle RPM in Gear 500 ± 50
Weight
(may vary depending on model) 20 in. (L) Models: 503 lbs. (228 kg) 25 in. (X) Models: 524 lbs. (238 kg)
30 in. (Z) Models: 530 lbs. (240 kg)
Lubrication Evinrude/Johnson XD100 Oil
Refer to Recommended Lubricants on p. 168
Engine Type 90° V 6-Cylinder Loop-Charged
Displacement 200.1 cu. in. (3279 cm3)
Bore 3.854 in (97.89 mm)
Stroke 2.858 in. (72.60 mm)
Standard Bore 3.8535 to 3.8545 in. (97.87 to 97.90 mm)
To bore oversize, add piston oversize dimension to standard
bore
Top Crankshaft Journal 1.6199 to 1.6204 in. (41.15 to 41.16 mm)
Center Crankshaft Journals 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 1.4995 to 1.5000 in. (38.09 to 38.106 mm)
Piston Ring End Gap, Both 0.022 to 0.028 in. (0.57 to 0.72 mm)
FUEL
Fuel/Oil Ratio EMM Controlled
Starting Enrichment EMM Controlled
Preferred Fuel Regular unleaded gasoline
Acceptable Fuel See Fuel Requirements on p. 138 for additional information.
Minimum (High) Fuel Pressure
@ IDLE RPM – 500 ± 50 22 to 28 psi (152 to 193 kPa)
Minimum Fuel Lift Pump Pressure
@ IDLE RPM – 500 ± 50 3 psi (21 kPa)
Maximum Fuel Inlet Vacuum 4 in. Hg. (13.5 kPa)
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.
See Fuel Requirements on p. 138 for additional information.

13
Reference Information
Service Specifications 90° 3.3 L Models
1
ELECTRICAL
HP 200, 225, 250
Minimum Battery
Requirements 675 CCA (845 MCA); or 750 CCA (940 MCA) below 32°F (0°C)
(Use a 107 amp-hr battery for extreme applications.)
Alternator Dual Voltage 50 Amp with Voltage Regulator and Battery Iso-
lation. Refer to Predelivery and Installation Guide for multi-
ple battery applications.
Tachometer Setting 6 pulse (12 pole)
Charging Isolator Integral, Terminal on Engine Harness
Engine Fuse P/N 967545 – 10 A
COOLING
Thermostat 143°F (62°C)
Maximum Temperature 190°F (88°C)
Water pressure 15 to 17 psi @ 5000 RPM
IGNITION
Type Capacitor Discharge
Firing Order 1-2-3-4-5-6
Ignition Features EMM Controlled
RPM Limit 6050
Crankshaft Position Sensor Air Gap Fixed
Spark Plug Champion †QC8WEP @ 0.028 ± 0.003 in. (0.71 mm)
Refer to Electronic Parts Catalog (EPC)
GEARCASE
Gear Ratio “M2” Type Gearcase: 13:24 (.542) (1.85:1)
Lubricant HPF Pro Gearcase Lubricant
Capacity “M2” Type Gearcase: 38.9 fl. oz. (1150 ml)
“M2” Type – Counter Rotation: 35.8 fl. oz. (1060 ml)
Shift Rod Height 20 in. (L) Models: 21 29/32 (556.25 mm) ± one-half turn
25 in. (X) Models: 26 29/32 (683.25 mm) ± one-half turn
30 in. (Z) Models: 31 29/32 (810.25 mm) ± one-half turn
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEU-
TRAL and FORWARD
POWER TRIM/TILT
Lubrication Power Trim/Tilt & Power Steering Fluid or
GM Dexron †II Automatic Transmission Fluid
Fluid Capacity 21 fl. oz. (622 ml)
Trim Range 0° to 21°
Tilt Range 22° to 75°
Tilt UP Stall Pressure 1500 psi (10342 kPa)
Tilt IN Stall Pressure 800 psi (5516 kPa)

Reference Information
Service Specifications 90° 3.4 L Models
14
Service Specifications 90° 3.4 L Models
ENGINE
HP 250, 300
Full Throttle Operating Range 5300–6000 RPM
Power 250 HP: (183.9 kw) @ 5600 RPM
300 HP: (220.6 kw) @ 5600 RPM
Idle RPM in Gear 500 ± 50
Weight
(may vary depending on model) 20 in. (L) Models: 507 lbs. (230 kg) 25 in. (X) Models: 528 lbs. (239 kg)
30 in. (Z) Models: 534 lbs. (242 kg)
Lubrication Evinrude/Johnson XD100 Oil
Refer to Recommended Lubricants on p. 168
Engine Type 90° V 6-Cylinder Loop-Charged
Displacement 210.0 cu. in. (3441 cc)
Bore 3.854 in (97.89 mm)
Stroke 3.000 in. (76.20 mm)
Standard Bore 3.8535 to 3.8545 in. (97.87 to 97.90 mm)
To bore oversize, add piston oversize dimension to standard
bore
Top Crankshaft Journal 1.6199 to 1.6204 in. (41.15 to 41.16 mm)
Center Crankshaft Journals 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 1.4995 to 1.5000 in. (38.09 to 38.106 mm)
Piston Ring End Gap, Both 0.022 to 0.028 in. (0.57 to 0.72 mm)
FUEL
Fuel/Oil Ratio EMM Controlled
Starting Enrichment EMM Controlled
Preferred Fuel Regular unleaded gasoline
Acceptable Fuel See Fuel Requirements on p. 138 for additional information.
Minimum (High) Fuel Pressure
@ IDLE RPM – 500 ± 50 22 to 28 psi (152 to 193 kPa)
Minimum Fuel Lift Pump Pressure
@ IDLE RPM – 500 ± 50 3 psi (21 kPa)
Maximum Fuel Inlet Vacuum 4 in. Hg. (13.5 kPa)
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.
See Fuel Requirements on p. 138 for additional information.

15
Reference Information
Service Specifications 90° 3.4 L Models
1
ELECTRICAL
HP 250, 300
Minimum Battery Requirements 675 CCA (845 MCA); or
750 CCA (940 MCA) below 32°F (0°C)
(Use a 107 amp-hr battery for extreme applications.)
Alternator Dual Voltage 50 Amp with Voltage Regulator and Battery Iso-
lation. Refer to Predelivery and Installation Guide for multi-
ple battery applications.
Tachometer Setting 6 pulse (12 pole)
Charging Isolator Integral, Terminal on Engine Harness
Engine Fuses P/N 967545 – 10 A
COOLING
Thermostat 143°F (62°C)
Maximum Temperature 190°F (88°C)
Water pressure 18 to 25 psi @ 5000 RPM
IGNITION
Type Capacitor Discharge
Firing Order 1-2-3-4-5-6
Ignition Features EMM Controlled
RPM Limit 6050
Crankshaft Position Sensor Air Gap Fixed
Spark Plug Champion †QC8WEP @ 0.028 ± 0.003 in. (0.71 mm)
Refer to Electronic Parts Catalog (EPC)
GEARCASE
Gear Ratio “M2” Type Gearcase: 13:24 (.542) (1.85:1)
Lubricant HPF Pro Gearcase Lubricant
Capacity “M2” Type Gearcase: 38.9 fl. oz. (1150 ml)
“M2” Type – Counter Rotation: 35.8 fl. oz. (1060 ml)
Shift Rod Height 20 in. (L) Models: 21 29/32 (556.25 mm) ± one-half turn
25 in. (X) Models: 26 29/32 (683.25 mm) ± one-half turn
30 in. (Z) Models: 31 29/32 (810.25 mm) ± one-half turn
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEU-
TRAL and FORWARD
POWER TRIM/TILT
Lubrication Power Trim/Tilt & Power Steering Fluid or
GM Dexron †II Automatic Transmission Fluid
Fluid Capacity 21 fl. oz. (622 ml)
Trim Range 0° to 21°
Tilt Range 22° to 75°
Tilt UP Stall Pressure 1500 psi (10342 kPa)
Tilt IN Stall Pressure 800 psi (5516 kPa)

16
Reference Information
Wire Size Table
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 identify the
diameter of round, electrically conducting wire. Increasing gauge numbers result in decreasing 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 diame-
ter 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
Cable, Hose, and Wire Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Control Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Battery Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SystemCheck Harness Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
I-Command Network Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ICON Network Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Water Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Oetiker Clamp Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Tilt Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Trim Sending Unit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Dual-Outboard Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Engine Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Running the Outboard Using a Hose and Flushing Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Tilt Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Swivel Bracket and Trailering Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Throttle and Shift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Gearcase Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Trim and Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Indexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fuel and Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Oil Filters and Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Hoses and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Exhaust Pressure Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Anti-Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Gearcase Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Pre-Season Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Submerged Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Oetiker Clamp Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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:
Place lifting tool on flywheel and seat the three
screws completely.
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 all other 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.
Model Lifting Fixture
90° V6 P/N 396748 with
1 3/4 in. screws
1. Lifting fixture
2. 1 3/4 in. screws (Qty. 3) 002419
2
1

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