BRP EVINRUDE E-TEC 115 HP 2011 User manual

Printed in the United States.
© 2010 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
BRP US Inc.
Technical Publications
250 Sea Horse Drive
Waukegan, Illinois 60085 United States
† 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:
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 HPF XR™ Gearcase Lubricant
Evinrude ® / Johnson ® XD100™ Outboard Oil HPF PRO™ Gearcase Lubricant
Gel-Seal II™

2
SERVICE MANUAL
CONTENTS
SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE
1 REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
2 ROUTINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 ENGINE COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . 47
4 ENGINE MANAGEMENT MODULE (EMM) . . . . . . . . . . 51
5 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . . 85
7 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
8 OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
9 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
10 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
11 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
12 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
GEARCASE – STANDARD ROTATION . . . . . . . . . . . . 275
GEARCASE – COUNTER ROTATION . . . . . . . . . . . . . 307
13 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S–1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I–1
TROUBLE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . T–1
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, P/N 5008526.

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
EMISSION-RELATED INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
MANUFACTURER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
DEALER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OWNER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
EPA EMISSION REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

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:
Indicates an instruction which, if
not followed, could severely damage engine
components or other property.
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
Evinrude/Johnson Genuine Parts or parts with
equivalent 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 seri-
ous injury
CAUTION
Indicates a hazardous situation which, if
not avoided, could result in minor or mod-
erate personal injury.
NOTICE

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 propeller can continue to turn even after the engine is off. Remove propeller before ser-
vicing 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.
Definite resistance to tightening must be felt when reusing a locking fastener. If replacement
is indicated, use only authorized replacement or equivalent.

6
REFERENCE INFORMATION
ABBREVIATIONS USED IN THIS MANUAL
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
Ohms
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
EMISSION-RELATED INSTALLATION INSTRUCTIONS
1
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.
Maintenance, replacement, or repair of the emis-
sion control devices and systems may be per-
formed by any marine SI (spark ignition) engine
repair establishment or individual.
Manufacturer’s Responsibility
Beginning with 1999 model year outboards, man-
ufacturers 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/Johnson outboards that carry an
emissions control information label, adjustments
must be kept within published factory specifica-
tions.
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 exam-
ple.
Owner’s Responsibility
The owner/operator is required to have outboard
maintenance performed to maintain emission lev-
els within prescribed certification standards.
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 emis-
sions levels to exceed their predetermined factory
specifications.
Tampering with the fuel system to change horse-
power or modify emission levels beyond factory
settings or specifications will void the product war-
ranty.
EPA Emission Regulations
All new 1999 and more recent Evinrude/Johnson
outboards are certified to the EPA as conforming
to the requirements of the regulations for the con-
trol of air pollution from new watercraft marine
spark ignition outboards. This certification is con-
tingent 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 list-
ing 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:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
501 3rd St. NW
Washington, DC 20001
EPA INTERNET WEB SITE:
www.epa.gov

8
REFERENCE INFORMATION
MODEL DESIGNATION
MODEL DESIGNATION
Model and serial numbers are located on the swivel bracket and on the powerhead.
BE 200 DP X II E
STYLE:
J = Johnson
E = Evinrude
HORSEPOWER
LENGTH:
= 15” Std.
L = 20” Long
Y = 22.5” Special
X = 25” X-long
Z = 30” XX-long
MODEL YR:
I=1
N=2
T=3
R=4
O=5
D=6
U=7
C=8
E=9
S=0
Ex: II = 2011
MODEL RUN
or SUFFIX
DESIGN FEATURES:
B = Blue Paint
C = Counter Rotation
D = Evinrude E-TEC®
E = Electric Start w/Remote Steering
F = Direct-Injection
G = Graphite Paint
H = High Output
J = Jet Drive
M = Military
P = Power Trim and Tilt
R = Rope Start w/Tiller Steering
S = Saltwater Approved
T = Tiller Steering
TE = Tiller Electric
V = White Paint
W = Commercial Model
PREFIX:
B = Bodensee model
D = ICON model
1. Model and serial number 005231
1
1. Serial number 005232
1

REFERENCE INFORMATION
MODELS COVERED IN THIS MANUAL
9
1
MODELS COVERED IN THIS MANUAL
This manual covers service information on all 105.4 cubic inch (1.7 L) and 158.2 cubic inch (2.6 L), 60° V
Evinrude E-TEC models.
Mode
l
Dis
p
lacement Gearcase Hei
g
ht Color Description
E115DPLIIB 1.7 L,105.4 ci .500 S2 20" Blue Steel Steering Arm,Standard Styling
E115DSLIIB 1.7 L,105.4 ci .500 S2 20" White Stainless Steering Arm,Standard Styling
E115DBXIIB 1.7 L, 105.4 ci .444 O 25" Blue Stainless Steering Arm, Standard Styling
E115DPXIIB 1.7 L, 105.4 ci .444 O 25" White Stainless Steering Arm, Standard Styling
E115DCXIIA 1.7 L,105.4 ci .444 OCR 25" White Stainless Steering Arm,Standard Styling
E115DHLIIR 1.7 L,105.4 ci .500 S2 20" Blue Steel Steering Arm,H.O.Styling
E115DHXIIR 1.7 L,105.4 ci .444 O 25" White Stainless Steering Arm,H.O.Styling
E115HSLIIR 1.7 L,105.4 ci .500 S2 20" White Stainless Steering Arm, H.O.Styling
E130DPLIIR 1.7 L,105.4 ci .500 S2 20" Blue Steel Steering Arm,Standard Styling
E130DSLIIR 1.7 L,105.4 ci .500 S2 20" White Stainless Steering Arm, Standard Styling
E130DPXIIR 1.7 L,105.4 ci .444 O 25" White Steel Steering Arm,Standard Styling
E130DCXIIR 1.7 L,105.4 ci .444 OCR 25" White Stainless Steering Arm,Standard Styling
E150DPLIIB 2.6 L,158.2 ci .538 O 20" Blue Steel Steering Arm, Standard Styling
E150DHLIIB 2.6 L, 158.2 ci .538 L2 20" Blue Steel Steering Arm,H.O.Styling
E150HSLIIA 2.6 L,158.2 ci .538 L2 20" White Stainless Steering Arm,H.O.Styling
E150DSLIIB 2.6 L,158.2 ci .538 O 20" White Stainless Steering Arm,Standard Styling
E150DBXIIB 2.6 L, 158.2 ci .542 M2 25" Blue Stainless Steering Arm,Standard Styling
E150DPXIIB 2.6 L, 158.2 ci .542 M2 25" White Stainless Steering Arm,Standard Styling
E150DCXIIB 2.6 L,158.2 ci .542 M2 CR 25" White Stainless Steering Arm, Standard Styling
E175DPLIIB 2.6 L,158.2 ci .538 O 20" Blue Steel Steering Arm, Standard Styling
E175DSLIIB 2.6 L,158.2 ci .538 O 20" White Stainless Steering Arm,Standard Styling
E175DPXIIB 2.6 L, 158.2 ci .542 M2 25" White Stainless Steering Arm,Standard Styling
E175DCXIIB 2.6 L,158.2 ci .542 M2 CR 25" White Stainless Steering Arm, Standard Styling
E200DPLIIE 2.6 L,158.2 ci .538 O 20" Blue Steel Steering Arm, Standard Styling
E200DSLIIE 2.6 L,158.2 ci .538 O 20" White Stainless Steering Arm,Standard Styling
E200DPXIIE 2.6 L, 158.2 ci .542 M2 25" White Stainless Steering Arm,Standard Styling
E200DCXIIE 2.6 L,158.2 ci .542 M2 CR 25" White Stainless Steering Arm, Standard Styling

10
REFERENCE INFORMATION
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
ENGINE
HP 115, 130 150, 175, 200
Full Throttle
Operating Range 5500–6000 RPM 4850–5850 RPM
Power 115 HP: (85.8 kw) @ 5750 RPM
130 HP: (96.9 kw) @ 5750 RPM
150 HP: (111.9 kw) @ 5350 RPM
175 HP: (130.5 kw) @ 5350 RPM
200 HP: (149.1 kw) @ 5350 RPM
Idle RPM in Gear 115: 625 ± 50
115 HO, 130: 580 ± 50 500 ± 50
Test Propeller V4 20 in. (L) Models: P/N 386246 or P/N 433068 V4 25 in. (X) and V6 Standard Rotation Models: P/N 387388
V6 Counter Rotation Models: P/N 398673
Weight
(may vary depending
on model)
115-20 in. (L): 375 lbs. (170 kg)
115 HO, 130-20 in. (L): 390 lbs. (177 kg)
115-25 in. (X): 390 lbs. (177 kg)
115 HO, 130-25 in. (X): 405 lbs. (184 kg)
20 in. (L): 418 lbs. (190 kg)
25 in. (X): 433 lbs. (196 kg)
Lubrication Evinrude/Johnson XD100 Oil or Evinrude/Johnson XD50 Oil
Refer to Recommended Lubricants on p. 168
Engine Type 60° V 4-Cylinder Loop-Charged 60° V 6-Cylinder Loop-Charged
Displacement 105.4 cu. in. (1727 cm3) 158.2 cu. in. (2592 cm3)
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)
Top Crankshaft Journal 2.1870 to 2.1875 in. (55.55 to 55.56 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 1.3757 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
Fuel/Oil Ratio EMM Controlled
Starting Enrichment EMM Controlled
Preferred Fuel Regular unleaded gasoline
Acceptable Fuel See Fuel Requirements on p. 137 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 to 4 psi (21 to 28 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. 137 for additional information.

REFERENCE INFORMATION
SERVICE SPECIFICATIONS
11
1
ELECTRICAL
HP 115, 130 150, 175, 200
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 Isolation. Refer to Predeliv-
ery and Installation Guide for multiple 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 230°F (110°C) Below 3000 RPM and 194°F (90°C) Above 3000 RPM
Water pressure V4: 21 to 23 psi @ 5000 RPM
V6: 23 to 25 psi @ 5000 RPM
IGNITION
Type Capacitor Discharge
Firing Order 1-2-3-4 1-2-3-4-5-6
Ignition Features EMM Controlled
RPM Limit 6250
Crankshaft Position Sensor Air
Gap Fixed
Spark Plug Refer to Emission Control Information Label
Champion†QC10WEP @ 0.028 ± 0.003 in. (0.76 mm)
Refer to Emission Control Information Label
GEARCASE
Gear Ratio
V4 “S2” Type Gearcase: 13:26 (.500) (2:1)
V4 “O” Type Gearcase: 12:27 (.444) (2.25:1)
V6 “O” Type Gearcase: 14:26 (.538) (1.86:1)
V6 “M2” Type Gearcase: 13:24 (.542) (1.85:1)
V6 “L2” Type Gearcase:14:26 (.538) (1.86:1)
Refer to GEARCASE TYPES on p. 263
Lubricant HPF XR Gearcase Lubricant
Capacity
“S2” Type Gearcase: 31.6 fl. oz. (935 ml)
V4 “O” Type Gearcase: 32.8 fl. oz. (970 ml)
V6 “O” Type Gearcase: 33.1 fl. oz. (980 ml)
“M2” Type Gearcase: 38.9 fl. oz. (1150 ml)
“M2” Type – Counter Rotation: 35.8 fl. oz. (1060 ml)
“L2” Type Gearcase: 32.5 fl. oz. (960 ml)
Shift Rod Height 20 in. (L) Models: 20.945 (532 mm) ± one-half turn
25 in. (X) Models: 25.945 (659 mm) ± one-half turn
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD
POWER TRIM/TILT
Lubrication (Single Piston style): Evinrude/Johnson Biodegradeable TNT Fluid
(Three Piston style): Evinrude/Johnson Power Trim/Tilt & Power Steering Fluid or GM
Dextron†II Automatic Transmission Fluid
Fluid Capacity 21 fl. oz. (622ml)
Trim Range 0° to 21°
Tilt Range 22° to 75°

12
REFERENCE INFORMATION
STANDARD TORQUE SPECIFICATIONS
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 listed
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
locking fastener (locknut or patch screw)
if its locking feature becomes weak. Defi-
nite resistance 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/
Johnson Genuine Parts.
Nautical Orientation 006411

ROUTINE SERVICE
13
2
ROUTINE SERVICE
TABLE OF CONTENTS
INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
LIFTING THE OUTBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
OUTBOARD RIGGING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
CONTROL CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
BATTERY CABLE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
SYSTEMCHECK HARNESS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
I-COMMAND NETWORK CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
ICON NETWORK CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
WATER PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
BATTERY AND BATTERY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
OETIKER CLAMP SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
TILT LIMIT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
TRIM SENDING UNIT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
TRIM TAB ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
DUAL-OUTBOARD ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
ENGINE FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
RUNNING THE OUTBOARD USING A HOSE AND FLUSHING ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . .33
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
SWIVEL BRACKET AND TRAILERING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
THROTTLE AND SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
FUEL AND OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
OIL FILTERS AND OIL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
AIR SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
HOSES AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
EXHAUST PRESSURE FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
PRE-SEASON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
SUBMERGED ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

14
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
Engine
Care
Product Routine Inspection
Every 300 hours
or every three
years (1)
(1) Average recreational use. Commercial use, heavy use, or use in salt or polluted water requires more frequent inspection and maintenance.
Engine Monitor self-test and warning horn, check 
Emergency stop circuit and lanyard, check operation 
Controls, steering and tilting; check operation 
Engine mounting hardware, re-tighten (40 ft. lbs.) 
Fasteners, tighten any loosened components 
Water intake screens, check condition 
Cooling system; check water pump indicator / water pressure 
Anticorrosion anodes, check condition 
Gearcase, check condition 
Propeller, check condition 
Fuel and oil systems, inspect and repair leaks (2)
(2) Emission-related component

Check battery connections and condition 
Access EMM information, resolve any service codes 
Electrical and ignition wires, inspect for wear or chafing 
Fuel filter, replace 
Oil filters, replace 
Gearcase lubricant, replace A 
Spark plugs, inspect or replace (2) 
Thermostats, inspect and check operation (2) 
Grease fittings, lubricate (3)
(3) Annually in salt water applications
C
Power trim/tilt and fluid level, inspect B 
Propeller shaft splines, inspect and lubricate (3) C
Starter pinion shaft, inspect and lubricate (3) D
Control cables, inspect and adjust 
Steering cable, inspect and lubricate C 
Water pump, inspect / replace (more often if water pressure loss or overheating occurs) 
AHPF Pro Gearcase Lubricant
B Power Trim/Tilt Fluid (Three ram hydraulic systems)
Biodegradeable TNT Fluid (Single ram hydraulic systems)
CTriple-Guard Grease
D Starter Bendix Lube Only

15
ROUTINE SERVICE
LIFTING THE OUTBOARD
2
LIFTING THE
OUTBOARD
Use correct Lifting Fixture to lift outboard:
Install Lifting Fixture, P/N 342672, on crankshaft.
Tighten mounting screw securely using an Allen 1/
4 in. hexagonal wrench.
Fasten appropriate chain hook to eye of tool.
Carefully hoist outboard with chain and unbolt out-
board mounting brackets from frame.
OUTBOARD RIGGING
CONNECTIONS
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: Control cable function must be
identified before 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.
WARNING
To avoid personal injury, make sure the lift-
ing 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
60° V4–V6 P/N 342672
1. Center retaining screw 004945
1
1. Shift cable casing guide extended to midpoint
2. Throttle cable casing guide retracted DP0811
30501
1
2

16
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
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.
Cable, Hose, and Wire Routing
Refer to Control Cable Identification on p. 15.
Remove two screws and bracket that fasten the
grommet to lower motor cover.
Route all hoses, control cables, and wiring
through a protective sleeve or conduit into the
boat and through the grommet.
The fuel hose may be routed through the protec-
tive sleeve or through an alternate hole in the
lower motor cover grommet.
To route the fuel hose outside the sleeve, trim the
material covering the alternate fuel hose slot in
the grommet.
1. Straight section
2. Angled section DP0818
DP0817
Locked Retainer Clip
1. Angled section behind straight section DP0817A
1
2
1
CAUTION
To prevent accidental starting while servic-
ing, disconnect the battery cables at the
battery. Twist and remove all spark plug
leads.
1. Grommet retaining bracket 003964
1. Alternate fuel hose location 003970
1
1

17
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
2
Refer to the following diagram to ensure proper
positioning of rigging components in grommet.
The main wiring harness, battery cables, oil tank
sending unit harness, and any ICON or I-Com-
mand network cables should be routed along the
same path to the starboard side of the powerhead.
Secure all cables with clamps.
After installation, make sure there
is enough clearance for all cables to avoid
binding or chafing through all engine steering
and tilting angles.
Control Cable Installation
Refer to Control Cable Identification on p. 15.
Remove control cable trunnion covers and cable
attachment hardware.
1. Fuel supply hose
2. Fuel supply hose--alternate location
3. Oil supply hose
4. Oil tank sending unit harness
5. Battery cables
6. Main wire harness (MWS)
7. Shift cable
8. Throttle cable
9. Accessory charge wires
10. CANbus harness
11. Water pressure hose
12. Speedometer hose
000095c
1. Alternate fuel hose location 004946
1
4
7
11
8
10
9
3
6
12
2
5
1
1. Anchor points 004949
1. Trunnion covers 004955
1
NOTICE
1

18
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
Shift Cable Installation and Adjustment
Place the shift cable on the shift lever pin and
install the washer and retainer clip. Refer to Cable
Retainer Clip Installation on p. 16.
IMPORTANT: Do not bend or deform clip.
Make sure the remote control, gearcase, shift link-
age, and shift cable are in NEUTRAL.
Hold the shift linkage in NEUTRAL.
Push and pull on the shift cable and observe the
cable slack. Hold the casing guide in the center of
the slack.
Adjust shift cable trunnion to align with center of
the trunnion block. Place cable trunnion in trun-
nion block.
Install trunnion cover and screw. Tighten screw to
a torque of 60 to 80 in. lbs. (7 to 9 N·m).
Throttle Cable Installation and Adjustment
With remote control lever in NEUTRAL, pull firmly
on throttle cable casing to remove slack.
Place throttle cable on throttle lever pin and install
washer and retainer clip. Refer to Cable Retainer
Clip Installation on p. 16.
Make sure that idle stop of the throttle lever is
against the crankcase.
Adjust the throttle cable trunnion to align with the
trunnion block. Place the cable trunnion in the
trunnion block.
IMPORTANT: Move control handle to FOR-
WARD and pull back slowly to NEUTRAL. Make
sure the engine throttle lever is against the stop. If
not, remove slack by adjusting cable trunnion.
1. Shift cable retainer clip and washer
2. Shift cable trunnion 004956
21
1. Throttle cable retainer clip and washer 004957
1. Throttle linkage, idle stop against crankcase 004947
1
1