BRP Evinrude E-TEC Series User manual

©2012 Bombardier Recreational Products Inc. (BRP). All rights reserved. ®,TM and the BRP logo are trademarks of BRP or its affiliates.
www.brp.com
SKI-DOO®SEA-DOO®CAN-AM®
LYNX®EVINRUDE®JOHNSON®ROTAX®
*5009015*
Evinrude E-TEC Installation and Predelivery P/N 5009015 Nov. 2012
Installation and Predelivery
November 2012

Printed in the United States.
© 2012 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
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† 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.
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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™
Original Instructions

2
INSTALLATION & PREDELIVERY
INSTALLATION & PREDELIVERY
TABLE OF CONTENTS
BOAT RIGGING
REMOTE CONTROLS
CONTROL SYSTEM SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CONTROL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CONTROL CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INFORMATION DISPLAY SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SYSTEMCHECK GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
I-COMMAND DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SYSTEMCHECK (MWS) HARNESS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
I-COMMAND HARNESS CONNECTIONS WITH MECHANICAL REMOTE CONTROL . . . . . . . . . . . . . . . . . . . . . 13
EVINRUDE ICON / I-COMMAND HARNESS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BATTERY RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BATTERY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BATTERY CABLE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BATTERY SWITCHES AND MULTIPLE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
AUXILIARY BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BATTERY AND SWITCH WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FUEL SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REGULATIONS AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PERMANENT FUEL TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PORTABLE FUEL TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL SYSTEM PRIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FUEL FLOW REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOTE OIL TANK INSTALLATION (V4 – V6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOTE OIL FILL KIT (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CABLE AND HOSE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
BOAT CABLE AND HARNESS ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PROTECTIVE SLEEVE/CONDUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
BATTERY CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
FUEL HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OIL SUPPLY HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OETIKER CLAMP SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

INSTALLATION & PREDELIVERY
3
OUTBOARD INSTALLATION
HULL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
TRANSOM MEASURING AND DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
LIFTING THE OUTBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
STEERING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
OUTBOARD MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
OUTBOARD RIGGING
COMMON PRACTICES – ALL MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
CONTROL CABLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
CABLE RETAINER CLIP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
EVINRUDE E-TEC 90° V MODELS 200–300 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
EVINRUDE E-TEC 60° V MODELS 115–200 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
EVINRUDE E-TEC MODELS 40–90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
EVINRUDE E-TEC MODELS 15–30 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
FUEL AND OIL PRIMING
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
FUEL SYSTEM PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
OIL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
RECOMMENDED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
OIL INJECTION RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
BREAK-IN OILING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
OIL SUPPLY PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
PREDELIVERY
BEFORE START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
RUNNING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
PROPELLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
WATER TEST AND FINAL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
ENGINE MOUNTING HEIGHT AND JACK PLATE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
FUEL SYSTEM VACUUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
ENGINE WATER PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
WATER PRESSURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
TILT LIMIT SWITCH ADJUSTMENT (75 – 300 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
TRIM SENDING UNIT ADJUSTMENT (75 – 300 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
TRIM SENDING UNIT ADJUSTMENT (25 – 60 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
TRIM TAB ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
DUAL-OUTBOARD ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
SAMPLE PREDELIVERY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

4
INSTALLATION & PREDELIVERY
SAFETY INFORMATION
This pu blication is written fo r qualified, facto ry-
trained technicia ns who ar e alrea dy familiar with
the use of Evinrude/Johnson Special Tools. The
included in formation is not a substitu te for wo rk
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 unt il yo u have read
and understood these instructions completely.
Torque wre nch tig htening specifications must
strictly be adhered to.
Should removal of any locking fastener (lock tabs,
locknuts, or p atch screws) be requ ired, a lways
replace with a new one.
When repla cement p arts are requ ired, use Evin-
rude/Johnson Genuine Parts or parts with equiva-
lent characteristics, including type, streng th a nd
material. Use of subst andard 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 p arts that can move, such as
flywheels, propellers, etc.
Some componen ts 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 th is manual, YOU ALONE must
decide if your actions might injure people or dam-
age the outboard.
This document ma y be tra nslated into othe r la n-
guages. In the event of any discrepancy, the Eng-
lish version shall prevail.
ADANGER
Indicates a hazardous situation which, if
not avoided, will result in death or serious
injury.
AWARNING
Indicates a hazardous situation which, if
not avoided, could result in death or seri-
ous injury
ACAUTION
Indicates a hazardous situation which, if
not avoided, could result in minor or mod-
erate personal injury.
NOTICE

INSTALLATION & PREDELIVERY
5
ADANGER
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.
AWARNING
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
INSTALLATION & PREDELIVERY
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
ΩOhms
VVolts
VAC Volts Alternating Current
VDC Volts Direct Current
ABYC American Boat & Yacht Council
ATDC after top dead center
AT air temperature sensor
BPS barometric pressure sensor
BTDC before top dead center
CCA cold cranking amps
CFR Code of Federal Regulations
CPS crankshaft position sensor
EMM Engine Management Module
EPA Environmental Protection Agency
ICOMIA International Council of Marine
Industry Associations
ID Inside dimension
MCA marine cranking amps
MWS modular wiring system
NMEA National Marine Electronics Assoc.
ROM read only memory
S.A.F.E. speed adjusting failsafe electronics
SAC start assist circuit
SAE Society of Automotive Engineers
SYNC synchronization
TDC top dead center
TPS throttle position sensor
USCG United States Coast Guard
WOT wide open throttle
WTS water temperature sensor

7
INSTALLATION & PREDELIVERY
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.
Maintenance, replacement, or rep air of the emis-
sion control de vices and systems ma y be per-
formed by any ma rine SI (sp ark ig nition) engine
repair establishment or individual.
Manufacturer’s Responsibility
Beginning with 1999 model year o utboards, man-
ufacturers o f ma rine outboards must de termine
the exha ust emissio n levels for each outbo ard
horsepower family and certif y the se o utboards
with the Unite d States of America Environmental
Protection Age ncy (EP A). An emissions control
information labe l, showing emission leve ls a nd
outboard specifications, mu st be placed o n each
outboard at the time of manufacture.
Dealer’s Responsibility
When pe rforming service on all 1 999 a nd more
recent Evinrude/Johnson outboards that carry an
emissions control information la bel, adjustments
must be kept with in pub lished factory specifica-
tions.
Replacement or repair of any emission rela ted
component must b e exe cuted in a manne r that
maintains emission levels within the prescrib ed
certification standards.
Dealers are not to mo dify the outbo ard in an y
manner th at would alter the horsepower or allow
emission levels to excee d their predete rmined
factory specifications.
Exceptions include manu facturer’s prescrib ed
changes, such as altitude ad justments, for exa m-
ple.
Owner’s Responsibility
The owner/operator is required to have outboa rd
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 wo uld a lter th e horsepower or a llow e mis-
sions levels to exceed their predetermined factory
specifications.
Tampering with the fuel system to change horse-
power or mo dify emission levels beyond fa ctory
settings or specifications will void the product war-
ranty.
EPA Emission Regulations
All new 19 99 and more recent Evinrude/Johnson
outboards are certified to the EPA as confo rming
to the requirements of the regulations for the con-
trol of air pollutio n from new watercraf t 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 followe d
and, whe never pra ctical, ret urned to the original
intent of the design. The responsibilities liste d
above are gen eral and in no way a comple te list-
ing of the r ules and reg ulations pert aining to th e
EPA re quirements on e xhaust emissions for
marine products. For more detailed information on
this subject, you may cont act th e fo llowing 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
BOAT RIGGING
REMOTE CONTROLS
BOAT RIGGING
REMOTE CONTROLS
Control System Selection
Outboard remot e cont rol systems pro vide the
operator with tools for:
•Starting and stopping the engine
•Shifting into Forward, Neutral, or Reverse
•Changing engine speed
•Changing the tilt/trim angle of the outboard.
The remote control system must in clude t he fo l-
lowing features:
•Shift stroke mu st be 1.125 to 1. 330 in. (28.6 to
33.8 mm) between Neutral and Forward
•Throttle stroke must PUSH for open
•Start-in-gear prevention
•Emergency stop swit ch with lanyard—multiple-
outboard inst allations re quire sep arate st art
switches and a single emergency stop switch
•Connections for engine monitor warning system
Refer to Engine Monitor System on p. 11.
Several re mote contro l options, including bo th
mechanical and e lectronic systems, are available
in the Evinrude/Johnson Genuine Parts and
Accessories catalog.
Mechanical control systems use push/pull
cables to physically move the sh ift and throttle
components on the outboard.
These systems use a Mo dular Wiring System
(MWS) ha rness to carry st art, stop, and trim sig-
nals (analog) to the outb oard. S pecific harness
selection depends on the type of Information Dis-
play system being used. Refer to INFORMATION
DISPLAY SYSTEMS on p. 11.
Electronic control systems, such as Evinrude
ICON, manag e all engine control functions
through a low-voltage, digital data network.
These systems can only be used with ou tboards
equipped for electronic control, including Evinrude
ETEC mo dels ide ntified wit h a “DE” pre fix in t he
model number.
Conversion kit s are ava ilable to add e lectronic
control capabilities to standard ETEC models from
150 to 300 HP, 2008 and newer.
ICON style multiple start switches with master
power/emergency stop switch 007875
AWARNING
The remote control used must have start-
in-gear prevention. This feature can pre-
vent injuries resulting from unexpected
boat movement when the outboard starts.
Always install and recommend use of an
emergency stop/key switch. Doing so will
reduce the risk of personal injury or death
should the operator fall away from the con-
trols or out of the boat.
Evinrude ICON multi-engine control 007986

9
BOAT RIGGING
REMOTE CONTROLS
1
Control Installation
Plan the inst allation of re mote co ntrols carefully,
following all instructions provided with the control.
Select an appropriate location based on the boat
configuration.
IMPORTANT: The mounting location must be a
flat surface and must be strong enough to provide
rigid support. S trengthen moun ting surface a s
necessary.
Place remote cont rol at proposed locatio n and
check clearan ce a round remote con trol leve r at
full throttle in FORWARD and then at full throttle in
REVERSE. There must be at least 2.5 in. (64 mm)
of clearance between the handle and any part of
the boat throughout the control lever travel.
Use an app ropriate drill template to cut mo unting
holes. T emplates are includ ed with the control
instructions.
Install control with hardware provided.
IMPORTANT: Make sure remote control assem-
bly is secure and does not move during operation.
1. Side console
2. Center console
005471
1 2
Typical control clearances 007920
1. Template 007922
85.5°
FWD
15.0°
15.0°
40.5°
NEUTRAL
REV
2.5 in (64 mm)
1

10
BOAT RIGGING
REMOTE CONTROLS
Control Cable Routing
Control cables and harnesses should be routed
along a protected path to the rear of the boat and
secured to prevent movement or damage.
Harness connections should be moun ted in a dry
location, away from bilge and motor well areas.
Control cables should be long en ough to allow a
12 in. (30 cm) cable loop at the fro nt of the out-
board when the cables are routed from the side of
the splash well.
Evinrude ICON Networks
All control infor mation is transferred between the
outboard and an Evinrude ICON system through a
single network cab le. For comple te installation
instructions, refer to the Evinrude ICON Remote
Control System Installation Guide, P/N 764952.
When installing an ICON network, remember:
•Control network must include two cable hubs
•DO NOT use the key switch to power accesso-
ries (switched B+)—use an ICON Accessory
Power Relay Kit
•The ICON Gateway provides a conne ction for
an I-Command Information Display network.
Refer to Evinrude ICON / I-Command Harness
Connections on p. 14 for a typical network instal-
lation diagram.
1. Surface side-mount remote control
2. Cable support
3. 12 in. (30 cm) cable loop at front of outboard
DR4277
12 3

11
BOAT RIGGING
INFORMATION DISPLAY SYSTEMS
1
INFORMATION DISPLAY
SYSTEMS
Engine Monitor System
All remote controlled outboards must be equipped
with an engine monitoring syste m to warn the
operator of conditions that could damage the out-
board.
The eng ine monitor system includes sensors on
the outboard and oil tank, a warning horn, a dash-
mounted display, and related wiring.
The outb oard’s EMM sen ds information about
monitored functions to:
•SystemCheck gauges, or
•An I-Command or ICON display.
IMPORTANT: Operating the outboa rd without
an engine monito r will void the warranty for fail-
ures related to monitored functions.
SystemCheck Gauges
SystemCheck g auges a re u sed with mechanical
remote control systems only.
SystemCheck gauges receive mon itored informa-
tion fro m t he outboard throu gh a Modular Wiring
System (MWS) harness.
Refer to SystemCheck (MWS) Harness Con-
nections on p. 12.
I-Command Displays
I-Command dig ital displays are designed spe cifi-
cally fo r NMEA 2000 cer tified Evinrude E-TEC
outboards. Th ese displays provide enh anced
engine and bo at p erformance information . Multi-
ple f unctions a re integra ted into th e e asy-to-use
displays. Additional displays and accessories can
be added with the plug and play design.
I-Command information displays can be used with
either a mechanical remote control system or with
an Evinrude ICON system. For complete installa-
tion instructions, refer to I-Command Installation
Guide.
When inst alling an I-Command ne twork, remem-
ber:
•A termina tor must b e in stalled at each end of
the network
•There should be no ope n o r unu sed network
device connectors
•The network sho uld b e grou nded a t a single
location only
•A maximum of 50 devices ca n be att ached to
the network *
•The distance betwee n any two po ints on the
network must not exceed 100 meters (328 ft.).
* The EMM on Evinrude E-TEC outboards has a
load equivalency number of 1. Less than 50 mA of
the network’s power is used by the EMM.
If a mechanical con trol is u sed, the I-Command
network re ceives mo nitored in formation through
an I-Command network harness con nected
directly to the outboard’s EMM. An I-Command
Ignition and Trim harness is required to carry start,
stop, and trim signals to the outboard.
Refer to I-Command Harness Connections
With Mechanical Remote Control on p. 13.
If a n ICON control is use d, the I-Command ne t-
work receives monito red infor mation throug h the
ICON control network gateway.
Refer to Evinrude ICON / I-Command Harness
Connections on p. 14.
Typical I-Command and SystemCheck gauges 007988

12
BOAT RIGGING
INFORMATION DISPLAY SYSTEMS
SystemCheck (MWS) Harness Connections
NO OIL
WATER TEMP
CHECK ENGINE
LOW OIL
2
5
6
4
3
PUL
REV
PUL
GND
+12V
0
2
1
34
5
6
7
1
2
3
4
5
6
G
I
S
G
I
S
Typical MWS wiring with a side-mount mechanical remote control 007989
1. 6-Pin Connector – Connect to a pre-wired remote control or to a dash-mounted key switch.
2. 3-Pin Connector – Connect to remote control trim switch or to a dash-mounted trim switch.
3. Black, purple, white/tan wires – Connect to the trim gauge.
4. Black, purple, gray wires – Connect to a conventional tachometer when a SystemCheck tachom-
eter is not used.
5. 2-Pin Connector – Must connect to the warning horn in all installations.
6. 8-Pin Connector – Connect to a SystemCheck gauge or tachometer.

13
BOAT RIGGING
INFORMATION DISPLAY SYSTEMS
1
I-Command Harness Connections With Mechanical Remote Control
BUSSBUSS BUSSBUSS
3A
DEVICEDEVICE DEVICEDEVICE DEVICEDEVICE DEVICEDEVICE DEVICEDEVICE
BUSSBUSS BUSSBUSS BUSSBUSS
EP- 85 MemoryModule
DEVICE DEVICE DEVICE DEVICE
BUSS BUSSBUSS BUSSBUSS
MENU
DOWN
UP
EXIT
PAGES
ENTER
15
10
5
0
20 25
30
35
40
Water
MPH
15.2
MENU
DOWN
UP
EXIT
PAGES
ENTER
30
20
10
0
40
50
60
70
x 100
RPM
3550
1
3
4
2
5
6
Typical I-Command wiring with a binnacle-mount mechanical remote control 007990
1. I-Command Ignition and Trim Harness
2. I-Command Network Harness
3. 6-Pin Connector – Connect to a pre-wired remote control or to a dash-mounted key switch.
4. 3-Pin Connector – Connect to remote control trim switch or to a dash-mounted trim switch.
5. Purple, black wires – Connect to network power supply.
6. 4-Pin Amp Connector – Connect to outboard EMM.

14
BOAT RIGGING
INFORMATION DISPLAY SYSTEMS
Evinrude ICON /I-Command Harness Connections
FUSE
OFF
RUN
BUSS
BUSS
BUSS
BUSS
DEVICE
DEVICE
DEVICE
DEVICE
DEVICE
DEVICE
BUSS
BUSS
BUSS
BUSS
DEVICE
DEVICE
10
20 30 40
50
60
70
0
x 100
RPM
3550
UP
DOWN
EXIT
PAGES
ENTER
MENU
10
20 30 40
50
60
70
0
x 100
RPM
3550
UP
DOWN
EXIT
PAGES
ENTER
MENU
10
20 30 40
50
60
70
0
x 100
RPM
3550
UP
DOWN
EXIT
PAGES
ENTER
MENU
10
20 30 40
50
60
70
0
x 100
RPM
3550
UP
DOWN
EXIT
PAGES
ENTER
MENU
(+)
(–)
( + )
BUSS
BUSS
BUSS
BUSS
DEVICE
DEVICE
DEVICE
DEVICE
BUSS
BUSS
DEVICE
DEVICE
DEVICE
DEVICE
BUSS
BUSS
BUSS
BUSS
DEVICE
DEVICE
10
20 30 40
50
60
70
0
x 100
RPM
3550
UP
DOWN
EXIT
PAGES
ENTER
MENU
10
20 30 40
50
60
70
0
x 100
RPM
3550
UP
DOWN
EXIT
PAGES
ENTER
MENU
10
20 30 40
50
60
70
0
x 100
RPM
3550
UP
DOWN
EXIT
PAGES
ENTER
MENU
10
20 30 40
50
60
70
0
x 100
RPM
3550
UP
DOWN
EXIT
PAGES
ENTER
MENU
Port
Center
Accessory Harness and Relay Kit
Starboard
Hub
Main
Station
Control
Gateway
Module
Trim Switch
Panel
Master
Power
Switch
Emergency
Stop Switch
Panel
Buss Cable
Extension
Start/Stop
Switch Panel
Start/Stop
Switch Panel
Trim Switch
Panel
Information
Display
Second
Station
Control
Backbone Buss Cable
Information
Display
Hub
Buss Cable
Extension
Typical Evinrude ICON network for three outboards and two control stations 007978

15
BOAT RIGGING
BATTERY INSTALLATION
1
BATTERY INSTALLATION
Each o utboard requ ires it s own starting ba ttery.
Select a battery th at meet s or exceeds the mini-
mum requirements.
Battery Recommendations
Battery Location
Proper installation will prevent b attery movement
while underway.
•Secure all batteries in protected locations
•Place battery as close to the outboard as possi-
ble
•Battery location must pro vide a ccess fo r pe ri-
odic maintenance
•Use battery mounting trays or bat tery boxes on
all battery installations
•Connections and terminals must be covered
with an insulator
•Battery connection s mu st be cle an and free
from corrosion
•Read and un derstand the safety info rmation
supplied with the battery before installation.
Battery Connections
IMPORTANT: Connect the battery positive (+)
cable to the battery positive (+) post FIRST. Con-
nect the ba ttery negative (–) ca ble to th e battery
negative (–) post LAST.
Install a st arwasher on the threaded battery post.
Stack cables from the outboard, then cables from
accessories. Finish this connection with a hex nut.
Do not use wing nuts to fasten ANY
battery cables. Wing nuts can loosen and
cause electrical system damage not covered
under warranty.
Tighten a ll conn ections securely. Apply Triple-
Guard grease to prevent corrosion.
Outboard Model Battery Rating
115–300 HP 675 CCA (845 MCA), or
800 CCA (1000 MCA)
below 32°F (0°C)
107 amp-hr in extreme
applications
15–90 HP 640 CCA (800 MCA), or
800 CCA (1000 MCA)
below 32° F (0° C)
107 amp-hr in extreme
applications
AWARNING
Keep the battery connections clean, tight,
and insulated to prevent their shorting or
arcing and causing an explosion. If the bat-
tery mounting system does not cover the
connections, install protective covers.
Check often to see that connections stay
clean and tight.
Marine Style Battery Post
1. Starwasher
2. Hex nut
3. Terminal Insulator
DR5103
3
2
1
NOTICE

16
BOAT RIGGING
BATTERY INSTALLATION
Battery Cable Requirements
Evinrude outbo ards are shippe d with stranded
copper bat tery ca bles for typical inst allations in
which the starting battery is close to the transom.
Specialized outb oard inst allations with e xtended
length ba ttery cable s require an increased wire
size. Refer to the following table.
IMPORTANT: Inadequate ba ttery cables can
affect the performance of an outb oard’s high
amperage start circuit and th e cran king speed of
the outboard. DO NOT use aluminum wire cables.
Use ONLY AWG stranded copper wire cables.
Battery Switches and Multiple
Batteries
A multiple battery setup, including marine batte ry
selector switches, can provide fle xibility i n sing le
and dual outboard installations.
Refer to Battery and Switch Wiring Diagrams
on p. 18 for battery connection options.
The battery selection function can be used for
emergency starting if a primary bat tery become s
discharged.
The OFF po sition o f the batte ry sele ctor switch
can be used to minimize battery discharge during
periods of non-use.
Typical battery functions
Primary
•Used as starting battery under normal operating
conditions.
•Red (+) cable connected to battery switch.
•Primary battery is charge d by conne ction to
main red (+) outboard battery cable.
Dual outbo ard installations can utilize the oppos-
ing outboard's primary battery as a secondary bat-
tery for emergency starting only.
Secondary
•Used as back-up starting battery un der abn or-
mal operating conditions.
•Red (+) cable connected to battery switch.
•Secondary b attery is charged independently
from primary battery.
Accessory
•Not used as starting battery.
•Isolated from outboard start function.
•No red (+) cable connected to battery switch.
Secondary and accessory batte ries are often
charged by an iso lated batte ry ch arging circuit.
Refer to Auxiliary Battery Charging on p. 17.
Battery Switch Requirements
Battery switches must mee t the following require-
ments.
•The switch must be approved for marine use.
•The switch sh ould be a “make before break”
design.
•Switch amperage rating should be adequate for
the outboard it will be used on.
•Use one batt ery switch for each outboa rd
installed.
•Use appropriately sized wire and terminals.
•Use AWG stranded copper wire.
Battery Switch Location
•Locate battery switch as close t o the bat teries
as possible.
•Locate swit ch so that it cannot be accid ently
bumped or switched.
•Refer to the battery switch manufacturer’s
installation instructions.
•Fasten all battery switches to solid surfaces.
•Route wiring as directly as possible.
•Support the battery switch as needed to prevent
abrasion.
•Use appropriate wiring and connectors.
•Seal all connections an d te rminals with liquid
neoprene to prevent corrosion.
Insulate all battery positive (+) ter-
minals to prevent shorting.
15–30 HP 40–300 HP
1 to 10 Ft.
(.3 to 3 m)
6 Gauge 4 Gauge
11 to 15 Ft.
(3.4 to 4.6 m)
4 Gauge 2 Gauge
16 to 20 Ft.
(4.9 to 6.1 m)
2 Gauge 1 Gauge
NOTICE

17
BOAT RIGGING
BATTERY INSTALLATION
1
Battery Switch Operation
•Select the primary battery for normal operation.
•Secondary batteries should only be selected for
emergency starting.
•ALL or BOTH switch position is fo r emergency
starting only.
Provide operator with the documentation sup-
plied by the battery switch manufacturer. Make
sure that the operator is informed of proper
battery switch operation.
The negative (–) terminals of a mul-
tiple 12-volt battery installation must be con-
nected together.
Auxiliary Battery Charging
EVINRUDE E-TEC V4 – V6 MODELS
Evinrude E-TEC V4–V6 outboards are e quipped
with isolated battery char ging capability. The iso-
lated charge connection must only be used to
charge a single 12-volt battery or two 12- volt bat-
teries wired in parallel.
Never connect an external battery
isolator to the stator of an Evinrude E-TEC.
Accessory Cha rge Lead Kit, P/N 5006253, is
routed from a connector on the outboard’s electri-
cal harness to the accessory battery.
The accessory charging kit must
never be connected to any battery of a 24-volt
electrical system.
EVINRUDE E-TEC 40 – 90HP MODELS
Evinrude E-TEC 40 – 9 0 HP outb oards do n ot
have a built in isolator featu re. Proper methods
must be used to connect a second battery.
Battery charging output on 40 – 90 HP mode ls is
25 Amps. Be su re to follow published st andards
for wire gauge selection. Refer to Battery Cable
Requirements on p. 16.
If a battery isolator is desired, a batter y switch,
such as P/N 506161, and a volt age sensitive
relay, such as BEP model 710-125A, can be used
to create a battery isolator/combiner.
The voltage sensitive relay (VSR) regu lates
charging of a second battery based on prede ter-
mined voltage levels of the primary battery.
Never connect an external battery
isolator to the stator of an Evinrude E-TEC.
90° V6 Models
1. Accessory battery charge connector
004125
NOTICE
NOTICE
1
60° V4–V6 Models
1. Accessory battery charge connector
004944
1
NOTICE
NOTICE

18
BOAT RIGGING
BATTERY INSTALLATION
Battery and Switch Wiring Diagrams
Single outboard
Two outboards: Two starting batteries each
S
BOTH
OFF
12
VSR
OFF
ON
+
PRIMARY
#1
S
12
OFF
BOTH
SECONDARY
+
PRIMARY
#1
S
+#2
PRIMARY
#1
SECONDARY
#2
12 4
3
Positive (+) Battery Cable
Negative (–) Battery Cable
Accessory charge wire (V models)
50 amp fuse
1. Single starting battery with ON/OFF switch
2. Two starting batteries with isolator/combiner (15 – 90 HP models)
3. Voltage sensitive relay
4. Two starting batteries with Auxiliary charging kit (V models)
008056
SECONDARY
+
PRIMARY
S
+
12
OFF
BOTH
SECONDARY
+
PRIMARY
#1
S
+
#2
#1 #1 #2 #2
12
OFF
BOTH
Positive (+) Battery Cable
Negative (–) Battery Cable
Accessory charge wire (V models)
50 amp fuse
008055