Evinrude E-TEC E115DPLSCR User manual

Printed in the United States.
© 2008 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
BRP US Inc.
Technical Publications
250 Sea Horse Drive
Waukegan, Illinois 60085 United States
† AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II
are registered trademarks of Tyco International, Ltd.
† Amphenol is a registered trademark of The Amphenol Corporation.
† 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 ® Nut Lock™
Johnson ® Screw Lock™
Evinrude ® E-TEC ® Ultra Lock™
FasTrak™ Gel-Seal II™
S.A.F.E.™ Moly Lube™
SystemCheck™ Triple-Guard ® Grease
I-Command™ DPL™ Lubricant
Evinrude ® / Johnson ® XD30™ Outboard Oil 2+4 ® Fuel Conditioner
Evinrude ® / Johnson ® XD50™ Outboard Oil Carbon Guard™
Evinrude ® / Johnson ® XD100™ Outboard Oil HPF XR™ Gearcase Lubricant
Twist Grip™

2
TABLE
OF
CONTENTS
SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 INSTALLATION AND PREDELIVERY . . . . . . . . . . . . . . 27
3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 ENGINE COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . 89
5 ENGINE MANAGEMENT MODULE (EMM) . . . . . . . . . . 93
6 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . 127
8 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
9 OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
10 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
11 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
12 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
13 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
STANDARD ROTATION . . . . . . . . . . . . . . . . . . . . . . . . 307
COUNTER ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . 338
14 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I–1
TROUBLE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . T–1
DIAGRAMS
EMM SERVICE CODE CHART

INTRODUCTION
3
INTRODUCTION
CONTENTS
ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ENGINE EMISSIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
IDENTIFYING MODEL AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

SAFETY INFORMATION
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This manual is written for qualified, factory-trained
technicians who are already familiar with the use
of Evinrude®/Johnson®Special Tools. This man-
ual is not a substitute for work experience. It is an
organized guide for reference, repair, and mainte-
nance of the outboard(s).
This manual uses the following signal words iden-
tifying important safety messages.
IMPORTANT: Identifies information that will
help prevent damage to machinery and appears
next to information that controls correct assembly
and operation of the product.
These safety notices mean:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Always follow common shop safety practices. If
you have not had training related to common shop
safety practices, you should do so to protect your-
self, as well as the people around you.
It is understood that this manual may be trans-
lated into other languages. In the event of any dis-
crepancy, the English version shall prevail.
To reduce the risk of personal injury, safety warn-
ings are provided at appropriate times throughout
the manual.
DO NOT make any repairs until you have read the
instructions and checked the pictures relating to
the repairs.
Be careful, and never rush or guess a service pro-
cedure. Human error is caused by many factors:
carelessness, fatigue, overload, preoccupation,
unfamiliarity with the product, and drugs and alco-
hol use, to name a few. Damage to a boat and
outboard can be fixed in a short period of time, but
injury or death has a lasting effect.
When replacement parts are required, use
Evinrude/Johnson Genuine Parts or parts with
equivalent characteristics, including type, strength
and material. Using substandard parts could
result in injury or product malfunction.
Torque wrench tightening specifications must be
strictly followed. Replace any locking fastener
(locknut or patch screw) if its locking feature
becomes weak. Definite resistance to turning
must be felt when reusing a locking fastener. If
replacement is specified or required because the
locking fastener has become weak, use only
authorized Evinrude/Johnson Genuine Parts.
If you use procedures or service tools that are not
recommended in this manual, YOU ALONE must
decide if your actions might injure people or dam-
age the outboard.
DANGER
Indicates an imminently hazardous situa-
tion which, if not avoided, WILL result in
death or serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, CAN result in severe
injury or death.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, MAY result in minor
or moderate personal injury or property
damage. It also may be used to alert
against unsafe practices.

DANGER
Contact with a rotating propeller is likely to result in serious injury or death. Assure the
engine and prop area is clear of people and objects before starting engine or operating boat.
Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and
the propeller can continue to turn even after the engine is off. Remove propeller before ser-
vicing and when running the outboard on a flushing device.
DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to
accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled,
can cause serious brain damage or death.
WARNING
Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172
kPa).
The motor cover and flywheel cover are machinery guards. Use caution when conducting
tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and
clothing away from rotating parts.
During service, the outboard may drop unexpectedly. Avoid personal injury; always support
the outboard’s weight with a suitable hoist or the tilt support bracket during service.
To prevent accidental starting while servicing, disconnect the battery cables at the battery.
Twist and remove all spark plug leads.
The electrical system presents a serious shock hazard. DO NOT handle primary or secondary
ignition components while outboard is running or flywheel is turning.
Gasoline is extremely flammable and highly explosive under certain conditions. Use caution
when working on any part of the fuel system.
Protect against hazardous fuel spray. Before starting any fuel system service, carefully
relieve fuel system pressure.
Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular
phones in the vicinity of a fuel leak or while fueling.
Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and
causing an explosion.
Always work in a well ventilated area.
Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak.
Definite resistance to tightening must be felt when reusing a locking fastener. If replacement
is indicated, use only authorized replacement or equivalent.

6
INTRODUCTION
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
CPS crankshaft position sensor
EMM Engine Management Module
ICOMIA International Council of Marine
Industry Associations
MCA marine cranking amps
MWS modular wiring system
NMEA National Marine Electronics Assoc.
NTC negative temperature coefficient
PTC positive temperature coefficient
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
WOT wide open throttle
WTS water temperature sensor

7
INTRODUCTION
ENGINE EMISSIONS INFORMATION
ENGINE EMISSIONS
INFORMATION
Maintenance, replacement, or repair of the
emission control devices and systems may be
performed by any marine SI (spark ignition)
engine repair establishment or individual.
Manufacturer’s Responsibility
Beginning with 1999 model year outboards, man-
ufacturers of marine outboards must determine
the exhaust emission levels for each outboard
horsepower family and certify these outboards
with the United States of America Environmental
Protection Agency (EPA). An emissions control
information label, showing emission levels and
outboard specifications, must be placed on each
outboard at the time of manufacture.
Dealer’s Responsibility
When performing service on all 1999 and more
recent Evinrude/Johnson outboards that carry an
emissions control information label, adjustments
must be kept within published factory specifica-
tions.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the outboard in any
manner that would alter the horsepower or allow
emission levels to exceed their predetermined
factory specifications.
Exceptions include manufacturer’s prescribed
changes, such as altitude adjustments, for exam-
ple.
Owner’s Responsibility
The owner/operator is required to have outboard
maintenance performed to maintain emission lev-
els within prescribed certification standards.
The owner/operator is not to, and should not allow
anyone to, modify the outboard in any manner
that would alter the horsepower or allow emis-
sions levels to exceed their predetermined factory
specifications.
Tampering with the fuel system to change horse-
power or modify emission levels beyond factory
settings or specifications will void the product war-
ranty.
EPA Emission Regulations
All new 1999 and more recent Evinrude/Johnson
outboards are certified to the EPA as conforming
to the requirements of the regulations for the con-
trol of air pollution from new watercraft marine
spark ignition outboards. This certification is con-
tingent on certain adjustments being set to factory
standards. For this reason, the factory procedure
for servicing the product must be strictly followed
and, whenever practical, returned to the original
intent of the design. The responsibilities listed
above are general and in no way a complete list-
ing of the rules and regulations pertaining to the
EPA requirements on exhaust emissions for
marine products. For more detailed information on
this subject, you may contact the following loca-
tions:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
501 3rd St. NW
Washington, DC 20001
EPA INTERNET WEB SITE:
www.epa.gov

8
INTRODUCTION
MODEL DESIGNATION
MODEL DESIGNATION
BE 200 DP X SC A
PREFIX
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: SC = 2008
MODEL RUN
or SUFFIX
DESIGN FEATURES:
AP = Advanced Propulsion
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 Edition
T = Tiller Steering
TE = Tiller Electric
V = White Paint
W = Commercial Model

9
INTRODUCTION
MODELS COVERED IN THIS MANUAL
MODELS COVERED IN
THIS MANUAL
This manual covers service information on all
105.4 and 158.2 cubic inch, 60° V Evinrude
E-TEC®models.
Identifying Model and Serial
Numbers
Outboard model and serial numbers are located
on the swivel bracket and on the powerhead.
Model Number Shaft Color Gearcase
E115DPLSCR 20” BL “S”
E115DSLSCR 20” WH “S”
E115DBXSCR 25” BL “O”
E115DPXSCR 25” WH “O”
E115DCXSCS 25” WH “O” CR
E150DPLSCR 20” BL “O”
E150DHLSCR 20” BL “L”
E150DHLSCF 20” BL “L2”
E150HSLSCS 20” WH “L”
E150HSLSCF 20” WH “L2”
E150DSLSCR 20” WH “O”
E150DBXSCR 25” BL “M”
E150DBXSCF 25” BL “M2”
E150DPXSCR 25” WH “M”
E150DPXSCF 25” WH “M2”
E150DCXSCR 25” WH “M” CR
E150DCXSCF 25” WH “M2” CR
E175DPLSCR 20” BL “O”
E175DSLSCR 20” WH “O”
E175DPXSCR 25” WH “M”
E175DPXSCF 25” WH “M2”
E175DCXSCR 25” WH “M” CR
E175DCXSCF 25” WH “M2” CR
Model Number Shaft Color Gearcase
E200DPLSCA 20” BL “O”
E200DSLSCA 20” WH “O”
E200DPXSCA 25” WH “M”
E200DPXSCF 25” WH “M2”
E200DCXSCA 25” WH “M” CR
E200DCXSCF 25” WH “M2” CR
1. Model and serial number 005231
1. Serial number 005232
1
1

10
INTRODUCTION
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
ENGINE
HP 115 150, 175, 200
Full Throttle
Operating Range 5500–6000 RPM 4850–5850 RPM
Power 115 HP: (85.8 kw) @ 5750 RPM 150 HP: (111.9 kw) @ 5350 RPM 175 HP: (130.5 kw) @ 5350 RPM
200 HP: (149.1 kw) @ 5350 RPM
Idle RPM in Gear 550 ± 50 500 ± 50
Test Propeller V4 20 in. (L) Models: P/N 386246 or P/N 433068 V4 25 in. (X) and V6 Standard Rotation Models: P/N 387388
V6 Counter Rotation Models: P/N 398673
Weight
(may vary depending
on model)
20 in. (L) Models: 375 lbs. (170 kg)
25 in. (X) Models: 390 lbs. (177 kg) 20 in. (L) Models: 418 lbs. (190 kg) 25 in. (X) Models: 433 lbs. (196 kg)
Lubrication Evinrude/Johnson XD100 Oil or Evinrude/Johnson XD50 Oil
Refer to Oil Requirements on p. 66
Engine Type 60° V 4-Cylinder Loop-Charged 60° V 6-Cylinder Loop-Charged
Displacement 105.4 cu. in. (1727 cm3) 158.2 cu. in. (2592 cm3)
Bore 3.601 in (91.47 mm)
Stroke 2.588 in. (65.74 mm)
Standard Bore 3.6005 to 3.6015 in. (91.45 to 91.48 mm)
Top Crankshaft Journal 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Center Crankshaft Journals 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Bottom Crankshaft Journal 1.5747 to 1.5752 in. (40.0 to 40.01 mm)
Rod Crankpin 1.3757 to 1.3762 in. (34.94 to 34.96 mm)
Piston Ring End Gap, Both 0.011 to 0.023 in. (0.28 to 0.58 mm)
FUEL
Fuel/Oil Ratio EMM Controlled
Starting Enrichment EMM Controlled
Preferred Fuel Regular unleaded gasoline
Acceptable Fuel See Fuel Requirements on p. 65 for additional information.
Minimum (High) Fuel Pressure
@ IDLE RPM – 500 ± 50 22 to 28 psi (152 to 193 kPa)
Minimum Fuel Lift Pump Pressure
@ IDLE RPM – 500 ± 50 3 to 4 psi (21 to 28 kPa)
Maximum Fuel Inlet Vacuum 4 in. Hg. (13.5 kPa)
Minimum Octane 87 AKI (R+M)/2 or 90 RON
Additives 2+4 ®Fuel Conditioner, Fuel System Cleaner
Use of other additives may result in engine damage.
See Fuel Requirements on p. 65 for additional information.

INTRODUCTION
SERVICE SPECIFICATIONS
11
ELECTRICAL
HP 115 150, 175, 200
Minimum Battery
Requirements
675 CCA (845 MCA); or
750 CCA (940 MCA) below 32°F (0°C)
(Use a 107 amp-hr battery for extreme applications.)
Alternator Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation
Tachometer Setting 6 pulse (12 pole)
Charging Isolator Integral, Terminal on Engine Harness
Engine Fuses P/N 967545 – 10 A
COOLING
Thermostat 143°F (62°C)
Maximum Temperature 230°F (110°C) Below 3000 RPM and 194°F (90°C) Above 3000 RPM
Water pressure 21 psi minimum @ 3000 RPM
IGNITION
Type Capacitor Discharge
Firing Order 1-2-3-4 1-2-3-4-5-6
Ignition Features EMM Controlled
RPM Limit 6250
Crankshaft Position Sensor Air
Gap Fixed
Spark Plug
Refer to Emission Control Information Label
Champion†QC10WEP @ 0.028 ± .003 in. (0.76 mm)
Refer to Emission Control Information Label
GEARCASE
Gear Ratio
V4 “S” Type Gearcase: 13:26 (.500) (2:1)
V4 “O” Type Gearcase: 12:27 (.444) (2.25:1)
V6 “M” Type Gearcase: 13:24 (.542) (1.85:1)
V6 “O” Type Gearcase: 14:26 (.538) (1.86:1)
V6 “L” Type Gearcase:14:26 (.538) (1.86:1)
Refer to GEARCASE TYPES on p. 305
Lubricant HPF XR Gearcase Lubricant
Capacity
“S” Type Gearcase: 31.6 fl. oz. (935 ml)
V4 “M” Type Gearcase: 43.0 fl. oz. (1270 ml)
V6 “M” Type Gearcase: 44.0 fl. oz. (1300 ml)
“M” Type – Counter Rotation: 41 fl. oz. (1220 ml)
“O” Type Gearcase: 33.1 fl. oz. (980 ml)
“L” Type Gearcase: 33.1 fl. oz. (980 ml)
Refer to GEARCASE TYPES on p. 305
Shift Rod Height 20 in. (L) Models: 20.945 (532 mm) ± one-half turn
25 in. (X) Models: 25.945 (659 mm) ± one-half turn
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD
POWER TRIM/TILT
Lubrication 115 (Single Piston style): Evinrude/Johnson Biodegradeable TNT Fluid
115-200 (Three Piston style): Evinrude/Johnson Power Trim/Tilt & Power Steering
Fluid or GM Dextron†II Automatic Transmission Fluid
Fluid Capacity 21 fl. oz. (622ml)
Trim Range 0° to 21°
Tilt Range 22° to 75°

12
INTRODUCTION
STANDARD TORQUE SPECIFICATIONS
STANDARD TORQUE
SPECIFICATIONS PRODUCT REFERENCE AND ILLUSTRATIONS
BRP US Inc. reserves the right to make changes
at any time, without notice, in specifications and
models and also to discontinue models. The right
is also reserved to change any specifications or
parts, at any time, without incurring any obligation
to equip same on models manufactured prior to
date of such change. Specifications used are
based on the latest product information available
at the time of publication.
The continuing accuracy of this manual cannot be
guaranteed.
All photographs and illustrations used in this man-
ual may not depict actual models or equipment,
but are intended as representative views for refer-
ence only.
Certain features or systems discussed in this
manual might not be found on all models in all
marketing areas.
All service technicians must be familiar with nauti-
cal orientation. This manual often identifies parts
and procedures using these terms.
Size In. Lbs. Ft. Lbs. N·m
No. 6 7–10 0.58–0.83 0.8–1.1
No. 8 15–22 1.25–1.83 1.7–2.5
No. 10 24–36 2–3 2.7–4.0
No. 12 36–48 3–4 4.0–5.4
1/4 in. 60–84 5–7 7-9.5
5/16 in. 120–144 10–12 13.5–16.5
3/8 in. 216–240 18–20 24.5–27
7/16 in. 336–384 28–32 38–43.5
IMPORTANT: These values apply only when
a specific torque for a specific fastener is not
listed in the appropriate section. When tighten-
ing two or more screws on the same part, DO
NOT tighten screws completely, one at a time.
WARNING
Torque wrench tightening specifications
must be strictly adhered to. Replace any
locking fastener (locknut or patch screw)
if its locking feature becomes weak. Defi-
nite resistance to turning must be felt
when reusing a locking fastener.
If replacement is specified or required
because the locking fastener has become
weak, use only authorized Evinrude/
Johnson Genuine Parts.
Nautical Orientation 006411

SPECIAL TOOLS
13
1
SPECIAL TOOLS
TABLE OF CONTENTS
DIAGNOSTIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
UNIVERSAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
ELECTRICAL / IGNITION TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
FUEL /OIL SYSTEM TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
POWERHEAD TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
GEARCASE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
TRIM AND TILT TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
SHOP AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

14
SPECIAL TOOLS
DIAGNOSTIC TOOLS
DIAGNOSTIC TOOLS
UNIVERSAL TOOLS
Diagnostic Software P/N 764642 764642 Bootstrap tool P/N 586551 002276 Interface cable P/N 437955 45583
Universal Puller Set P/N 378103 32885
Lifting tool P/N 342672 44686
Slide hammer P/N 391008 CO1577
Lifting eye P/N 321537 23701
Flywheel service kit P/N 434649
Includes P/N 5007181 adapter 46215
Slide hammer P/N 432128 15345
Flywheel holder P/N 771311 42938
Flywheel puller adapter kit
P/N 5007181 005314
Slide hammer adapter P/N 390898 15356

15
SPECIAL TOOLS
UNIVERSAL TOOLS
1
Small puller jaws P/N 432131 23150
Tilt tube nut wrench P/N 342680 46879
Temperature gun P/N 772018 45240
Large puller jaws P/N 432129 23148
Tilt tube service kit P/N 434523 33249
Fresh water flusher P/N 500542 50110
Bearing puller jaws P/N 432130 23149
Puller Bridge – 432127 23146
Oetiker†pincers, P/N 787145 001081
Syringe P/N 346936 50243

16
SPECIAL TOOLS
ELECTRICAL / IGNITION TOOLS
ELECTRICAL / IGNITION TOOLS
Digital multimeter
Ohms resolution 0.01
Purchase through local supplier
DRC7265
Stator Test Adapter P/N 5006211 004222
Peak reading voltmeter
P/N 507972 49799
Crimping pliers P/N 322696 30387
Connector tool P/N 342667 42004
Test probe kit P/N 342677 45241
Tachometer/timing light P/N 507980 49789
AMP†connector tools
Primary Lock Tool P/N 777077
Secondary Lock Tool P/N 777078
Release Tool P/N 351413
Lock Installer P/N 777079
002277

17
SPECIAL TOOLS
FUEL /OIL SYSTEM TOOLS
1
FUEL /OIL SYSTEM TOOLS
POWERHEAD TOOLS
Fuel pressure gauge (60 PSI)
P/N 5007100
90° fitting, P/N 353322
005339 Fuel pressure gauge (15 PSI)
P/N 5006397
90° fitting, P/N 353322
004560 Injector test fitting kit
P/N 5005844 002465
Alignment pin kit P/N 5007167 005279
Cylinder bore gauge P/N 771310 45303
Piston stop tool P/N 342679
Replacement tip P/N 5006098 46543
Rod cap alignment fixture
P/N 396749 21596
Torquing socket P/N 331638 000797
Crankshaft bearing and sleeve
installer P/N 338647 21953B

18
SPECIAL TOOLS
GEARCASE TOOLS
GEARCASE TOOLS
Wrist pin bearing installer
P/N 336660 41029 Wrist pin pressing tool P/N 326356 23668
1. Wrist pin retaining ring driver
P/N 318599
2. Wrist pin cone P/N 318600
DR1641
1 2
Ring compressor – standard
·P/N 336314 CO3768
Universal Driveshaft Shimming Tool
P/N 5005925
1. Lower Driveshaft Shimming Bolt
(S2 gearcase) P/N352878
002601
1
Universal Pinion Bearing Remover
and installer kit P/N 5005927 002805 Gearcase filler P/N 501882\ 49790