BRP Evinrude E-TEC G2 User manual

Printed in the United States.
© 2016 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.
† ThreeBond is a registered trademark of ThreeBond International, Inc.
The following trademarks are the property of BRP US Inc. or its affiliates:
Evinrude ® SystemCheck™
Evinrude ® E-TEC ® 2+4 ® Fuel Conditioner
Evinrude ® ICON™ Triple-Guard ® Grease
Evinrude ®ICON II ™ HPF PRO™ Gearcase Lubricant
Evinrude ®ICON-Touch ™ DPL™ Lubricant
Evinrude ®i-Dock ™ Gel-Seal II™
Evinrude ® XD50™ Outboard Oil Nut Lock™
Evinrude ® XD100™ Outboard Oil Screw Lock™
I-Command™ Ultra Lock™
S.A.F.E.™ Moly Lube™

2
Service Manual
Contents
1 Reference Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Routine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Engine Cover and Frame Service . . . . . . . . . . . . . . . . . . 55
4 Engine and Control Systems . . . . . . . . . . . . . . . . . . . . . . 77
5 System Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6 Electrical and Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
8 Oiling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
9 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
10 Evinrude ICON II Remote Control System . . . . . . . . . . 223
11 Powerhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
12 Exhaust Housing & Adapter . . . . . . . . . . . . . . . . . . . . . 283
13 Stern and Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
14 Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
S Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
T Trouble Check Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
I Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
Fault Code Tables
Diagrams
For complete outboard rigging and control installation information, refer to the current Evinrude E-TEC
G2 Installation and Predelivery Guide.

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
EPA Internet Web Site: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Model Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 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 Genuine Parts or parts with equivalent char-
acteristics, 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
CAN Controller Area Network
CCA Cold Cranking Amps
CFR Code of Federal Regulations
CPS Crankshaft Position Sensor
DPS Dynamic Power Steering
ETB Electronic Throttle Body
ETC Electronic Throttle Controller
EGT Exhaust Gas Temperature
EMM Engine Management Module
EPA Environmental Protection Agency
ESC Electronic Shift Controller
FNR Forward, Neutral, Reverse
FWD Forward
HPS Helm Pressure Sensor
ICOMIA International Council of Marine
Industry Associations
ID Inside Dimension
LED Light Emitting Diode
MCA Marine Cranking Amps
MWS Modular Wiring System
NMEA National Marine Electronics Assoc.
OOC Out Of Correlation
PBLC Public (NMEA 2000) Network
PPS Pump Pressure Sensor
PRVT Private (Remote Control) Network
PTPS Port Steering Pressure Sensor
REV Reverse
ROM Read Only Memory
S.A.F.E. Speed Adjusting Failsafe Electronics
SAC Start Assist Circuit
SAE Society Of Automotive Engineers
SPS Shift Position Sensor
STPS Starboard Steering Pressure Sensor
STS Steering Position Sensor
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
1200 Pennsylvania Ave. NW
Mail Code 6403J
Washington D.C. 20460
EPA Internet Web Site:
www.epa.gov/otaq

Reference Information
Model Designation
10
Model Designation
Engine Identification
Model and serial numbers are located on the swivel bracket and on the powerhead.
E 250 L HO AG B
HORSEPOWER SHAFT LENGTH:
L20 in. Long
X25 in. X-long
Z30 in. XX-long
MODEL IDENTIFICATION
The first two characters identify
Model Version:
AAA First major variant
ABA Second major variant
AF A Third major variant
•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.
DESIGN FEATURES:
CCounter Rotation
DEvinrude E-TEC
GGraphite Paint
HHigh Output
OHydraulic Steering
(non-power assist)
U300 HP with Water Valve
PREFIX:
AAlternate Feature*
EEvinrude
The third character identifies
Model Revision:
AAAFirst revision
AABSecond revision
Subsequent revisions continue
through the alphabet in order
(A through Z).
*An “A” prefix in the model number of an Evinrude E-TEC G2 indicates a Counter-Rotation model with Dynamic
Power Steering (DPS).
1. Model and serial number 009146
1
1. Serial number 009147
1

Reference Information
Models Covered
11
1
Models Covered
This service manual covers information on the following Evinrude E-TEC G2, 210 cubic inch (3.4 L),
74° V6, models, starting with serial numbers:
AB models, s/n 5410201
AF models, s/n 5421512
AG and newer models, s/n 5437485
Model Shaft Standard Special
HP Number Length Style Gear Ratio Steering Graphics Features Features
200 E200LHA_ _ 20 SLX 13:24/0.542/1.85:1
DPS
1Custom H.O.
Di
g
ital EST
2H.O.
E200LHOA_ _ 20 SLX 13:24/0.542/1.85:1 Hydraulic Custom H.O.
Di
g
ital EST
2H.O.
E200XHAB_ _ 25 SLX 13:24/0.542/1.85:1
DPS
1
H.O. Standard Di
g
ital EST
2H.O.
E200XHCAB_ _ 25 SLX Counter
Rotation 13:24/0.542/1.85:1 Hydraulic
H.O. Standard
Digital EST 2H.O.
A200XHCA_ _ 25 SLX Counter
Rotation 13:24/0.542/1.85:1 DPS 1Custom H.O. Digital EST 2CR/DPS 3,
H.O.
225 E225X_ _ _ 25 SLX 13:24/0.542/1.85:1
DPS
1Standard
Di
g
ital EST
2
E225XC_ _ _ 25 SLX Counter
Rotation 13:24/0.542/1.85:1 Hydraulic Standard Digital EST 2
225H E225LH_ _ _ 20 SLX 13:24/0.542/1.85:1
DPS
1Custom H.O.
Di
g
ital EST
2H.O.
E225XH_ _ _ 25 SLX 13:24/0.542/1.85:1
DPS
1Custom H.O.
Di
g
ital EST
2H.O.
E225XCH_ _ _ 25 SLX Counter
Rotation 13:24/0.542/1.85:1 DPS 1Custom H.O. Digital EST 2H.O.
E225LHO_ _ _ 20 SLX 13:24/0.542/1.85:1 Hydraulic Custom H.O.
Di
g
ital EST
2H.O.
250 E250X_ _ _ 25 SLX 13:24/0.542/1.85:1
DPS
1Standard
Di
g
ital EST
2
E250Z_ _ _ 30 SLX 13:24/0.542/1.85:1
DPS
1Standard
Di
g
ital EST
2
E250XC_ _ _ 25 SLX Counter
Rotation 13:24/0.542/1.85:1 Hydraulic Standard Digital EST 2
A250XC_ _ _ 25 SLX Counter
Rotation 13:24/0.542/1.85:1 DPS 1Standard Digital EST 2CR/DPS 3
E250ZC_ _ _ 30 SLX Counter
Rotation 13:24/0.542/1.85:1 Hydraulic Standard Digital EST 2
A250ZC_ _ _ 30 SLX Counter
Rotation 13:24/0.542/1.85:1 DPS 1Standard Digital EST 2CR/DPS 3
250H E250LH_ _ _ 20 SLX 13:24/0.542/1.85:1
DPS
1Custom H.O.
Di
g
ital EST
2H.O.
E250XH_ _ _ 25 SLX 13:24/0.542/1.85:1
DPS
1Custom H.O.
Di
g
ital EST
2H.O.
E250XCH_ _ _ 25 SLX Counter
Rotation 13:24/0.542/1.85:1 DPS 1Custom H.O. Digital EST 2H.O.
E250LHO_ _ _ 20 SLX 13:24/0.542/1.85:1 Hydraulic Custom H.O.
Di
g
ital EST
2H.O.
300 E300LU_ _ _ 20 SLX 13:24/0.542/1.85:1
DPS
1Standard
Di
g
ital EST
2
E300XU_ _ _ 25 SLX 13:24/0.542/1.85:1
DPS
1Standard
Di
g
ital EST
2
E300ZU_ _ _ 30 SLX 13:24/0.542/1.85:1
DPS
1Standard
Di
g
ital EST
2
E300XCU_ _ _ 25 SLX Counter
Rotation 13:24/0.542/1.85:1 Hydraulic Standard Digital EST 2
A300XCU_ _ _ 30 SLX Counter
Rotation 13:24/0.542/1.85:1 DPS 1Standard Digital EST 2CR/DPS 3
E300ZCU_ _ _ 30 SLX Counter
Rotation 13:24/0.542/1.85:1 Hydraulic Standard Digital EST 2
A300ZCU_ _ _ 30 SLX Counter
Rotation 13:24/0.542/1.85:1 DPS 1Standard Digital EST 2CR/DPS 3
1. Dynamic Power Steering 2. Digital Electronic Shift & Throttle 3. Alternative Feature: Counter-Rotation model with DPS
Gearcase

12
Reference Information
Service Specifications
Service Specifications
HP 200 225 250 250 H.O. 300
Engine
Full Throttle Operating Range 5400-6000
RPM 5400-6000 RPM 5400-6000 RPM 5400-6000 RPM 5400-6000 RPM
Power 200 HP (147.1 kw)
@ 5500 RPM
225 HP
(165.5 kw)
@ 5500 RPM
250 HP
(183.9 kw)
@ 5500 RPM
250 HP
(183.9 kw)
@ 5750 RPM
300 HP
(220.6 kw)
@ 5750 RPM
Idle RPM in NEUTRAL 500 ± 50 RPM
Idle RPM in Gear 500 ± 50 RPM
Weight (may vary depending on model) 20 in. (L) Models 537 lbs. (244 kg)
25 in. (X) Models 558 lbs. (253 kg)
30 in. (Z) Models 570 lbs. (259 kg)
Lubricant – Preferred Lubricant
–Acceptable Lubricant Evinrude XD100, Evinrude XD50
Synthetic TC-W3 NMMA-certified oil
Capacity 2.0 gallons (7.5 liters)
Engine Type 74° V 6-Cylinder Loop-Charged
Displacement 210 cu. in. (3.4 L, 3441 cm3)
Bore 3.854 in. (97.89 mm)
Stroke 3.000 in. (76 mm)
Standard Bore 3.8535 to 3.8550 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)

Reference Information
Service Specifications
13
1
HP 200 225 250 250 H.O. 300
Fuel / Oil System
Fuel/Oil Ratio 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
Fuel Pressure (minimum) – Lift Pump
–High Pressure Pump 6 psi (41 kPa) @ idle 26 to 32 psi (179 to 220 kPa) @ 5500
Fuel Pressure (maximum) – Lift Pump
–High Pressure Pump 3 psi (21 kPa) @ 5500 RPM 34 to 40 psi (234 to 275 kPa) @ idle RPM
Maximum Fuel Inlet Vacuum 4 in. Hg. (13.5 kPa)
Fuel Filters – Inline
– Water Separating P/N 357797 P/N 502906
Fuel Additives 2+4 Fuel Conditioner, Fuel System Cleaner.
Use of other additives may result in engine damage.
Electrical System
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 Predelivery and Installation Guide for multiple battery applications.
Analog Tachometer Setting 6 pulse (12 pole)
Charging Isolator Integral, Terminal on Engine Harness
Engine Fuses 3 Amp MINIFUSE, P/N 3011805, 5 Amp MINIFUSE, P/N 514764,
10 Amp MINIFUSE, P/N 514766, 30 Amp MINIFUSE, P/N 3011729
Engine Relays – Starter
– B+ to 55 V System 12V 35A SPDT, P/N 3011790 12V 35A SPDT, P/N 3011790
Cooling System
Thermostat 143°F (62°C)
Maximum Temperature 203°F (95°C)
Water pressure – Idle
– @ 5500 RPM 5 to 8 psi (34 to 55 kPa) > 25 psi (>172 kPa)
Pressure Relief Valve (open) 28 psi (193 kPa) (approximate)

Reference Information
Service Specifications
14
HP 200 225 250 250 H.O. 300
Ignition System
Type Inductive Discharge
Firing Order 1-2-3-4-5-6
Ignition Features EMM Controlled
RPM Limit (in gear) 6250 RPM
Crankshaft Position Sensor Air Gap Fixed
Spark Plug Champion†QC8WEPI @ 0.028 ± 0.003 in. (0.71 mm)
Gearcase
Gear Ratio “SLX” Type Gearcase: 13:24 (.542) (1.85:1)
Lubricant HPF Pro Gearcase Lubricant
Capacity – Standard Rotation
– Counter Rotation
Gearcase only – 38.9 fl. oz. (1180 ml)
Gearcase, vent hose and oil reservoir 45.6 fl. oz. (1350 ml)
Gearcase only – 39 fl. oz. (1154 ml)
Gearcase, vent hose and oil reservoir 44.7 fl. oz. (1324 ml)
Shift Rod Height N/A
Trim & Tilt System
Lubrication Power Trim/Tilt Fluid, P/N767969
Fluid Capacity 24 fl. oz. (710 ml)
Trim Range 0° to 21° (-6° to 15°)
Tilt Range 22° to 81° (16° to 75°)
Steering System
Hydraulic Steering Fluid SeaStar Hydraulic fluid, P/N 770891
Fluid Capacity
(NOT including helm or hydraulic hoses) 10 oz. (300 ml) (approximate)
Steering Range (lock to lock) –32° to +32°, 64° Total (see engine Profile Drawing)

Routine Service
15
2
Routine Service
Table of Contents
Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oetiker Clamp Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Gearcase Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuel and Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Exhaust Pressure Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Anti-Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pre-Season Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lifting The Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Rigging Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Before Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Engine Mounting Height and Jack Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fuel System Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Engine Water Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Trim & Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Tilt Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Trim Gauge Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
i-Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Dynamic Power Steering (DPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Multiple Outboard Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Submerged Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Engine Submerged (Not Running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Engine Submerged (Running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Engine Submerged (In Salt Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Prolonged Submersion (Fresh or Salt Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Filling and Bleeding the Hydraulic Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Hydraulic Steering Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Single Station / Single Engine Steering Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Single Station / Multiple Engine Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Steering System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Oetiker Clamp Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

16
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.
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 G2 outboards.
Description of Service
Every 500 hours or every 5 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  
Cooling system; check water pump indicator / water pressure  
Displays & gauges, self-test/warning horn, check operation  
Emergency cut–off switch(es) and tether cord, check operation  
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, inspect level A
Gearcase lubricant, replace A
Grease fittings, lubricate (3)
(3) Annually in salt water applications
C
Oil filter, replace 
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) 
Steering system, inspect fluid level, check hydraulic hose condition, check operation D
Thermostats, inspect and check operation (2) 
Water pump, replace (more frequent if water pressure loss or overheating occurs) 
AHPF Pro Gearcase Lubricant D Hydraulic Fluid, P/N 770891.
BPower Trim/Tilt Fluid, P/N 767969 Anti-Corrosion Spray
CTriple-Guard Grease “6 in 1” Multi-Purpose Lubricant

17
Routine Service
Maintenance
2
Maintenance
Batteries
Each outboard requires its own starting battery.
Select a battery that meets or exceeds the mini-
mum requirements.
Battery Recommendations
Battery Location
Proper installation will prevent battery movement
while underway.
•Secure all batteries in protected locations
•Place battery as close to the outboard as possi-
ble
•Battery location must provide access for peri-
odic maintenance
•Use battery mounting trays or battery boxes on
all battery installations
•Connections and terminals must be covered
with an insulator
•Battery connections must be clean and free
from corrosion
•Read and understand the safety information
supplied with the battery before installation.
Battery Connections
Check battery connections frequently. Periodically
remove battery to clean and service connections.
•Confirm that battery meets the minimum engine
requirements.
•Connections must be clean and tight.
•Observe all wiring connections prior to disas-
sembly.
Disconnecting the Battery
Disconnect battery negative (–) cable first and the
battery positive (+) cable last.
Clean all terminals, battery posts, and connectors
with a solution of baking soda and water. Use a
wire brush or battery terminal tool to remove cor-
rosion buildup. Rinse and clean all surfaces.
Connecting the Battery
IMPORTANT: Connect the battery positive (+)
cable to the battery positive (+) post FIRST. Con-
nect the battery negative (–) cable to the battery
negative (–) post LAST.
Install a starwasher on the threaded battery post.
Stack cables from the outboard, then cables from
accessories. Finish this connection with a hex nut.
Tighten all connections securely. Apply Triple-
Guard grease to prevent corrosion.
WARNING
Battery electrolyte is acidic—handle with
care. If electrolyte contacts any part of the
body, immediately flush with water and seek
medical attention.
Outboard
Model Battery Rating
200–300 HP 675 CCA (845 MCA), or
800 CCA (1000 MCA) below
32°F (0°C) 107 amp-hr in extreme
applications
WARNING
Keep the battery connections clean, tight, and
insulated to prevent their shorting or arcing
and causing an explosion. If the battery
mounting system does not cover the connec-
tions, install protective covers. Check often to
see that connections stay clean and tight.
NOTICE
Do not use wing nuts to fasten ANY battery
cables. Wing nuts can loosen and cause elec-
trical system damage not covered under war-
ranty.
Marine Style Battery Post
1. Starwasher
2. Hex nut
3. Terminal Insulator
009166
1
3
2

18
Routine Service
Maintenance
Oetiker Clamp Servicing
See the Oetiker Clamp Chart on p. 54.
Clamp Identification
Use Oetiker clamps for making hose connections.
These clamps provide corrosion resistance, mini-
mize the potential for abrasion of rigging compo-
nents, and provide solid, permanent connections.
The selection and installation of an Oetiker clamp
is essential in the proper sealing of hose connec-
tions.
The clamp identification numbers appear on the
side of the clamp, near the top of the ear. Refer to
Oetiker Clamp Chart on p. 54 chart for clamp
dimensions.
Clamp Selection
To select the correct size Oetiker clamp, measure
the outside diameter of the hose when installed on
the fitting.
Chose a clamp so that the outside diameter of the
hose is approximately in the middle of the clamp-
ing range of the clamp.
Refer to Oetiker Clamp Chart on p. 54.
Clamp Installation
A constant stress should be applied to close the
ear clamps. This method ensures a positive stress
on the hose and does not result in excessive com-
pression or expansion of the band material.
IMPORTANT: Use only Oetiker recommended
tools to close Oetiker stepless clamps.
Oetiker pincers, P/N 787145, are available in the
Evinrude Genuine Parts and Accessories Catalog.
•Position correct size clamp over hose.
•Install hose on fitting.
Larger size Oetiker clamps may come apart
during handling. To reassemble the clamp, con-
nect the end loop to the end hook. Make sure the
alignment tab is installed into the alignment slot.
WARNING
DO NOT re-use Oetiker clamps. Fuel leakage
could contribute to a fire or explosion.
1. Clamp identification numbers 000093
1
787145
1. End loop
2. End hook
3. Alignment tab
4. Alignment slot
5. Correctly assembled clamp
009095
434
35
1
2

19
Routine Service
Maintenance
2
•Close clamp ear fully with Oetiker pincers (pli-
ers).
Clamp Removal
Method 1: Position Oetiker pincers across clamp
ear and cut clamp.
Method 2: Lift end of stepless clamp with screw-
driver.
Use Oetiker pincers (pliers) to grip clamp. Pull
clamp off of connection and discard.
Cooling System
Check the condition of cooling system compo-
nents regularly:
•water intake screens
•water pump
•all internal water passages
•thermostats
•all external water hoses and fittings
•vapor separator cooling passages and fittings
•EMM cooling passages and fittings
•overboard water pressure indicator.
Water Intake Screens
Inspect condition of water intake screens. Clean
or replace as needed.
Confirm function of overboard water pressure indi-
cator.
Engine Flushing
Flush the outboard with fresh water following each
use in brackish, salt, or polluted water to minimize
the accumulation of scale and silt deposits in cool-
ing system passages.
The outboard can be flushed on the trailer or at
dockside; running or not running.
IMPORTANT: The outboard must be located in a
well ventilated area with appropriate ground drain-
age during the flushing procedures.
Keep water inlet pressure between 20 to 40 psi
(140 to 275 kPa).
1. Open clamp
2. Closed clamp 000092
000108
000090
12
1. Water intake screens 009041
1
1

20
Routine Service
Maintenance
Flushing — Outboard Running
Place outboard in VERTICAL (DOWN) position in
a well ventilated area.
Thread garden hose into flushing port.
Turn water supply on.
Run outboard at IDLE only until full operating tem-
perature is reached.
Leave the outboard in VERTICAL (DOWN) posi-
tion long enough for the powerhead to drain com-
pletely.
Reinstall propeller.
Flushing — Outboard Not Running
Place outboard in VERTICAL (DOWN) position.
Thread garden hose into flushing port.
Turn water supply ON.
Flush outboard for at least five minutes.
Turn off water supply and remove garden hose.
Leave the outboard in VERTICAL (DOWN) posi-
tion long enough for the powerhead to drain com-
pletely.
Propeller Shaft
Debris from the water can become lodged around
propeller shaft. Frequent inspection can minimize
potential gearcase damage.
Remove propeller. Refer to Propeller Hardware
Installation on p. 360.
Inspect bushing and blade surfaces. Replace
damaged or worn propellers.
Clean propeller shaft. Inspect propeller shaft
seals. Replace damaged or worn seals.
Apply Triple-Guard grease to entire length of pro-
peller shaft prior to installing propeller.
Reinstall propeller hardware and propeller.
Gearcase Lubricant
Refer to the Inspection and Maintenance
Schedule on p. 16 for service frequency.
Lubricant Level
Remove the starboard side panel.
IMPORTANT: ALWAYS check the fill level of the
gearcase lubricant at the oil reservoir before re-
moving the drain/fill plug.
WARNING
To prevent injury from contact with rotating
propeller, remove the propeller before flush-
ing.
009071
WARNING
When servicing the propeller, always shift the
outboard to NEUTRAL position, turn the key
switch OFF and remove the key, so the out-
board cannot be started accidentally.
1. Lubricant reservoir 009140
1