Evinrude E-Tec 40 HP User manual

Printed in the United States.
© 2011 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.
The following trademarks are the property of BRP US Inc. or its affiliates:
Evinrude ® Twist Grip™
Johnson ® Nut Lock™
Evinrude ® E-TEC ® Screw Lock™
FasTrak™ Ultra Lock™
S.A.F.E.™ Moly Lube™
SystemCheck™ Triple-Guard ® Grease
I-Command™ DPL™ Lubricant
Evinrude ® ICON™ 2+4 ® Fuel Conditioner
Evinrude ® / Johnson ® XD30™ Outboard Oil Carbon Guard™
Evinrude ® / Johnson ® XD50™ Outboard Oil HPF XR™ Gearcase Lubricant
Evinrude ® / Johnson ® XD100™ Outboard Oil HPF PRO™ Gearcase Lubricant
Gel-Seal II™

2
SERVICE MANUAL
CONTENTS
SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE
1 REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
2 ROUTINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 ENGINE COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . 49
4 ENGINE MANAGEMENT MODULE (EMM) . . . . . . . . . . 53
5 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . . 87
7 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
8 OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
9 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
10 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
11 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
12 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
GEARCASE SERVICE, 40 – 65 HP MODELS . . . . . . . 296
GEARCASE SERVICE, 75 – 90 HP MODELS . . . . . . . 318
13 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
14 MANUAL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I–1
TROUBLE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . T–1
DIAGRAMS
IMPORTANT: For complete outboard rigging and control installation information, refer to the Predeliv-
ery and Installation Guide included with the service manual set.
All special tools referenced in this manual can be found in the Special Tools Guide, P/N 5008526.

REFERENCE INFORMATION
3
1
REFERENCE INFORMATION
TABLE OF CONTENTS
SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
EMISSION-RELATED INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
MANUFACTURER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
DEALER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OWNER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
EPA EMISSION REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

REFERENCE INFORMATION
SAFETY NOTICE
SAFETY NOTICE
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
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 required, use
Evinrude/Johnson Genuine Parts or parts with
equivalent characteristics, including type, strength
and mate rial. Use of subst andard p arts 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 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 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

REFERENCE INFORMATION
SAFETY NOTICE
1
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
REFERENCE INFORMATION
ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL
Units of Measurement List of Abbreviations
A Amperes
amp-hr Ampere hour
fl. oz. fluid ounce
ft. lbs. foot pounds
HP horsepower
in. inch
in. Hg inches of mercury
in. lbs. inch pounds
kPa kilopascals
ml milliliter
mm millimeter
N·m Newton meter
P/N part number
psi pounds per square inch
RPM revolutions per minute
°C degrees Celsius
°F degrees Fahrenheit
ms milliseconds
µs microseconds
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
REFERENCE INFORMATION
EMISSION-RELATED INSTALLATION INSTRUCTIONS
1
EMISSION-RELATED
INSTALLATION
INSTRUCTIONS
Failing to follow these instructions when
installing a certified engine in a vessel violates
federal law (40 CFR 1068.105 (b)), subject to
fines or other penalties as described in the
Clean Air Act.
Maintenance, replacement, or 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 1 999 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 that 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 pertaining 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
REFERENCE INFORMATION
MODEL DESIGNATION
MODEL DESIGNATION
Model and serial numbers are located on the swivel bracket and on the powerhead.
BE 200 DP X IN E
STYLE:
J = Johnson
E = Evinrude
HORSEPOWER
LENGTH:
= 15” Std.
L = 20” Long
Y = 22.5” Special
X = 25” X-long
Z = 30” XX-long
MODEL YR:
I= 1
N= 2
T= 3
R= 4
O= 5
D= 6
U= 7
C= 8
E= 9
S= 0
Ex: IN = 2012
MODEL RUN
or SUFFIX
DESIGN FEATURES:
B = Blue Paint
C = Counter Rotation
D = Evinrude E-TEC®
E = Electric Start w/Remote Steering
F = Direct-Injection
G = Graphite Paint
H = High Output
J = Jet Drive
M = Military
P = Power Trim and Tilt
R = Rope Start w/Tiller Steering
S = Saltwater Approved
T = Tiller Steering
TE = Tiller Electric
V = White Paint
W = Commercial Model
PREFIX:
B = Bodensee model
D = ICON model
1. Model and serial number 002224
1
1. Serial number 002225
1

REFERENCE INFORMATION
MODELS COVERED IN THIS MANUAL
9
1
MODELS COVERED IN THIS MANUAL
This manual covers service information on all 52.7 cubic inch (.86 L), 2-Cylinder; and 79 cubic inch (1.29
L), 3-Cylinder Evinrude E-TEC models.
Model Displacement Gearcase Height Color
Description
E40DRLINC .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Manual Tilt, Tiller Steering, Rope Start
E40DTLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Tiller Steering, Electric Start
E40DPLINC .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Remote Steering, Electric Start
E40DSLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" White Power Tilt, Remote Steering, Electric Start
E40DHLINS .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Remote Steering, Electric Start, H.O. Stylin
g
E40DHSLINS .86 L, 52.7 ci 12:32 / 0.375 F 20" White Power Tilt, Remote Steering, Electric Start, H.O. Stylin
g
E50DTLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Tiller Steering, Electric Start
E50DPLINC .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Remote Steering, Electric Start
E50DSLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" White Power Tilt, Remote Steering, Electric Start
E60DTLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Tiller Steering, Electric Start
E60DPLINC .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Power Tilt, Remote Steering, Electric Start
E60DSLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" White Power Tilt, Remote Steering, Electric Start
E65WDRLINM .86 L, 52.7 ci 12:32 / 0.375 F 20" Blue Manual Tilt, Tiller Steering, Rope Start
E65WDRYINM .86 L, 52.7 ci 12:32 / 0.375 F 22.5" Blue Manual Tilt, Tiller Steering, Rope Start
E75DPLINC 1.29 L, 79.0 ci 13:26 / 0.50 S 20" Blue Power Tilt, Steel Steering Arm
E75DSLINM 1.29 L, 79.0 ci 13:26 / 0.50 S 20" White Power Tilt, Stainless Steering Arm
E90DPLINC 1.29 L, 79.0 ci 13:26 / 0.50 S 20" Blue Power Tilt, Steel Steering Arm
E90DSLINS 1.29 L, 79.0 ci 13:26 / 0.50 S 20" White Power Tilt, Stainless Steering Arm
E90DPXINC 1.29 L, 79.0 ci 12:27 / 0.444 O 25" White Power Tilt, Stainless Steering Arm
E90WDELINM 1.29 L, 79.0 ci 13:26 / 0.50 S 20" Blue Manual Tilt, Steel Steering Arm, Commercial Model
E90WDEXINM 1.29 L, 79.0 ci 12:27 / 0.444 O 25" White Manual Tilt, Steel Steering Arm, Commercial Model

10
REFERENCE INFORMATION
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
40 – 65 HP E-TEC Models
ENGINE
Full Throttle
Operating Range RPM
40 HP – 5000 to 6000 RPM
50 HP – 5500 to 6000 RPM
60 HP – 5500 to 6000 RPM
65 HP – 5500 to 6000 RPM
Power
40 HP (29.4 kw) @ 5500 RPM
50 HP (36.8 kw) @ 5750 RPM
60 HP (44.1 kw) @ 5750 RPM
65 HP (47.8 kw) @ 5750 RPM
Idle RPM in Gear 800 ± 50 EMM Controlled
Idle RPM in Neutral 750 ± 50 EMM Controlled
Test Propeller P/N 382861
Weight
(may vary depending
on model)
(RL) Models: 232 lbs. (105 kg)
(HL, PL, SL, TL) Models: 240 lbs. (109 kg)
Lubrication Evinrude/Johnson XD100, XD50, XD30; or
NMMA TC-W3 certified
Engine Type In-line, 2 Cylinder, Two-Cycle
Displacement 52.7 cu. in. (864 cc)
Bore 3.601 in (91.47 mm)
Stroke 2.588 in. (65.74 mm)
Standard Bore 3.6005 to 3.6015 in. (91.45 to 91.48 mm)
To bore oversize, add piston oversize dimension to standard bore
Top Crankshaft Journal 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Center Crankshaft Journal 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Bottom Crankshaft Journal 1.5747 to 1.5752 in. (40.0 to 40.01 mm)
Rod Crankpin 1.3757 to 1.3762 in. (34.94 to 34.96 mm)
Piston Ring End Gap, Both 0.011 to 0.023 in. (0.28 to 0.58 mm)
FUEL
Fuel/Oil Control EMM Controlled
Starting Enrichment EMM Controlled
Minimum (High) Fuel Pressure 24 to 28 psi (165 to 193 kPa)
Minimum Fuel Lift
Pump Pressure 3 psi (21 kPa)
Maximum Fuel Inlet Vacuum 4 in. Hg.
Minimum Octane 87 AKI (R+M)/2 or 90 RON
Additives
2+4 ®Fuel Conditioner, Fuel System Cleaner
Use of other additives may result in engine damage.
See Fuel Requirements on p. 131 for additional information

REFERENCE INFORMATION
SERVICE SPECIFICATIONS
11
1
40 – 65 HP E-TEC Models
ELECTRICAL
Minimum Battery
Requirements 640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C)
Alternator 25-Amp fully regulated. Refer to Predelivery and Installation Guide for multiple battery
applications.
Tachometer Setting 6 pulse (12 pole)
Engine Fuse P/N 967545 – 10 A
COOLING
Thermostat 14 3°F (62°C)
Maximum Temperature 212°F (100°C)
Water pressure 12 to 14 psi @ 5000 RPM
IGNITION
Type Capacitor Discharge
Firing Order 1-2
Ignition Timing EMM Controlled
RPM Limit in Gear 6250
RPM Limit in Neutral 1800
Crankshaft Position Sensor Air
Gap Fixed
Spark Plug Refer to Emission Control Information Label
Champion† QC10WEP @ 0.028 ± 0.003 in. (0.71 mm)
GEARCASE
Gear Ratio 12:32 (.375)
Lubricant HPF XR Gearcase Lube
HPF Pro in high performance or commercial applications
Capacity 22 fl. oz. (650 ml)
Shift Rod Height 20 in. (L) Models: 21.38 (543 mm) ± one-half turn
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD
POWER TRIM/TILT
Lubrication Evinrude/Johnson Biodegradable TNT Fluid
Fluid Capacity 15.2 fl. oz. (450 ml)
Trim Range 0° to 15°
Tilt Range 16° to 65°

12
REFERENCE INFORMATION
SERVICE SPECIFICATIONS
75 – 90 HP E-TEC Models
ENGINE
Full Throttle
Operating Range RPM 4500 to 5500 RPM
Power 75 HP (56 kw) @ 5000 RPM
90 HP (67.1 kw) @ 5000 RPM
Idle RPM in Gear 700 ± 50 EMM Controlled
Idle RPM in Neutral 600 ± 50 EMM Controlled
Test Propeller (L) Models: P/N 386246
(X) Models: P/N 387388
Weight
(may vary depending
on model)
(L) Models: 320 lbs. (145 kg)
(X) Models: 335 lbs. (152 kg)
Lubrication Evinrude/Johnson XD100, XD50, XD30; or
NMMA TC-W3 certified
Engine Type In-line, 3 Cylinder, Two-Cycle
Displacement 79.1 cu. in. (1296 cc)
Bore 3.601 in (91.47 mm)
Stroke 2.588 in. (65.74 mm)
Standard Bore 3.6005 to 3.6015 in. (91.45 to 91.48 mm)
To bore oversize, add piston oversize dimension to standard bore
Top Crankshaft Journal 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Center Crankshaft Journals 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Bottom Crankshaft Journal 1.5747 to 1.5752 in. (40.0 to 40.01 mm)
Rod Crankpin 1.3757 to 1.3762 in. (34.94 to 34.96 mm)
Piston Ring End Gap, Both 0.011 to 0.023 in. (0.28 to 0.58 mm)
FUEL
Fuel/Oil Control EMM Controlled
Starting Enrichment EMM Controlled
Minimum (High) Fuel Pressure 24 to 28 psi (165 to 193 kPa)
Minimum Fuel Lift
Pump Pressure 3 psi (21 kPa)
Maximum Fuel Inlet Vacuum 4 in. Hg.
Minimum Octane 87 AKI (R+M)/2 or 90 RON
Additives
2+4 ®Fuel Conditioner, Fuel System Cleaner
Use of other additives may result in engine damage.
See Fuel Requirements on p. 131 for additional information

13
REFERENCE INFORMATION
SERVICE SPECIFICATIONS
1
75 – 90 HP E-TEC Models
ELECTRICAL
Minimum Battery
Requirements 640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C)
Alternator 25-Amp fully regulated. Refer to Predelivery and Installation Guide for multiple battery
applications.
Tachometer Setting 6 pulse (12 pole)
Engine Fuse P/N 967545 – 10 A
COOLING
Maximum Temperature 212°F (100°C)
Thermostat 143°F (62°C)
Water pressure 19 to 21 psi @ 5000 RPM
IGNITION
Type Capacitor Discharge
Firing Order 1-2-3
Ignition Timing EMM Controlled
RPM Limit in Gear 6250
RPM Limit in Neutral 1800
Crankshaft Position Sensor Air
Gap Fixed
Spark Plug Refer to Emission Control Information Label
Champion† QC10WEP @ 0.028 ±.003 in. (0.71 mm)
GEARCASE
Gear Ratio 20 in. (L) Models: 13:26 (.500)
25 in. (X) Models: 12:27 (.444)
2:1
2.25:1
Lubricant HPF XR Gearcase Lube
Capacity 20 in. (L) Models: 31.6 fl. oz. (935 ml)
25 in. (X) Models: 32.8 fl. oz. (970 ml)
Shift Rod Height 20 in. (L) Models: 21.25 (539.75 mm) ± one-half turn
25 in. (X) Models: 26.25 (666.75 mm) ± one-half turn
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD
POWER TRIM/TILT
Lubrication Single Piston System–Evinrude/Johnson Biodegradable TNT Fluid
Fluid Capacity 21 fl. oz. (620 ml)
Trim Range 0° to 15°
Tilt Range 16° to 65°

14
REFERENCE INFORMATION
STANDARD TORQUE SPECIFICATIONS
STANDARD TORQUE
SPECIFICATIONS PRODUCT REFERENCE AND ILLUSTRATIONS
BRP US Inc. reserves the right to make changes
at a ny time, wit hout no tice, in specificatio ns a nd
models and also to discon tinue models. The rig ht
is also reserve d to change any specifications or
parts, at any time, without incurring any obligation
to equ ip same on mode ls manufactured prior to
date of such ch ange. Specifications used are
based on the late st product information a vailable
at the time of publication.
The continuing accuracy of this manual cannot be
guaranteed.
All photographs and illustrations used in this man-
ual may no t de pict a ctual models or equipment,
but are intended as representative views for refer-
ence only.
Certain features or systems discussed in this
manual mig ht not be found o n all mod els in all
marketing areas.
All service technicians must be familiar with nauti-
cal orient ation. This manual of ten identifies p arts
and procedures using these terms.
Size In. Lbs. Ft. Lbs. N·m
No. 6 7–10 0.58–0.83 0.8–1.1
No. 8 15–22 1.25–1.83 1.7–2.5
No. 10 24–36 2–3 2.7–4.0
No. 12 36–48 3–4 4.0–5.4
1/4 in. 60–84 5–7 7-9.5
5/16 in. 120–144 10–12 13.5–16.5
3/8 in. 216–240 18–20 24.5–27
7/16 in. 336–384 28–32 38–43.5
M3 15–22 1.25–1.83 1.7–2.5
M4 24–35 2–2.9 2.7–4.0
M5 35–60 2.9–5 4.0–6.8
M6 84–106 7–8.8 9.5–12
M8 177–204 14.7–17 20–23
M10 310–336 25.8–28 35–38
IMPORTANT: These values apply only when a
specific torque for a specific fastener is not listed
in the appropriate section. When tightening two
or mo re screws on the same p art, DO NOT
tighten screws completely, one at a time.
AWARNING
Torque wrench tightening specifications
must be strictly adhered to. Replace any
locking fastener (locknut or patch screw)
if its locking feature becomes weak. Defi-
nite resistance to turning must be felt
when reusing a locking fastener.
If replacement is specified or required
because the locking fastener has become
weak, use only authorized Evinrude/John-
son Genuine Parts.
Nautical Orientation 006411

ROUTINE SERVICE
15
2
ROUTINE SERVICE
TABLE OF CONTENTS
INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
LIFTING THE OUTBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
OUTBOARD RIGGING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
CONTROL CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
SYSTEMCHECK HARNESS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
I-COMMAND NETWORK CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
WATER PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
BATTERY AND BATTERY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
OETIKER CLAMP SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
STEERING FRICTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
THROTTLE FRICTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
TILT LIMIT SWITCH ADJUSTMENT (75 – 90 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
TRIM SENDING UNIT ADJUSTMENT (40 – 60 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
TRIM SENDING UNIT ADJUSTMENT (75 – 90 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
TRIM TAB ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
DUAL-OUTBOARD ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
ENGINE FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
RUNNING THE OUTBOARD USING A HOSE AND FLUSHING ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . .36
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
TILLER HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
SWIVEL BRACKET AND TRAILERING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
THROTTLE AND SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
FUEL AND OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
OIL FILTERS AND OIL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
AIR SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
HOSES AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
FUEL SYSTEM TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
INTERNAL ENGINE TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
ADDITIONAL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
PRE-SEASON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
SUBMERGED ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

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

17
ROUTINE SERVICE
LIFTING THE OUTBOARD
2
LIFTING THE
OUTBOARD
Use correct Lifting Fixture to lift outboard:
With re coil st arter re moved, Place lif ting t ool on
flywheel and se at the three screws completely.
Refer to RECOIL STARTER REMOVAL on
p. 363.
Use only the 1 1/8 in. (short)
screws, P/N 398067, included with the tool to
avoid damage to electronic components under
the flywheel.
Fasten appropriate chain hoo k to eye of too l.
Carefully hoist outboard with chain and unbolt out-
board mounting brackets from frame.
OUTBOARD RIGGING
CONNECTIONS
IMPORTANT: For complete outboard riggin g
and remote control installation information, refer to
the Predelivery and Installation Guide included
with the service manual set.
Common Practices – All Models
Control Cable Identification
IMPORTANT: Identify con trol ca ble fun ction
before rigging outboard.
Identify each control cable:
•Put the co ntrol handle into NEUTRAL positio n.
The throttle cable casing guide will retract com-
pletely and the shift cable casing guide will go to
the midpoint of its travel.
Extend the control cables and lubricate them with
Triple-Guard grease.
AWARNING
To avoid personal injury, make sure the lift-
ing capacity of the hoist is at least twice
the weight of the outboard.
DO NOT allow the lift hook or chain from
the hoist to come in contact with any part
of the engine during lifting.
Model Lifting Fixture
40–90 HP P/N 396748 with
1 1/8 in. screws
1. Lifting fixture
2. 1 1/8 in. screws 002098
2
1
NOTICE
1. Shift cable casing guide extended to midpoint
2. Throttle cable casing guide retracted DP0811
30501
1
2

18
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
Cable Retainer Clip Installation
When installing retainer clips on control arm lin k-
age pins, clips should be locked and must not be
bent or deformed.
For proper installation, review the following steps:
•Place washer on pin.
•Position retainer clip with straight section on the
bottom and angled section on the top.
•Use long nose pliers to insert straight section of
clip into linkage pin hole.
•Push th e clip toward s t he h ole while li fting on
the curved end with the pliers.
•Be sure retainer clip fully engages the pin.
•Lock the retainer by moving the an gled section
behind the straight section.
Cable, Hose, and Wire Routing
Refer to Control Cable Identification on p. 17.
Apply soapy water to the inside surfaces of grom-
met and install cables and fuel line as shown:
Place the g rommet int o position in the lower
engine cover.
When g rommet is in p lace and all cables have
been installed, tighten a tie strap around the out-
side of the gromme t to form a watertight sea l
around the cables.
1. Straight section
2. Angled section DP0818
DP0817
Locked Retainer Clip
1. Angled section behind straight section DP0817a
1
2
1
ACAUTION
To prevent accidental starting while servic-
ing, disconnect the battery cables at the
battery. Twist and remove all spark plug
leads.
1. Throttle cable
2. Shift cable
3. Main wiring harness
4. Battery cable
5. Fuel line
001998
002104
3
4
5
1
2