Evinrude E-tec 2011 Series Technical manual

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Product Service Update
BRP US Inc.
Technical Publications
300 Sea Horse Drive
Waukegan, Illinois 60085 United States
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The following trademarks are the property of BRP US Inc. or its affiliates:
Printed in the United States
© 2011 BRP US Inc. All rights reserved.
TM, ® and the BRP logo are registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
Evinrude ® E-TEC ® S.A.F.E. Evinrude ® / Johnson ® XD30™ Outboard Oil
Johnson ® SystemCheck™ Evinrude ® / Johnson ® XD50™ Outboard Oil
FasTrak™ Triple-Guard Evinrude ® / Johnson ® XD100™ Outboard Oil
I-Command™ DealerPort ® TBX™
Evinrude ® ICON™ BossWeb Viper™

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GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WARRANTY INFORMATION – NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WARRANTY INFORMATION – OUTSIDE OF NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FIELD SERVICE AND TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TECHNICAL PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2011 PRODUCT IMPROVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
15 – 90 HP INLINE MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
115 – 300 HP 60°/90° V4/V6 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
15 – 30 HP MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
75 – 90 HP (1.3L) MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
115 – 300 HP 60°/90° V4/V6 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
200 – 300 HP 90° V6 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
EVINRUDE DIAGNOSTICS SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
IMPROVEMENTS AND CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
EVINRUDE ICON REMOTE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .43
ICON KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ICON RIGGING KIT SELECTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ICON INSTALLATION TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
ICON SERVICE TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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CONTENTS
I-COMMAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
I-COMMAND INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
PARTS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
P&A INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
NEW SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
ELECTRICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
EVINRUDE E-TEC SPARK PLUG SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
EMM SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
EVINRUDE E-TEC GEARCASE LINE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
2011 EVINRUDE E-TEC GEARCASE APPLICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
EVINRUDE E-TEC SHIFT ROD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
EXTERNAL WATER SCREENS AND APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
2011 RPM QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
2011 WATER PRESSURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
BULLETINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
TOPIC REFERENCE INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

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5
GENERAL INFORMATION

6
CONTACT INFORMATION
Dealers outside of North America should contact their regional
office. Refer to Dealers – Outside North America (BRP Interna-
tional Offices) on p. 7.
Dealers – North America
North American dealers should use the following contact informa-
tion.
Technical Support
After Sales Support
250 Sea Horse Drive
Waukegan, IL 60085
Ph: 1-800-888-4662 (Authorized Dealers only)
Fax: [phone] (Authorized Dealers only)
Warranty Administration Support
After Sales Support
250 Sea Horse Drive
Waukegan, IL 60085
Ph: 1-800-888-4662 (Authorized Dealers only)
Fax: [phone] (Authorized Dealers only)
Consumer Support
BRP US Inc. Customer Support Services
250 Sea Horse Drive
Waukegan, IL 60085
Ph: 1-847-689-7090 (Non-authorized dealers/consumers)
Fax [phone] (Non-authorized dealers/consumers)
Parts & Accessories Support
North American dealers may call 1-800-888-4662 for technical
assistance with parts and accessories.
•Select option 3 for ordering assistance, pricing, and back order
or returns information.
•Select option 6 for service parts issues, or application and war-
ranty questions.
To speed up the process, have your dealer number, the engine
model number, part number and invoice date available.
Technical Training Support
For questions regarding technical training, contact the Technical
Training Center.
Technical Training Center
250 Sea Horse Drive
Waukegan, IL 60085
Ph: 1-847-689-7500
Fax: [phone]

7
AFTER SALES SUPPORT
Dealers – Outside North America
(BRP International Offices)
AUSTRALIA
Bombardier Recreational Products Australia Pty Limited
56 Canterbury Road
Bankstown 2200
New South Wales, Australia
Phone: [phone]
BENELUX
BRP Europe
Skaldenstraat 125
B-9042 Gent Belgium
Phone: [phone]
BRAZIL
Bombardier Recreational Products do Brasil
Rodovia Anhanguera Km 104 - Loteamento Tecno Park
Condominio Empresarial AZTech
Avenida James Clerck Maxwell, 280 Modulo 04
Campinas, SP 13069-380 Brasil
Phone [phone]
CARIBBEAN AND LATIN AMERICA
BRP US Inc.
1600 Sawgrass Corporate Parkway, Suite 150
Sunrise FL 33323
954-846-1442
EUROPE, MIDDLE EAST AND AFRICA
BRP International Division
5-7 CH Chemin du Messidor
Lausanne Switzerland
Phone: [phone]
FRANCE
Bombardier Recreational Products France
Les Jardins de la Duranne Bâtiment C
510 rue René Descartes
F - 13857, Aix en Provence France
Phone: [phone]
GERMANY
BRP Germany GmbH
Itterpark 11
D-40724 Hilden
Germany
Phone: [phone]
JAPAN
BRP Japan Limited
15/F Parale Mitsui Building
8 Higashadi-Cho, Kawasaki-Ku
Kawasaki 210-0005
Phone: [phone]
NEW ZEALAND
BRP New Zealand
7-11 Arwen Place
East Tamaki
Auckland 2130
Phone: [phone]
SPAIN
BRP Recreational Products Spain S.L.
c/ Bertrán i Musitu 99-101
Edificio Brasil
08840 Viladecans-Barcelona Spain
Phone: [phone]
UK AND IRELAND
BRP Recreational Products UK Ltd
4 Brunel Close
Ebblake Industrial Estate
Verwood Dorset UK BH31 6BA
Phone: [phone]

8
WARRANTY INFORMATION –
NORTH AMERICA
North American dealers should use the following information.
Warranty Allowance Claims
All warranty allowance claims should be entered online when pos-
sible. When a written warranty Allowance Request Form,
P/N 773629, is required it should be mailed to:
BRP US Inc.
After Sales Support
P.O. Box 597
Sturtevant, WI 53177
Warranty parts returned with a Warranty Allowance Request Form,
P/N 773629, should be shipped to:
U.S. dealers ship to:
BRP US Inc.
After Sales Support
300 Sea Horse Drive Dock 5
Waukegan, IL 60085
Canadian dealers ship to:
BRP Warranty Returns – Waukegan
c/o Affiliated Global Logistics
500 Carlingview Drive
Etobicoke, ON M9W 5R3
Prior Authorization Required for Parts and
Accessories Warranty
If a replacement part or a dealer-rebuild fails, contact
Evinrude/Johnson After Sales Support. Dealers are not authorized
to rebuild assemblies without prior authorization.
Have your dealer number, the engine model and serial number,
part number and invoice date available.
Certain parts or assemblies may require additional documentation:
•BRP invoice for the assembly
•installation work order
•previous work order for original repair
•sales receipt (over the counter sales)
Refer to “Parts and Accessories Claims” in the current Warranty
Procedures Manual.
B.E.S.T. Warranty
As outboards enter the service period of a B.E.S.T. contract, there
are several requirements that dealers and customers should be
aware of:
•A 300 hour service (or 3 year inspection) on every outboard
•An inspection report must be provided before any B.E.S.T con-
tract repairs are performed
•Engine must have less than 1000 hours
•There is a $50.00 deductible for each B.E.S.T. contract repair
•Dealers must qualify all engine repairs for outboards with
B.E.S.T. coverage
Refer to Administrative Bulletin 2010-04(A) for complete details
and coverage checklist.

9
AFTER SALES SUPPORT
WARRANTY INFORMATION –
OUTSIDE OF NORTH AMERICA
Dealers outside of North America should contact their regional
office for processing of warranty allowance claims, or returning
parts. Refer to Dealers – Outside North America (BRP Interna-
tional Offices) on p. 7.
Predelivery Checklist Included in Shipping
Crate
A Predelivery Checklist is now included in the shipping crate
(owner’s package) of all Evinrude E-TEC outboards. A pack of ten
(10) predelivery checklist forms, P/N 5008381, is available through
Evinrude/Johnson Genuine Parts.
Dealers are REQUIRED to perform a complete predelivery inspec-
tion on each outboard. Dealers MUST keep predelivery checklists
on file for a minimum of seven years.
Refer to Predelivery Bulletin 2010-01(D) for complete details.

10
FIELD SERVICE AND TRAINING
Dealers outside of North America should contact their regional
office. Refer to Dealers – Outside North America (BRP Interna-
tional Offices) on p. 7.
Dealers – North America
Technical Service Representatives –
Applications Engineers (TSR-AE’s)
TSR–AE's support both Dealer and OEM Partners. TSR–AE tech-
nical support visits are coordinated through the After Sales Support
Call Center. Dealer and OEM Technicians should first contact the
After Sales Support Center Team to resolve technical issues. Con-
tact them at 1-800-888-4662 and follow the prompts.
TSR-AE's provide the following dealer support:
•Service department development assistance (Service Evalua-
tions and goal setting)
•Feedback reports for product and business trends
•Technical support of BRP Outboard Engine products
•Customer Relations
•Serve as instructors at Dallas, Tacoma and Laval Training Cen-
ters
TSR's provide the following OEM partner support:
•All aspects of rigging, technical training to ensure safety and
maximum performance for BRP powered boats
•Feedback reports for product and business trends
•Preparation and distribution of Performance Reports
Training
Schedule training online (www.DealerPort.com). For questions
contact the Technical Training Center.
Training courses are offered at the following locations:
•Waukegan, Illinois
•Morrow, Georgia
•Tacoma, Washington
•Laval, Quebec
•Dallas, Texas
Technician Certification
Technicians who achieved "Certified" status between June 2005
and June 2006 must attend the Outboard Certification Course by
May 30, 2011. Certified status WILL EXPIRE soon for technicians
who fall into this category.
Technicians who achieved "Certified" status prior to June 2005
were required to return in prior training seasons. Certified status is
EXPIRED for technicians who fall into this category. They should
return as soon as possible to recertify.

11
AFTER SALES SUPPORT
Master Technician Program
Technicians desiring Master Technician status MUST:
1. Maintain Certified status for at least 4 years (no lapses).
2. Successfully complete all updates by the due date.
3. Complete Outboard Certification Course in 4.5 days or less.
4. Upon successful completion of the Outboard Certification
Course, technicians who meet the qualifications, and who are
approved by their instructor(s) will be given the opportunity to
take the Master Technician exam.
5. Complete the 50 question exam with a minimum score of 90%.
The exam may include questions on ANY outboards sold or mar-
keted by BRP.
To maintain Master Technician status, technicians MUST:
•Complete all distance learning updates by the due date.
•Return for hands-on training when required. See Technician
Certification on p. 10.
•When returning to the Outboard Certification Course, technicians
must complete the course and pass Master Technician exam as
outlined in steps 3 through 5 above.
If a technician allows their Certification to lapse, Master Technician
status is lost.
A technician can take a missed exam at any time to have Certified
status reinstated. However, Master Technician status can only be
reinstated by again meeting the qualifications listed in steps 1
through 5 above.
TECHNICAL PUBLICATIONS
Changes to Service Manual Set
Please note the following changes to the 2011 Service Manuals
and Service Manual Sets:
•The Installation and Predelivery section has been removed from
individual service manuals.
•The Special Tools section has been removed from individual ser-
vice manuals.
•The 2011 Installation and Predelivery Guide has been added to
the Service Manual Set. Additional Installation and Predelivery
Guides may be ordered using P/N 5008506.
•The 2011 Special Tool Guide has been added to the Service
Manual Set.
IMPORTANT: The 2011 Special Tool Guide, P/N 5008526, con-
tains tools for current Evinrude E-TEC product only. Dealers should
retain a copy of the 2010 Special Tools Guide, P/N 5007858, or a
prior Special Tools Guide as a reference of tools for older outboard
products.

12
NOTES – GENERAL INFORMATION

13
2011 PRODUCT IMPROVEMENTS

14
1. Engine management software version and revision
1. 6-pin AMP connector (tiller harness)
2. 2-pin AMP connector (neutral switch)
1
2
1
15 – 90 HP INLINE MODELS
Engine Management Software 15 – 30 HP Models
Engine management software has been developed to improve emissions and
reduce fuel consumption on 15 – 30 HP models.
Update engine management software on engines with serial numbers 5283875
to 5289986.
Refer to Warranty Bulletin 2010-09(W).
Engine Wiring Harness Change 15 – 30 HP Models
Evinrude E-TEC 15 – 30 HP (C, H, R, and S-suffix) model outboards have a new
engine wiring harness to support changes to the Touch Troll and neutral
switches.
The Touch Troll switch connector has been eliminated. Wiring for the Touch Troll
switch has been relocated to a new 6-pin AMP connector of the tiller harness.
The neutral switch has a dedicated 2-pin AMP connector, similar to other
Evinrude E-TEC models.

15
2011 PRODUCT IMPROVEMENTS
New Flywheel Torque Specification 15 – 30 HP Models
When servicing flywheels on Evinrude E-TEC 15 – 30 HP outboards, torque the
flywheel nut to 66 to 70 ft. lbs (90 to 95 N·m).
IMPORTANT: Torque the flywheel using the correct flywheel holder. To prevent
damage to the crankcase or the cylinder block, DO NOT allow the flywheel
holder to rest against the mounting boss for the recoil starter.
Also refer to Service Bulletin 2010-08(S), or the 2011 Service Manual.
Lower Mount 15 – 30 HP Models
A bump stop washer, P/N 353674, was added to the lower mount on 15 – 30 HP
models. This change to improves impact protection, and provides common ser-
vice parts and procedures for all 15 – 30 HP models.
Refer to the correct Service Manual for lower mount service procedures.
1. Bump stop washer
1

16
1. Vent
1. Nut
2. Spring
1
1
2
Oil Cap Assembly, 15 – 90 HP Models
The oil cap used on 15 – 90 HP models has changed.
The oil cap has a redesigned vent valve, to help prevent oil from leaking out of
the vent while the engine is tilted.
Oil cap assembly, P/N 5008406, replaces oil cap assembly, P/N 5007256, and
services 2009 and newer 15 – 30 HP models and 2010 and newer 40 – 90 HP
(F-suffix) models.
Electric Starter Motor Change 40 – 65 HP Models
The electric starter motor used on Evinrude E-TEC 40 – 65 HP models has been
changed.
The starter features a new nut and spring to retain the drive gear. Previously, the
drive gear was retained with a clip, spring and spacers. This change improves
the durability of the starter and provides common service for all 15 – 65 HP mod-
els.
The electric starter motor, P/N 587045, services all 2004 and newer 15 – 65 HP
models.

17
2011 PRODUCT IMPROVEMENTS
Throttle Body Assembly 40 – 65 HP Models
A new throttle body assembly is used on all 40 – 65 HP models.
The throttle body assembly features a nickel-plated throttle valve, which
improves corrosion resistance and durability. The new throttle valve is silver in
color, while the previous throttle valve was gold in color.
The new throttle body assembly, P/N 5008407, services all 2004 and newer 40 –
65 HP models.
Exhaust Housings 40 – 65 HP Models
A change was made to the exhaust housing for 40 – 65 HP models.
Retainer tabs have been added to the exhaust housing to better secure the
engine wiring harness. Tie straps are now used to secure the engine wiring har-
ness, rather than the previous “J-clamps.”
This change also makes it easier to reinstall and secure the engine wiring har-
ness when servicing the engine.
Exhaust housing, P/N 5008275, services 2006 and newer 40 – 50 HP models.
Exhaust housing, P/N 5008274, services 2006 and newer 60 – 65 HP models.
1. Throttle valve
Exhaust Housing
1. Tie straps
1
1

18
1. Clamp, oil sensor to housing, P/N 982115
1
115 – 300 HP 60°/90° V4/V6 MODELS
Lower Engine Covers 115 – 200 HP 60° Models
Lower engine covers for 115 – 200 HP 60° models have been changed. The
lower engine covers feature a new fastener insert that reduces the risk of crack-
ing the lower engine covers during removal and installation.
Service parts for older product will supersede to new part numbers. Refer to the
correct Parts Catalog for parts ordering information.
Note: Do not use power/impact tools to tighten lower engine cover screws.
Oil Pressure Sensor 115 – 300 HPModels
Clamp, P/N 982115, is now used to retain the oil pressure sensor to the oil pump
housing on all V4 and V6 models.
This change improves the retention of the oil pressure sensor and provides com-
mon service parts for these models.