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2011 Product Service Update, P/N 5008496

1. a tat 57 PRA INFORMATION cis Je e Cure Sy es leet te Re en 58 SERVICE TOOLS score bat teenie wee AA EU E I E 61 NEW SERVICE TOOLS caida EE 62 REFERENCE EE 65 gem c E einer 66 ELECTRICAL INFORMATION RE Eege de Ste 66 ENEE QM EON pcc 67 EVINRUDE E TEC SPARK PLUG SERVICE CHART 68 EMM SERVICE CHART ee 69 EVINRUDE E TEC GEARCASE LINE DRAWINGS 222 40 22 2 70 2011 EVINRUDE E TEC GEARCASE APPLICATION CHART 1 2 2 2 2 72 EVINRUDE E TEC SHIFT ROD CHART 52 5 d eise eae cx mie s Dusk Sette ati di sate 74 EXTERNAL WATER SCREENS AND APPLICATIONS 75 2011 RPM QUICK REFERENCE CHART eet ne pe istud A QU rider eee A 76 2011 WATER PRESSURE CHART actin any wig cian M eat tin lata Da 77 SERVICE LITERATURE 862 532 uote reu tnr sea eli ue 78 BULLETINS a A ern ee 80 APPENDIX 2 23 uic are heure nn 83 TORIC REFERENCE EE 84 GENERAL INFORMATION BRP CONTACT INFORMATION Dealers outside of North America should c
2. EVINRUDE ESPEC Product Service Update BRP US Inc Technical Publications 300 Sea Horse Drive Waukegan Illinois 60085 United States T AMP is a registered trademark of Tyco International Ltd T Champion is a registered trademark of Federal Mogul Corporation T MicroSoft MicroSoft Windows XP Windows Vista and Windows 7 are registered trademarks of MicroSoft Corporation T Molex is a registered trademark of Molex Inc T NMEA is a registered trademark of the National Marine Electronics Association T Oetiker is a registered trademark of Hans Oetiker AG Maschinen The following trademarks are the property of BRP US Inc or its affiliates Evinrude 9 E TEC 9 S A FE Johnson SystemCheck FasTrak Triple Guard 1 DealerPort Evinrude ICON BossWeb Printed in the United States 2011 BRP US Inc All rights reserved Evinrude 9 Johnson 9 XD30 Outboard Oil Evinrude 9 Johnson 9 XD50 Outboard Oil Evinrude 9 Johnson 9 XD100 Outboard Oil TBX Viper TM and the BRP logo are registered trademarks of Bombardier Recreational Products Inc or its affiliates VELG GENERAL INFORMATION 4 42 kk weekend ee cou U es 5 CONTACT INFORMATION ciencia ie 6 WARRANTY INFORMATION NORTH AMERICA rr rrr erre 8 WARRANTY INFORMATION OUTSIDE OF NORTH AMERICA
3. 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 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 e When returning to the Outboard Certification Course technicians must complete the course and pass Master Technician exam as outlined in steps 3 through 5
4. 115 250 115 300 115 300 88 Where to Find Book Year Section Other References 60 models Powerhead replacement kits have revised oil 2009 Powerhead hose routing 60 models New flywheel cover 2009 Rigging 60 models gnition coil mounting bracket mounting 2009 Ignition amp Electrical location changed 60 models Starter cable service kit improves starting 2009 Ignition amp Electrical 60 models water separating fuel filter added to 2009 2009 Fuel System models 60 models vapor separator P N 5006084 pressure test 2009 Fuel System port changed 60 models Rear oil manifold bracket 2009 Oiling Systems 60 models Improved shift lever eliminates lost motion 2009 Gearcase 5 2008 Rigging 60 models only Oil filter installation 2009 Rigging 60 models only Flywheel Stud 2010 Product Improvements 60 V4 and 60 V6 90 V6 starter motors are different 2008 Ignition amp Electrical B ss 60 V6 90 V6 starter motors differences and 2009 Ignition amp Electrical 2008 and newer Service fuel injector electrical 2009 Fuel System connectors Code 77 Start assist circuit over current detected false 2009 Service Codes setting Model 115 300 115 130 115 130 115 130 115 300 115 300 150 200 150 200 150 200 150 250 150 250 150 250 150 250 150 250 150 250 150 300 150 300 2
5. 40 200 Parts amp Accessories 40 300 Longer engine mounting screws 2009 Rigging Bulletin 2008 05 P 40 300 Cylinder head temperature sensor installation change 2009 Ignition amp Electrical s 40 300 TNT models Melted wiring and bonding wires 2009 Ignition amp Electrical 40 300 Fuel injector seal kits 2009 Fuel System 40 300 Vapor separator filter P N 354190 now available 2009 Fuel System 86 Model 60 65 60 65 65 75 90 75 90 75 90 75 90 75 130 75 250 75 250 75 300 75 300 75 300 75 300 90 90 250 115 115 115 115 115 115 130 115 130 115 130 115 130 115 130 115 200 115 200 115 200 APPENDIX Where to Find Book Year Section Other References 2008 and newer Changes to temperature monitoring New trim and tilt assembly P N 5007776 manual relief 2009 Midsection valve improved Air Intake and Air Silencer 60 models only Melted propeller hub modification to 2008 Cooling System help prevent 60 models only Steering arm to cover bumper 2008 Engine Covers 60 models only Rear oil manifold multi point oiling 2008 Oiling System 2 Type Gearcase information 2008 Gearcase 87 LEG Model 115 200 115 200 115 200 115 200 115 200 115 200 115 200 115 200 115 200 115 200 115 200 115 200 115 200 115 200 115 250 115 250 115 250 115 250 115 250 115 250 115 250
6. 90 HP 20 inch I3 and H Type 15 30 HP I2 S2 Type 115 130 HP 20 inch V4 3 22 81 81mm O Type 90 130 HP 25 inch I3 amp V4 and F Type 40 65 HP I2 150 200 HP 20 inch 60 V6 70 REFERENCE L Type No longer produced M Type No longer produced L2 Type 150 H O 60 V6 20 inch and M2 Type 150 200 HP 60 V6 25 inch and 200 H O 90 V6 3 3L 20 inch 200 300 HP 90 V6 20 amp 25 inch 71 LEG 2011 EVINRUDE E TEC GEARCASE APPLICATION CHART Type u ESI nd SESTO 5 ka 19 5008162 39 up 13 28 465 2 15 1 392475 F 351147 P 327655 11 oz 325 ml 15 5 5008214 White 29 HP 13 28 465 2 15 1 392475 F 351147 327655 11 oz 325 ml F Type 5006558 Blue 40 60HP 20 12 32 375 2 67 1 398522 318353 21 oz 620 ml 5007628 White 40 60HP 20 12 32 375 2 67 1 398522 318353 21 oz 620 ml 5006126 65 22 5 12 32 375 2 67 1 398522 318353 21 oz 620 ml S Type 5006555 Blue 75 90HP 20 13 26 500 2 436746 345992 31
7. Concealed Side Mount Rigging Kit Not Available Rigging Kit P N 764981 Rigging Kit P N 764983 Rigging Kit P N 764985 Rigging Kit P N 764987 Rigging Kit P N 764989 Second Station Rigging Kits Include ICON Remote Control P N 765381 765382 765383 765384 765385 Emergency Stop Switch Panel P N 765379 765380 765372 765372 765372 Start Stop Switch Panel P N 765375 765376 765377 Trim Switch Panel P N 765388 765389 765390 Buss Cable Extension 15ft 4 57m P N 764948 Buss Cable Extension 20ft 6 1m P N 764949 Installation Instructions included ICON Remote Controls P N 355084 ICON Switch Panels P N 355085 ICON Quick Connect Guide P N 764953 EVINRUDE ICON REMOTE CONTROL SYSTEM 1 Damaged pins 1 Groove 2 Extra groove in the misaligned connector ICON INSTALLATION TIPS Buss Cable Issues Incorrect alignment and assembly of CON buss cables can result in a non func tional ICON network Use the following information to avoid network communica tion issues Assemble connectors dry Do NOT use Electrical Grease on this style connector Visually check the alignment and assembly of connectors Align tabs and sock ets of the female connector to the grooves and pins of the male connector Tighten locking rings of connectors finger tight Do not ro
8. QC12PEP 5001866 775983 QC12PEPB 5006525 763689 QC10WEP 5007419 764643 QC8WEP 5007597 QC10PEPB 5006308 778874 68 EMM SERVICE CHART EMMs cannot be ordered as a regular parts order since they must be programmed before shipping BEFORE ordering a replacement EMM Review Administrative Bulletin 2009 02 A for the policies and procedures for the Warranty Replacement of Evinrude E TEC EMMs REFERENCE Review Parts and Accessories Bulletin 2008 02 P for the policies and procedures for Service Replacement of Evinrude E TEC EMMs Model 2004 2005 2006 2007 2008 2009 2010 2011 15 30 HP 587062 587062 587062 40 50 HP 586759 586759 586759 586968 586968 586968 586968 60 65 HP 586759 586862 586970 586970 586970 586970 75 90 HP 586759 586759 586759 586970 586970 586970 586970 115 HP 60 V4 586867 586982 586982 115 130 HP 60 V4 587048 587048 587067 150 200 HP 60 V6 586707 586982 587048 587048 587067 200 250 HP 90 V6 3 3 L 586707 586707 586982 587048 587048 587067 250 300 HP 90 V6 3 4 L 586982 587048 587048 587115 Notes 1 2009 115 HP F suffix ONLY 2 2009 115 H O and 130 HP IMPORTANT Do NOT install an EMM from a newer engine on an older engine Changes in the newer models will result in damage to the EMM if installed on an older engine 69 Te BRP EVINRUDE E TEC GEARCASE LINE DRAWINGS S Type 75
9. inspect and lubricate 4 C X Gearcase check condition X Starter pinion shaft inspect and lubricate 4 D X Propeller check condition X Control cables inspect and adjust X Fuel and oil systems inspect and repair leaks X Steering cable inspect and lubricate X Check battery connections and condition X Water pump inspect replace X Access EMM information resolve any service codes X Exhaust back pressure fitting it equipped X Electrical and ignition wires inspect for wear or chafing X Oil filters remote tank engine 115 300 HP models X Emission related component Annually in salt water applications 1 2 3 4 A HPF Pro Gearcase Lubricant Average recreational use Commercial use heavy use or use in salt or polluted water requires more frequent inspection and maintenance Boat mounted fuel water separating filters should be replaced annually B Trim and Tilt Fluid use Biodegradeable Fluid on single ram hydraulic systems use Power Trim and Tilt Fluid on three ram hydraulic systems C Triple Guard Grease D Use Starter Bendix Lube only ELECTRICAL SYSTEM Starter Drive Gear Engagement 115 300 HP Models The problem A limited quantity of starter drive gears may be machined with the wrong chamfer beveled edge on the teeth of the gears If this condition exists 1 the starter drive gear bendix may not engage the ring gear of the flywheel and the starting process can fail Service replacement
10. 124 110 131 124 137 124 172 137 207 Notes 1 Water pressure readings in excess of 40 psi 275 kpa are possible for these models at boat speeds above 50 MPH 80 KPH 43 knots 77 BRP SERVICE LITERATURE 2011 Description English French Parts English French Operator s Operator s Catalog Service Service Guide Guide Manual Manual Evinrude Models 15 30 HP 215992 215993 5008317 5008326 5008327 40 60 HP 215994 215995 5008318 5008328 5008329 65 HP Commercial 216018 216019 5008318 5008328 5008329 55 HP MFE 215996 215997 5008319 5008330 5008331 75 90 HP 215998 215999 5008320 5008328 5008329 115 130 HP 60 V4 216000 216001 5008321 5008332 5008333 150 200 HP 60 V6 216000 216001 5008322 5008332 5008333 200 300 HP 90 V6 216002 216003 5008323 5008334 5008335 Literature Sets Reference 2011 Illustrated Parts amp Accessory Catalog 5008324 2011 Flat Rate Guide English 5008492 2011 Parts Catalog Set Paper 5008325 2011 Flat Rate Guide French 5008493 2011 Service Manual Set English 5008340 2011 Warranty Procedures English 5008494 2011 Service Manual Set French 5008341 2011 Warranty Procedures French 5008495 2011 Service Manual CD English 5008336 2011 Product Service Update English 5008496 2011 Service Manual CD French 5008337 2011 Product Service Update French 5009497 20
11. 2011 model Frequently Requested Part Numbers The following items are frequently requested part numbers and should be ordered as needed Predelivery Checklist P N 5008381 10 pack Warranty Allowance Requests warranty claim forms P N 773629 25 pack ROM Form form for return of unused saleable parts P N 11111 10 pack Model Year Reference Guide P N 5006145 2011 Predelivery and Installation Guide P N 5008506 ICON Installation Guide P N 764952 Users Guide P N 355917 3 5 inch Users Guide P N 355918 2 inch Product Selection Guide P N 764677 Available for download from DealerPort or BossWeb 58 Model Number Reference 1913 2005 1 BRP thrust bushing 2 Competitor s thrust bushing Propeller Shaft Failure PARTS AND ACCESSORIES Propeller Shaft Failures Propeller shaft failures can occur when incorrect propeller hardware is installed The thrust bushing provided with some competitor s propeller and removable hub kits may be significantly thinner than the thrust bushing provided with BRP propeller kits The surface area of the thrust bushing which contacts the propeller shaft does not provide sufficient clamp load after the propeller hardware and propeller are installed Insufficient clamp load causes the propeller to loosen and can result in scoring of the propelle
12. Dual Lever Binnacle Mount Step 3 Order P N for main or single station Rigging Kit Rigging Kit Rigging Kit Rigging Kit Rigging Kit Rigging Kit rigging kit P N 764990 P N 764980 P N 764982 P N 764984 P N 764986 P N 764988 Main Station Rigging Kits include ICON Remote Control P N 765412 765381 765382 765383 765384 765385 Master Power Key Switch P N 765371 765373 765374 765371 765371 765371 Start Stop Switch Panel P N 765378 765375 765376 765377 Trim Switch Panel P N 765388 765389 765390 Network Power Cable P N 764921 ICON Gateway Module Kit P N 764922 ICON Accessory Power Relay P N 765296 ICON Hubs 2 P N 764943 Buss Cable Extension 15ft 4 57m P N Kit includes 1 buss cable per engine Buss Cable Backbone 20ft 6 1m P N 764950 Buss Cable Backbone 25ft 7 4m P N 764951 Engine Identity Plug ID 1 P N 764916 Engine Identity Plug ID 2 P N 764917 Engine Identity Plug ID 3 P N 764918 Engine Identity Plug ID 4 P N 764919 ICON Remote Control User s Guide 765410 764954 Installation Instructions included ICON Remote Controls P N 355248 355084 ICON Switch Panels P N 355085 355085 ICON Gateway Module amp Cable Kit P N 355086 355086 ICON Accessory Power Relay Kit P N 355087 355087 ICON Quick Connect Guide P N 765409 764953 764948 45 46 Step 4 optional Order P N for second station rigging kit
13. North America BRP International Offices AUSTRALIA Bombardier Recreational Products Australia Pty Limited 56 Canterbury Road Bankstown 2200 New South Wales Australia Phone 612 9794 6600 BENELUX BRP Europe Skaldenstraat 125 B 9042 Gent Belgium Phone 32 9 218 26 00 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 55 19 3716 8600 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 41 21 318 78 00 AFTER SALES SUPPORT FRANCE Bombardier Recreational Products France Les Jardins de la Duranne Batiment C 510 rue Ren Descartes F 13857 Aix en Provence France Phone 83 4 42 94 25 00 GERMANY BRP Germany GmbH Itterpark 11 D 40724 Hilden Germany Phone 49 2103 960 680 JAPAN BRP Japan Limited 15 F Parale Mitsui Building 8 Higashadi Cho Kawasaki Ku Kawasaki 210 0005 Phone 81 44 200 1431 NEW ZEALAND BRP New Zealand 7 11 Arwen Place East Tamaki Auckland 2130 Phone 64 9 274 5718 SPAIN BRP Recreational Products Spain S L c Bertr n i Musitu 99 101 Edificio Brasil 08840 Viladecans Barcelona Spain Phone 34 93 636 10 97 UK AND IREL
14. can result in A cold running engine if the impeller is installed without the pressure relief valve and thermostat springs An engine overheat if the pressure relief valve and thermostat springs are installed without the new impeller 25 V 75 90 HP 1 3L MODELS Installation of Oil Pump Assembly The problem After installing a replacement oil pump assembly the LOW OIL warning light remains on even though the oil tank is full The cause Incorrect installation can result in the low oil switch being held ON by the oil pick up assembly The fix Be sure to install the oil pump pick up assembly straight into oil tank Refer to the correct Service Manual for installation instructions Make sure the oil pick up assembly is positioned in front of oil tank baffle This will prevent inter ference with the LOW OIL switch 26 1 Oil pick up assembly 2 Oiltank baffle Exhaust Back Pressure Fitting SERVICE INFORMATION 115 300 HP 60 90 V4 V6 MODELS Exhaust Back Pressure Fitting A blocked exhaust back pressure fitting can result in difficult starting or other run quality symptoms Use the Data Log feature of Evinrude Diagnostic software to monitor the exhaust back pressure on an engine that is difficult to start or runs poorly Normally exhaust back pressure readings are erratic If the data log shows read ings which tend to be linear check the back pressure senso
15. gauge battery cable Battery Recommendations Each outboard requires its own starting battery Use the chart below to select a battery that meets or exceeds the minimum requirements Outboard Model Outboard Model Battery Rating Battery Cable Length 15 30 HP 40 300 HP 675 CCA 845 MCA or 800 CCA 1 to 10 Ft 3 to 3 m 6 Gauge 4 Gauge al om MEN DEIOW ded C Er 107 amp hr in extreme applications to t 3 4 to 4 6 m 4G 2G e 640 CCA 800 MCA or 800 CCA 16 to 20 Ft 4 9 to 6 1 m 2 Gauge 1 Gauge 15 90 HP 1000 MCA below 32 F 0 C 66 107 amp hr in extreme applications REFERENCE 1 2 The chart below list all fuses available from Evinrude Johnson Genuine Parts etiam y and Accessories p Fuse Fuse Amp Fuse 3 P N Type Rating Color Esth Qty S n mm 114509 AGA 3 Glass 0 625 x 0 25 1 512129 AGA 5 Glass 0 625 x 0 25 5 510884 AGA 20 Glass 0 625 x 0 25 10 5 5031911 AGA 25 Glass 0 625 x 0 25 1 6 511386 AGA 30 Glass 0 625 x 0 25 1 es Lei 123852 AGC 1 Glass 1 25 x 0 25 1 SE 5030348 AGC 20 Glass 1 25 x 0 25 1 2 p 512672 AGU 40 Glass 1 5 x 0 411 1 3 AGU 3850985 AGU 50 Glass 1 5 x 0 411 1 4 ATC ATO 5 ATM Mini 982019 AGU 50 Glass 1 5 x 0 411 10 6 JT 763640 ATC ATO 1 Black 1
16. iras Service Bulletin 200 250 2005 models Oil priming issue 2008 Rigging 2004 02 D 200 250 90 models Adapter kit P N 5007589 2009 Midsection 200 250 90 3 3 L models Adapter P N 5001496 2009 Midsection 200 250 Issue with flushing adapter P N 775385 2009 Cooling System 200 250 Knock sensors added to these models 2010 Product Improvements 200 250 3 3 L Models Water plate P N 347251 2010 Service Tips 200 300 90 models Ignition coil mounting location coil damage 2009 Ignition amp Electrical 200 300 90 models Pinched oil lines 2009 Oiling Systems 200 300 90 models Powerhead to adapter gaskets different 2009 Midsection 200 300 90 models Trim and tilt assembly improvements 2009 Midsection 200 300 90 models New pinion bearing P N 5007751 2009 Gearcase 200 300 90 models Trim Limit Rod P N 354185 2010 Product Improvements 250 H O Important engine management software update 2009 Engine Management Software 4 250 Water pump installation 2009 Cooling Systems 5217 Sult 250 H O 300 Important engine management software update Warranty 2009 Engine Management Software 2008 06 W 250 300 Codes 1 through 6 Excessive knock detected 2009 Service Codes 90 Model 250 H O 300 250 H O 300 250 H O 300 250 H O 300 250 H O 300 250 H O 300 250 H O 300 250 H O 300 250 H O 3
17. shift linkage to the cylin der and crankcase This change improves the operation of the shift switch A new EMM and engine management software allow the shift switch to perform the following functions Start in gear protection prevents the starter motor from operating if the shift lever is not in NEUTRAL e Shift interrupt reduces shift effort when the engine is shifted out of gear Neutral rpm limit limits engine speed to approximately 1100 rpm when shift lever is in NEUTRAL position Note DE model engines CON Electronic Shift and Throttle do not have the shift switch Also see ICON Conversion Kit Installation 200 300 HP 90 V6 Models on p 49 Cooling System Change 250 300 HP 90 V6 3 4 L Models The cooling water hose from the vapor separator outlet to the exhaust adapter has been relocated to the exhaust emission test port of the exhaust adapter This change improves water pressure to the powerhead and provides additional water to cool the propeller hub 2011 PRODUCT IMPROVEMENTS Powerhead Change 200 300 HP 90 V6 Models The following changes have been made to improve powerhead durability Piston splash port and dome have been redesigned to improve durability of the piston Piston ring locating pins have been changed to reduce locating pin migration Oylinder sleeve oil grooves redesigned to provide consistent oil flow to piston skirt L2 Type Gearcase 58 Ratio Replaced by M2 T
18. starter motor assemblies P N 586957 and P N 586890 could experience this issue The Fix Remove starter motor assembly and identify the chamfer on the teeth of the starter drive gear Refer to Warranty Bulletin 2010 08 W for complete instructions 1 Chamfer FAQ Spark Plugs All Models The Service Teams are frequently asked if it is permissible to substitute spark plugs the answer is NO unless there is an APPROVED substitution At this time the only approved substitution is 2005 2006 Evinrude E TEC 200 CONTROL INFORMATI N BRP US Inc 250 HP 90 V6 3 3 L models THIS ENGINE CONFORMS TO MY2006 U S EPAAND CALIFORNIA EMISSION REGULATIONS FOR SI MARINE ENGINES U S EPA regulations prohibit modification to any system that could effect the DU e i ENGINE FAMILY FEL engine s exhaust emissions level This includes spark plugs Engine emission 1G SARE TC W3 certification REQUIRES only approved spark plugs be used in the engine ERG DES SEE OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS Refer to the Evinrude E TEC Spark Plug Service Chart on p 68 the appropri y Sea ate Parts Catalog or the Emissions Control Information ECI Label on the swivel bracket of the outboard for correct spark plug information ECI Label 1 Spark plug information 30 RONDA Negative battery cable Positive battery
19. terminal Observe voltage reading STEP 4 Connect positive lead to starter cable of solenoid terminal Connect negative lead to starter motor terminal Activate starter motor and observe voltage reading 31 A Inductive Ignition System The inductive IDI ignition system provides ignition spark with a fast rise time and a long continuous duration spark compared to the multi strike cd ignition used on older models The benefit is a smoother running engine under a variety of load conditions The inductive ignition uses an ignition coil which contains an internal circuit board to control current flow through the primary winding How it works System voltage 55 volts is supplied through the white red wire to the primary winding Ground is provided through the black wire to the circuit board and to the coil primary The EMM provides a low voltage control signal through orange wire to the circuit board When the circuit board receives the control signal it momentarily stops current flow through the coil primary winding The surrounding magnetic field collapses creating high voltage in the coil secondary winding IDI Ignition Coil Tests Because the ignition coil contains an internal circuit board there are no simple ignition coil tests available Before replacing an ignition coil be sure 55 V is supplied to the white red wire of the ignition coil connector e control signal is present on the o
20. 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 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 AFTER SALES SUPPORT 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 FIELD
21. the engine harness Refer to the installation instructions provided with ICON conversion kit P N 764979 49 ICON SERVICE TIPS ICON Troubleshooting Guide P N 356076 The ICON Troubleshooting Guide P N 356076 will automatically ship to all authorized U S and Canadian service dealers The CON Troubleshooting Guide contains installation tips to help avoid com mon problems Simple effective troubleshooting flow charts are also included to help dealers efficiently troubleshoot and make repairs to an CON network Additional copies may be ordered from Evinrude Johnson Genuine Parts and Accessories ICON Troubleshooting Guide Remote Control Neutral Position Before attempting to change CON network settings set shift and throttle calibra tion adjustments or perform troubleshooting steps Turn master power key switch to the ON position engine OFF Place control lever s in the NEUTRAL position Failure to follow these steps could result in false warnings or service codes or can disrupt network communication 9 5 1 Neutral position 50 EVINRUDE ICON REMOTE CONTROL SYSTEM 13 25 Accessory Power Relay Kit Battery Voltage Battery voltage of 13 25 VDC or higher is required for stable ICON network oper ation Inconsistent voltage on the ICON network can effect operation Use Evinrude Diagnostics sof
22. time the program is run an Initial Setup form will appear Initial setup items are set to default conditions Possible changes are as follows Unless directed by BRP do not uncheck Automatically Save Engine Data File EDF Upon Engine Connection If computer normally has an internet connection then check the Use Auto matic Website Updates Verify assigned website DealerPort or BossWeb depending on your sub scription service Changes to these selections may be made at any time by selecting the Tools menu and selecting Options Software Registration Software registration is required to run this program After the Initial Setup is complete the program will check for a prior version of Evinrude Diagnostics registration If prior version registration information is found Evinrude Diagnostics version 5 1 will automatically use the existing reg istration information e If a prior version is not found the user MUST complete the registration Enter your dealer number dealership name address and country An internet con nection is NOT needed to complete this registration Note Registration information is only used for identification purposes on printed reports 41 14 27 NOTES EVINRUDE DIAGNOSTICS SOFTWARE 42 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON KITS ICON Rigging Kits ICON rigging kits are designed to make rigging kit selection an easy three or four step process Refer to the ICON Ri
23. 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 2011 PRODUCT IMPROVEMENTS Oil Recirculation System Hoses 200 300 HP 90 V6 Models Oil recirculation hoses on all 200 300 HP 90 V6 models have been changed from black rubber to the blue hose used for oil distribution This change provides a common service part P N 778708 for the oil distribution and recirculation hose for these models 1 Recirculation hoses Rear Oiling System 250 300 HP 90 3 4 Models A new rear oil pump replaces the rear oil manifold on 250 300 HP 3 4 L mod els The oil pump is a positive displacement oil pump which supplies oil to each piston IMPORTANT Correct oil priming procedure is required when installing a new engine or after servicing the oil system on 3 4 L engines that use this oil pump Refer to Predelivery Bulletin 2010 02 D or the 2011 Service Manual for the correct oil priming procedure The rear oil pump requires a new EMM engine wiring harness and engine man agement software For this reason this oil pump CANNOT be fitted to older engines 1 Rear oil pump 19 1 Shift switch 1 Cooling water hose 20 Shift Switch 200 300 HP 90 V6 Models Shift switch P N 586861 has been relocated from the
24. 0 HP outboards and Injector Coefficient Database 2002 2006 Evinrude DI 75 250 HP outboards 2010 08 S Evinrude E TEC 15 30 HP Outboards Torque Change for Flywheel Nut 2010 09 S ALL New Service Tools 2011 Model Year 2010 10 S Evinrude E TEC 40 90 HP Outboards Installing Replacement Lower Engine Covers 80 REFERENCE Bulletin ee Number Models Subject Description Warranty W 2010 01 W 2010 Evinrude E TEC 75 HP 130HP Outboards Trim and Tilt Hydraulic Assembly Replacement 2010 02 W 2010 Evinrude E TEC 115 300 HP Outboards Oil Pump Assembly Replacement and Oil Hose Routing 2009 and 2010 Evinrude E TEC 15 65 HP and 2010 03 W 2009 Evinrude MFE 55 HP Outboards EPA CAMPAIGN Fuel Hose and Primer Bulb Assembly Replacement 2010 04 W 2010 and 2011 Evinrude E TEC 40 90 HP Outboards SAFETY CAMPAIGN Incorrectly Installed Clamps on Fuel Hoses 2010 05 W 2011 Evinrude E TEC 200 HP 250 HP 90 V6 3 3 L Shift Lever Cam Outboards 2010 06 W 2011 Evinrude E TEC 15 30 HP Outboards Shift Lever Screws 2010 07 W This bulletin was not issued 2010 08 W 2010 and 2011 Evinrude E TEC 115 300 HP Starter Drive Gear Engagement Outboards 2010 09 W 2011 Evinrude E TEC 15 30 HP Outboards EPA CAMPAIGN Engine Management Software Update 81 VELG NOTES REFERENCE 82 APPENDIX C TOPIC REFERENCE INDEX Model 25S dbs bbe sey
25. 00 5750 5750 150 HP 150 H O 60 V6 4850 5850 5500 5600 5350 175 HP 60 V6 4850 5850 5500 5600 5350 200 HP 60 V6 4850 5850 5600 5850 5350 200 H O 90 V6 3 3L 4500 5800 5500 5700 5150 225 HP 225 90 V6 3 3L 4500 5800 5500 5700 5150 250 HP 90 V6 3 3L 4500 5800 5500 5700 5150 250 H O 90 V6 3 4L 4500 6000 5500 5850 5250 300 HP 90 V6 3 4L 5000 6000 5500 5850 5500 76 How to Use the RPM Quick Reference Chart When selecting a propeller for an outboard and boat application refer to the recommended wide open throttle operating range for the outboard model When determining propeller selection choose a pro peller that will best suit the customer s needs For example choose a higher pitch propeller for low to mid rpm for light load cruising e choose a lower pitch propeller to attain top rpm for water skiing or other high load applications For best overall performance choose a propeller that allows the outboard to run in the optimum rpm range which is usually the point of peak horsepower Remember only a thorough water test will determine which propeller works best for a particular application 2011 WATER PRESSURE CHART This chart lists typical water pressure readings for 2011 model outboards for boat speeds up to 50 mph 80 kph 43 knots and is provided as a general guide for use when troubleshooting over heating or over cool
26. 00 250 200 250 200 250 200 250 200 250 200 250 APPENDIX Where to Find Book Year Section Other References 60 models only Air silencer change can improve 2008 Fuel System performance 60 models Newinner exhaust housing P N 354148 2009 Midsection improved water flow White Stars and Stripes decal kits How to identify L2 type gearcase 2009 Gearcase Powerhead installation apply Permatex 2 to gasket area 2009 Powerhead 90 models New trim and tilt assembly 2008 Midsection Engine idle temperature 2008 Cooling System Thermostat venting 2008 Cooling System Melted propeller hub modifications to help prevent 2008 Cooling System Fuel inlet hose clip 2008 Engine Covers DI models only Alternate spark plug for extended low 2008 Ignition amp Electrical speed operation Service Bulletin 2005 03 S Service Bulletin 2005 04 S Warranty Bulletin 2005 01 W 89 LEG Model Where to Find Book Year Section Other References on 2005 05 5 Spark plug life 2008 Ignition 8 Electrical 200 250 Service Bulletin 2006 02 S 200 250 Oil to fuel hose eliminated 2008 Oiling System 200 250 90 models Oil recirculation changes 2004 2006 to 2007 2008 Oiling System amp newer 200 250 90 models Flushing adapter 2008 Parts amp Accessories 2008 Powerhead 200 250 90 models Powerhead replacement kits 2009 Powerhead ONE
27. 00 250 H O 300 250 H O 300 300 300 4 stroke All All All All All All All All All All APPENDIX Other References New impeller housing P N 5007968 Warranty Bulletin 2009 Cooling Systems 2008 02 W New water pump kit P N 5007972 2009 Cooling Systems New impeller housing P N 5007968 2009 Cooling Systems m Warranty Bulletin Temperature sensor and clamp servicing 2009 Cooling Systems 2008 02 W Melted propeller hub with gearcase seals pushed out tip 2009 Cooling Systems to check for blocked cooling water passage 90 3 4 L models F suffix Adapter P N 5007973 2009 Midsection 90 3 4 L models C or S suffix Adapter P N 5007971 2009 Midsection 2009 Engine Management Software Temperature sensor and clamp servicing Important engine management software update warranty Bulletin P 9 9 P 2008 03 W M2 Type gearcase alignment pins 2009 Gearcase 4 Stroke accessories and service kits 2009 Parts amp Accessories im zh 2008 Cooling System Overboard indicator requirements 2009 Cooling System 2008 Water pressure chart 2008 Cooling System 2009 Water pressure chart 2009 Cooling System Pressure relief valve improvement 2008 Cooling System TW 2008 Cooling System Melted propeller hub modifications to help prevent 2009 Cooling System EMM LEDs 2008 Engine Management Module 2008 EMM not compatible with older engines 2008 Engine Management Module Fuel injectors Ball In Pl
28. 1 4in 66 675 cm 36 0 in 91 44 cm 2006 2011 25 O 44 352886 26 1 4 in 66 675 cm 35 85 in 91 05 cm E A gt 115 130 HP 2007 2011 20 S2 50 350464 20 15 16 in 53 20 cm 30 57 in 77 65 cm 2007 2011 25 O 44 352957 2515 16 in 65 90 cm 35 55 in 90 29 cm 150 200 HP 2007 2011 20 L L2 54 350464 20 15 16 in 53 20 cm 30 57 in 77 65 cm 60 V6 2007 2011 20 O 54 350464 20 15 16in 53 20 cm 30 57 in 77 65 cm 2007 2011 25 M M2 54 352808 2515 16 in 65 90 cm 35 32 in 89 71 cm E A gt rm SG 2005 2011 20 L L2 54 58 329864 21 29 32 in 55 60 cm 31 49 in 79 98 cm 200 300 HP 2005 2010 25 L L2 54 58 329865 26 29 32 in 68 30 cm 36 49 in 92 68 cm 90 V6 2005 2011 20 M M2 54 347300 21 29 32in 55 60 cm 31 25 in 79 37 cm 2005 2011 25 M M2 54 347301 26 29 32 in 68 30 cm 36 25 in 92 07 cm 2005 2011 30 M M2 54 347391 31 29 32in 81 00 cm 41 25in 104 77 cm gt ss SS 74 EXTERNAL WATER SCREENS AND APPLICATIONS REFERENCE This chart lists standard and available optional water screens For applications which may require additional cooling water select optional water screens based on the type of application M Type M2 Type and L2 Type Gearcases Water Screen Kit t Port Starboard Height Application High Performance P N 5005124 L2 Standard 348479 348480 Flush High Speed o
29. 11 Update CD English 355838 2011 Update CD French 355839 Special Tools Catalog 5008526 Predelivery amp Installation All Models English 5008506 Predelivery amp Installation All Models French 5008507 Predelivery amp Installation All Models Spanish 5008508 78 REFERENCE 2010 Description English French Parts English French Operator s Operator s Catalog Service Service Guide Guide Manual Manual Evinrude Models 25 30 HP 215932 215933 5007997 5008146 5008147 40 60 HP 215920 215921 5007998 5008148 5008149 65 HP Commercial 215922 215923 5007998 5008148 5008149 75 90 HP 215926 215927 5008000 5008148 5008149 115 130 HP 60 V4 215928 215929 5008001 5008152 5008153 150 200 HP 60 V6 215928 215929 5008002 5008152 5008153 200 300 HP 90 V6 215930 215931 5008003 5008154 5008155 Literature Sets Reference 2010 Illustrated Parts amp Accessory Catalog 5008005 2010 Special Tools Catalog 5007858 2010 Parts Catalog Set Paper 5008004 2010 Flat Rate Guide English 5007856 2010 Service Manual Set English 5008158 2010 Flat Rate Guide French 5007860 2010 Service Manual Set French 5008159 2010 Warranty Procedures English 5008129 2010 Service Manual CD English 5008156 2010 Warranty Procedures French 5008130 2010 Service Manual CD French 5008157 2010 Product Service Update English 5008168 2010 Pro
30. 150 ml 5007705 Blue Ga ii 20 25 13 24 542 1 85 1 5007389 F P R 347373 38 9 oz 1150 ml 5007669 White 90 V6 3 3L m i 13 24 542 1 85 1 5007389 F P R 347373 38 9 oz 1150 ml 5007669 White 90 V6 3 4L 257 30 13 24 542 1 85 1 5007389 F P R 347373 38 9 oz 1150 CORO 5007670 White 60 V6 25 13 24 542 1 8531 5007388 F P R 5008224 35 8 oz 1060 ml 5007670 White 90 V6 3 3L 257 30 13 24 542 1 85 1 5007388 F P R 5008224 35 8 2 1060 5007670 White 90 V6 3 4L 257 30 13 24 542 1 85 1 5007388 F P R 5008224 35 8 2 1060 L2 Type 5007668 Blue 60 V6 20 14 26 538 1 86 1 5007663 F P 353544 32 5 oz 960 ml 5007706 White 60 V6 20 14 26 538 1 86 1 5007663 F P 353544 32 5 oz 960 ml 5007668 Blue au 99599 20 25 14 26 538 1 86 1 5007663 F P 353544 32 5 oz 960 ml 5007706 White EOD YO 20 14 26 538 1 86 1 5007663 353544 32 5 oz 960 ml 3 3L 73 EVINRUDE E TEC SHIFT ROD CHART Model Shaft Gearcase Gear Shift Height Adjustment Shift Rod Length Type Ratio Rod P N 1 2 turn Dimension A 2004 2011 20 S 50 351179 211 4in 53 975 cm 31 0 in 78 74 cm 75 90 HP 2004 2005 25 O 44 351180 26
31. 5 30 25 30 25 30 25 30 25 30 25 30 25 30 25 30 25 30 25 30 40 40 40 60 40 60 40 60 40 60 40 60 40 60 40 90 40 90 40 90 40 90 Where to Find Book Year Section Other References Flywheel servicing 2010 Service Tips Water pump servicing 2010 Service Tips New model rigging information 2009 Rigging 222 Bulgin Fuel injector and vapor separator servicing new i Service Bulletin Oil recirculation diagram new model 2009 Oiling Systems New accessory kits for Evinrude E TEC 25 30 HP 2009 Parts amp Accessories Tilt assist kit for manual tilt models 2008 Parts amp Accessories Rope start models revised oil pump wire harness routing 2009 Ignition amp Electrical Oil recirculation changes 2004 2005 to 2006 amp newer 2008 Oiling System New trim and tilt assembly P N 5007774 manual relief 2009 Midsection valve improved Service Bulletin Engine idle temperature 2008 Cooling System 2006 07 S Engine cover material 2008 Engine Covers Spark plug replacement inductive ignition models 2008 Ignition amp Electrical Service Bulletin Spark plug life 2008 Ignition amp Electrical 2006 07 S 85 VELG Model Other References 40 90 40 90 40 90 40 90 40 90 40 90 40 90 40 90 40 90 40 90 40 90 40 90 40 90 40 90 40 90 40 90 40 90 40 115 40 115 40 115 40 115 40 115
32. 6 oz 935 ml 5006426 White 75 90 HP 20 13 26 500 2 436746 F P 345992 31 6 oz 935 ml S2 Type 5006326 Blue 60 V4 20 13 26 500 2 5006311 F P 352319 31 6 oz 935 ml 5006520 White 60 V4 20 13 26 500 2 5006311 F P 352319 31 6 oz 935 ml O Type 5007023 White 75 90 HP 25 12 27 444 2 25 1 435123 FP 336574 32 8 oz 970 ml 5007334 Blue 60 V4 25 12 27 444 2 25 1 435123 F P 336574 32 8 oz 1250 ml 5007023 White 60 V4 25 12 27 444 2 25 435123 336574 32 8 oz 970 ml 5006554 Blue 60 V6 20 14 26 538 1 86 1 5004218 F P R 336561 33 1 oz 980 ml 5007134 White 60 V6 20 14 26 538 1 86 1 5004218 F P R 336561 33 1 oz 980 ml CORO 5007594 White 60 V4 25 12 27 444 2 25 1 435932 F P 431702 72 REFERENCE Assembly Shaft Reverse Type Part No Color Model Family Length Gear Ratio Gear Set Gear Capacity M2 Type 5007705 Blue 60 V6 25 13 24 542 1 85 1 5007389 F P R 347373 38 9 oz 1150 ml 5007669 White 60 V6 25 13 24 542 1 85 1 5007389 F P R 347373 38 9 oz 1150 ml 5007705 Blue 90 V6 3 3L 20 13 24 542 1 85 1 5007389 F P R 347373 38 9 oz 1150 ml 5007705 Blue SET VG 20 25 13 24 542 1 85 1 5007389 F P R 347373 38 9 oz 1150 ml 5007669 White co 90 V6 20 13 24 542 1 85 1 5007389 347373 38 9 oz 1
33. 764538 ATC ATO 3 Violet 1 763641 ATC ATO 5 Tan 10 ATC ATO Fuse ATM Mini Fuse 967545 ATC ATO 10 Red 1 5032215 ATC ATO 15 Blue 1 7 ITF ee Fuse e ES 514021 ATC ATO 20 Yellow Dimension 5 5032230 ATC ATO 30 Green Diagram 1 514764 ATM Mini 5 Tan 5 514766 ATM Mini 10 Red 5 514767 ATM Mini 15 Blue 1 514768 ATM Mini 20 Yellow 1 5032630 ATM Mini 30 Green 1 5033633 JT 60 Yellow 1 304980 SFE 20 Glass 1 25 x 0 25 1 Fuse Dimension Diagram 67 27 EVINRUDE E TEC SPARK PLUG SERVICE CHART Model 2004 2005 2006 2007 2008 2009 2010 2011 15 H O 30 HP QC10WEP QC10WEP QC10WEP 40 50 HP QC12PEPt QC12PEPt QC12PEPBt QC12PEPBt QC10WEP QC10WEP QC10WEP QC10WEP 60 65 HP QC12PEPt QC12PEPt QC12PEPBt QC12PEPBt QC10WEP QC10WEP QC10WEP QC10WEP 75 90 HP QC12PEPt QC12PEPt 12 QC12PEPBt QC10WEP QC10WEP QC10WEP QC10WEP QC10PEPBt QC10WEP QC10WEP QC10WEP QC10WEP ECH QC10PEPBt QC10WEP QC10WEP QC10WEP eou AP QC10WEP QC10WEP QC10WEP QC10WEP QC8WEP QC8WEP QC8WEP 90 V6 3 3L 250 HO 300 HP QC8WEP QC8WEP QC8WEP QC8WEP 90 V6 3 4L t DO NOT substitute spark plugs on these models QC10WEP may be substituted for QC10PEPB on 2005 2006 200 250 HP 90 V6 models H suffix models use QC8WEP Spark Plug Part Numbers P N Spec Plug 4 pack 6 pack 24 pack
34. 9 FIELD SERVICE AND TRAINING sono od tci tek a tee e Fore AS p een 10 TECHNICAL PUBLICATIONS ppp 11 2011 PRODUCT IMPROVEMENTS 13 15 90 HP INLINE MODELS MC ee ee ee 14 115 300 HP 609902 V4 V6 MODELS re rre rre nnne ns 18 SERVICE INFORMATION A du SEELEN Ae d NEE m me e heie 23 FEN nee see 24 75 90 HP 1 31 MODELS nn SEDE OT ELA QU AN Kd ee leerer 26 115 300 HP 609902 V4 V6 MODELS 1 1 1 ns 27 200 300 HP 90 V6 MODELS 1 nre rn rne ns 28 MAINTENANCE sl ee ee Ku 29 ELECTRICAL SYSTEM lt a e caes 30 FUEL SYSTEM MM HEMDEN NN 33 SYSTEM ee EE 35 COOLING eeh 36 i T py RE ENG 37 EE Ne Gb 38 EVINRUDE DIAGNOSTICS SOFTWARE 39 IMPROVEMENTS AND CHANGES teat rr nennen 40 EVINRUDE ICON REMOTE CONTROL SYSTEM 43 ICONKITS ee area eels cM nc euer 44 ICON RIGGING KIT SELECTION CHART re eae nnns ns 45 NEE 47 IE ON SERVICE IIA 50 CONTENTS ECOMMAND au USUS Peer 53 I COMMAND INFORMATION ss mui Net uM eR dede e 54 PARTS AND ACCESSORIES 24 22
35. AND BRP Recreational Products UK Ltd 4 Brunel Close Ebblake Industrial Estate Verwood Dorset UK BH31 6BA Phone 44 1202 812 100 BRP 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
36. EC models Fuel Hoses All Models New and revised U S Environmental Protection Agency U S EPA regulations have resulted in a number of changes to fuel hoses New fuel rails are used on all 40 300 HP models The new fuel rails are con structed with a three layers of material to meet the U S EPA requirements for evaporative emissions Service parts for older product will supersede to new part numbers Refer to the appropriate Parts Catalog for correct parts ordering information SERVICE INFORMATION 15 30 HP MODELS SystemCheck Warnings Due to the limited number of circuit inputs and outputs to the EMM 15 30 HP models have limited warnings when a SystemCheck gauge is installed These models only provide tachometer signal and the LOW OIL warning to a System Check gauge Refer to the Operator s Guide for a complete explanation of warning system functions Engine Overheat Damage If a customer reports a loss of performance use Evinrude Diagnostics software to check for the following Code 31 Engine temperature over range Code 40 Engine temperature above range Low speed Code 43 Engine temperature above range e Recorded maximum engine temperature If any of these service codes are stored and the maximum engine temperature is over 248 F 120 C remove the gearcase Inspect the water pump and the exhaust housing megaphone for engine overheat damage Loss of performance will result
37. RWARD gear engagement Move the control lever to the REVERSE detent Manually turn the propeller shaft to confirm REVERSE gear engagement Move the control lever to the NEUTRAL detent Rotate the propeller shaft back and forth to ensure the face of the clutch dog does not contact FOR WARD or REVERSE gear If gear engagement is NOT correct a shift actuator motion fault can occur when the control lever is moved to FORWARD or REVERSE Use Evinrude Diagnostic software Settings screen and select the EST Calibra tion tab Use the Nudge buttons to adjust the shift stroke to the forward or backward direction Be sure to press the Save button after completing the adjustment After using the Nudge feature repeat the gear verification process Note Do NOT preload the shift actuator calibration toward FORWARD gear on outboards with a counter rotation gearcase 48 18 ess Fatta Fapta jeres Profiles History ea Exjt o Connect Status BM LED no acter PEN Sang Erane Farik qu Comfort Code 152 Shift Actuator Motion Fault EVINRUDE ICON REMOTE CONTROL SYSTEM 1 Neutral switch ICON Conversion Kit Installation 200 300 HP 90 V6 Models When installing an ICON conversion kit on 2011 and newer 200 300 HP 90 V6 models the shift switch must be removed Install protective cover P N 586821 on shift switch connector of
38. 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 e 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 10 Training Schedule training online www DealerPort com For questions contact the Technical Training Center Training courses are offered at the following locations e Waukegan Illinois Morrow Georgia Tacoma Washington Laval Quebec Dallas Texas
39. US dise EE Mc De a nei E ss 79 and larger en can beeen aan pare ties erre e ls Renee eher ira 79 60 65 HP re E AEN eee gg bi kezdes sa 80 124 390 AP amd essa datada a 81 OO FIP asi pr NE 81 115 HP and larget See Peewee Dr aa pa ae 81 115 RO T30RHP area as A are 83 1590 208 HP GO VG P oun a sola en aha beet ee 83 150 300 HP 60 VE and 0 VB unsere an 83 200 FLO 250 HP SONG euer ied ar CENTS eas ee ines deg 83 gem 300 HP SOVE acuda sos reellen 660 69 ae ps 84 BON as rara ee re ira da dC aa jad did 85 FOG Cuad wis pir A AE a A A hee 85 All eee eee Se ee eee ee ee ee ee E ee 85 ICON Remote Control System een 89 KOMMEN A area ka z ENS EVER baad 90 Parts and lee EENHEETEN 91 A o 91 SOAS sz cach eg AN A OEE ES 91 Stern Drive Aa cur rar nee ee eds er Oe aes See RR ene 92 TOUS iius cc eR aaa ta Gaeta hand aed eRe A SE ewes eee a E KR PR 93 84 APPENDIX The table provides a reference to information presented in previous Product Service Updates Model 15 30 1
40. 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 AFTER SALES SUPPORT 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 11 14 27 NOTES GENERAL INFORMATION 2011 PRODUCT IMPROVEMENTS 2009 E TECI 576 Horsepower Max Ergne RPM Cylinder Count Max Temp port Max Terre stdd 1 6 AMP connector tiller harness 2 2 AMP c
41. cable Solenoid Starter cable SERVICE INFORMATION Voltage Drop Test A voltage drop test is an effective and easy to perform electrical test The pur pose of this test is to make sure the load in the circuit consumes the maximum amount of voltage An excessive voltage drop in a circuit will result in the load not performing at its maximum potential Use a digital voltmeter to measure the voltage drop on each section of the start circuit Always connect the voltmeter leads with the positive red lead closest to the positive terminal and the negative black lead closest to the negative terminal of the battery If any voltage reading is greater than 0 5 VDC check that connections are clean tight and free of corrosion Clean or replace any corroded or damaged cables or connections Note Disconnect the Crankshaft Position Sensor CPS to prevent the engine from starting STEP 1 Connect voltmeter positive lead to the terminal for the negative battery cable at powerhead Connect voltmeter negative lead to negative battery post Activate starter motor and observe voltage reading STEP 2 Connect positive lead to battery positive terminal Connect neg ative lead to starter solenoid terminal Activate starter motor and observe voltage reading STEP 3 First activate starter motor Connect positive lead to starter solenoid terminal Connect negative lead to opposite starter solenoid
42. duct Service Update English 5008169 2010 Update CD English 355139 2010 Update CD French 355140 Predelivery amp Installation All Models English 5007857 Predelivery amp Installation All Models French 5007861 79 BULLETINS 2010 Bulletin Index Bulletin Number Models Subject Description Administrative A 2010 01 A 2010 Model Year Outboard Engines Inbox Components 2010 02 A Evinrude ICON Flat Rate Table 2010 03 A ALL EPA Campaign Label 2010 04 A ALL BEST Warranty Predelivery D 2010 01 D ALL Predelivery Checklist 2010 02 D 2011 Evinrude E TEC 250 300 HP 3 4 L Outboards New Installation and Predelivery Procedure Parts and Accessories P 2010 01 P I Command Digital Gauges Updating Software Service S 2010 01 S 2009 Evinrude E TEC 75 90 HP Outboards Incorrect Wiring Diagram in Service Manual P N 5007811 2010 02 S Evinrude E TEC 15 300 HP Outboards Wiring Resulting from Improper Rigging or Faulty Connec 2010 03 S Evinrude E TEC 75 90 HP Outboards 2 2 2010 04 S Evinrude E TEC 15 300 HP Outboards Warranty Powerhead Identification 2010 05 S Evinrude E TEC 150 200 HP 60 V6 Outboards Oil Distribution Hose Routing 2010 06 S ALL Operation in Oil Contaminated Water Evinrude E TEC 15 300 HP outboards 2010 07 S 1999 2001 Evinrude Ficht 75 25
43. e 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 17 1 Clamp oil sensor to housing P N 982115 18 115 300 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 HP Models Clamp P N 982115 is now used
44. from a damaged exhaust housing megaphone The megaphone can be damaged when a significant loss of water flow occurs Note Engine damage due to overheat conditions is NOT covered by the BRP Limited Warranty Customers should contact their insurance company to file a claim for financial assistance in the repair 24 No Bs WATERC TEMP CHECK ENGINE OIL NO luo I CHKILOW Typical SystemCheck Gauges 1 LOW OIL warning Exhaust Housing Megaphone e O 4 gt gt 4 V VW e u 2 N a A ON 48 4 A 9 Water Pump Repair 15 30 HP MOodels SERVICE INFORMATION Water Pump Impeller Kit P N 5008185 Water Pump Impeller Kit P N 5008185 is included with Water Pump Repair Kit P N 5008191 for service of 15 30 HP models The water pump impeller kit contains a new pressure relief valve spring P N 355169 and a new thermostat spring P N 355209 A change to the water pump impeller material improves the performance of the water pump This change affects engine water pressure and REQUIRES stron ger pressure relief valve and thermostat springs IMPORTANT REPLACE the pressure relief valve and thermostat springs when installing a water pump repair kit or a water pump impeller kit in any 2010 or older 15 30 HP model Failure to install the impeller assembly and springs as a set
45. ftware to run the update kit is available for use with Windows XP or Windows Vista Windows 7 Log into DealerPort www dealerport com or BOSSWeb www boss web brp com to download the latest Command software and information This tool was shipped automatically as part of the essential tool program Refer to Parts and Accessories Bulletin 2010 01 P or the instruction sheet provided with the kit SERVICE TOOLS Software Update Kit P N 765357 63 VELG NOTES TOOLS 64 REFERENCE BRP PAINT Paint codes have been added to the paper parts catalogs and to the Electronic Parts Catalogs EPC for the 2011 model year Color Spray Can PPG Paint Code Application Paint Catalyst PRIMER 777172 Midsection amp Gearcase PRIMER Gray W42650 W29741 Use for white engines PRIMER Black 5 61993 W29585 Use for blue engines BLACK Gloss 777179 W28610 W28792 Engine cylinder crankcase BLACK Military 351066 W43653 W26790 Covers Midsection amp Gearcase WHITE 777171 W28502 W45315 Base coat CLEARCOAT 772414 W29461 W26790 Use with base coat on upper amp lower engine covers BLUE Evinrude E TEC 351907 SAC61243 W45315 Base coat ELECTRICAL INFORMATION Battery Cable Length Guide Battery cable must be of the correct gauge to carry the electrical current required to start the outboard Use the chart below to select the correct
46. g into DealerPort www dealerport com or BOSSWeb www boss web brp com to download the latest Command software and information Refer to I Command Software Update Kit P N 765357 on p 63 ind Software Update Instructions incinded with Command Software Update 3 5 LCommand When multiple Digital Gange gangen refer to tastrucitos DealerPort 55 eG VELG I Command Bulletins This list of bulletins provides a reference to specific Command issues Bulletin Subject Affected Models Problem Number All Command Classicinstr rents Certain I Command Classic instruments may 2006 04 with date codes prior ta and includir accumulate moisture internally and experience P Instruments date code BE Are sueneci 9 excessive lens fogging Instruments with an accu pee mulation of internal moisture should be replaced NMEA 2000 Lowrance 1 depth finders and GPS All Evinrude E TEC 115 250 HP out units can interfere with engine management mod 2006 04 S 2 nn boards using CANBus network com ule EMM functions on certain Evinrude munications E TEC outboards during certain CANBus commu nication modes EGonma Newer 2005 amp newer 200 250 HP 90 V6 This bulletin provides information related to a 2007 01 P 4 2007 8 newer 115 200 HP 60 V4 V6 change Command network connectors Blue 2008 amp newer 40 90 HP t
47. g to gearcase alignment pins rect installation of the gearcase Use Gearcase Alignment Kit P N 5007231 to accurately align gearcase housing to exhaust housing on engines where the exhaust housing is not machined to accept the alignment pins Exhaust Housing 1 machined to accept exhaust housing to gearcase alignment pins 38 EVINRUDE DIAGNOSTICS SOFTWARE IMPROVEMENTS AND CHANGES New Software Version 5 1 Evinrude Diagnostics software is a Windows based diagnostic tool developed for re Evinrude E TEC outboards The latest version will communicate with DI engines Evinrude Diagnostics Software E back to 1997 Standard Version Model year changes require the release of new software versions Version 5 1 is required for model year 2012 and older New diagnostics software version 5 1 P N 5008689 automatically shipped to all authorized U S and Canadian service dealers as part of the North American Essential Tools and Software Program Existing dealers are charged a reduced price for this software as an annual software license renewal and update Evinrude Diagnostics software version 5 1 Minimum Hardware Requirements Personal Computer IBM compatible laptop computer Operating System Microsoft Windows 7 Vista XP 2008 or 2003 CPU Speed Pentium II 133 MHz or higher Memory 64 megabyte or more Hard disk 40 megabyte or more of free space Evinrude Diagnostics software version 5 1 F
48. gging Kit Selection Chart on p 45 for rig ging kit selection Each ICON rigging kit includes all the boat related ICON components needed to rig a single station or an optional second station plus the appropriate ICON remote control for the number of engines installed on the boat ICON Conversion Kits ICON Conversion Kits add digital electronic shift and throttle control to 2008 and newer Evinrude E TEC 150 300 HP models To add digital electronic shift and throttle control to an Evinrude E TEC outboard order ICON Conversion Kit P N 764979 for 200 300 HP 90 V6 models ICON Conversion Kit P N 765304 for 150 200 HP 60 V6 models ICON conversion kits must be installed by a dealer using Evinrude Diagnostics software used on a boat equipped with an CON remote control network used with ICON I Command or other NMEA 2000 compliant CANbus instru ments Update engine management software on 2008 2010 engines to ensure ICON compatibility Refer to the Installation Instructions provided with the kit Note 2007 and older models are NOT compatible with the CON remote control system 44 7 M A He ICON Rigging Kit ICON Conversion Kit EVINRUDE ICON REMOTE CONTROL SYSTEM ICON RIGGING KIT SELECTION CHART Step 1 Select number of engines 3 4 A Concealed Single Lever Step 2 Select appropriate remote control Side Mount Binnacle Mount
49. gram in the service manual Step 2 Inspect master power key switch wire harness for damage or short cir cuit Repair or replace damaged master power key switch or wire harness If the mas ter power key switch or wire harness is not damaged or the fuse fails again con tinue with Step 3 Step 3 Turn the master power key switch OFF Replace 3 amp fuse Step 4 Disconnect ALL hubs the back bone cable and buss cables including buss cables for ESM gateway module and accessory power relay from the CON network Step 5 Reconnect one hub or buss cable to the CON network Step 6 Turn master power key switch ON Step 7 If the fuse does not fail turn the master power key switch OFF Repeat steps 5 through 7 until the faulty hub or cable is reconnected and the 3 amp fuse fails Repair or replace the hub or buss cable that causes the 3 amp fuse to fail Step 9 Replace 3 amp fuse Verify remaining hubs or buss cables are not faulty Repeat steps 5 through 9 until all hubs and buss cables are reconnected to the CON network 52 3 Amp Fuse I COMMAND 4227 I COMMAND INFORMATION Instancing I Command digital gauges with software version 2 1 or higher support up to five engines and eight fuel tanks A NMEA 2000 network can be configured to support many instances of duplicate or similar devices on the same network Additional devices must be added through careful network configuration Instance n
50. head propeller 2008 Rigging 2009 Rigging 2008 Rigging Key switch orientation water drain 2009 Rigging 2008 Rigging Throttle cable adjustment 2009 Rigging Code 11 TPS out of idle range 2008 Service Codes Key switch accessory circuit Amperage limit OMC Service Bulletin 2092 93 All All All All All All All All All All All All All All All All All All All All All All All All All All All All All 94 VELG Model Other References Codes 101 through 106 Ignition timing circuit short 2009 Service Codes detected New crankshaft position sensor P N 587014 2009 Ignition amp Electrical Troubleshooting 5 volt sensor circuit 2009 Ignition amp Electrical E to starter solenoid servicing 2009 amp Electrical 4 Model All All All All All All All All All All All All All All ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control APPENDIX Where to Find Book Year Section Other References Evinrude Johnson XD 100 outboard oil 2009 Oiling Systems Evinrude Johnson XD 50 outboard oil 2009 Oiling Systems Evinrude Johnson XD 30 outboard oil 2009 Oiling Systems Oil type setting HO models XD 100 setting not available 2009 Oiling Systems Oil type setting use TCW 3 setting w
51. ify the hydraulic trim and tilt assembly Manual Relief Valves 1 P N 5006321 use in hyaraulic trim and tilt assembly P N 5005756 2 P N 5007782 red anodized use in hydraulic trim and tilt assembly P N 5007776 Hydraulic 3 f Manifold Use Parts Model Year Models Trim and Tilt Ge Assembly P N Description Catalog 2005 2 75 2005 2008 005 2008 5 90 5005756 Painted Gloss 2007 2008 115 130 Black 2007 2008 75 90 Anodized Flat 2009 or newer 2 5007776 newer Black 2009 or newer Manual Release Issue If a hydraulic trim and tilt assembly P N 5007776 cannot be lifted manually replace the manual release valve P N 5007782 The replacement manual release valve is identified by its red anodized color 37 GEARCASE Exhaust Housing to Gearcase Alignment Pins Current production M2 Type gearcases are fitted with exhaust housing to gear case alignment pins P N 350943 If installing a replacement M2 Type gearcase on a 2008 or older engine inspect the exhaust housing Make sure it is machined to accept the exhaust housing to gearcase alignment pins If the exhaust housing is not machined to accept the alignment pins remove the alignment pins from the replacement gearcase Failure to remove the exhaust housing to gearcase alignment pins can damage the exhaust housing mounting flange and prevent cor 17 Exhaust housin
52. 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 15 1 Vent 1 Nut 2 Spring 16 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 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 whil
53. ing issues REFERENCE Water pressure readings can vary depending on water inlet screen type hull design set up and operating conditions RPM 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 Model Water Pressure psi kpa 40 65 HP 4 5 5 6 7 9 10 11 14 15 15 17 16 18 16 18 14 16 12 14 10 12 27 34 34 41 48 62 68 75 96 103 103 117 110 124 110 124 96 110 82 96 68 82 75 90 HP 5 6 10 11 12 14 15 17 16 18 16 18 13 15 15 17 16 18 19 21 20 22 34 41 68 75 82 96 103 117 110 124 110 124 89 103 103 117 110 124 131 144 137 151 115 130 HP 5 6 9 10 12 14 15 17 18 20 20 21 20 22 21 23 21 23 21 23 21 23 60 V4 34 41 62 68 82 96 103 117 124 137 137 144 137 151 144 158 144 158 144 158 144 158 150 200 HP 4 5 9 11 14 16 17 19 19 21 20 22 20 22 21 23 22 24 23 25 24 26 60 V6 27 34 62 75 96 110 117 131 131 144 137 151 137 151 144 158 151 165 158 172 165 179 200 250 HP 3 5 7 9 8 10 9 11 10 12 11 13 12 14 13 15 14 16 15 17 16 18 90 V6 3 3L 27 34 48 62 55 68 62 75 68 82 75 89 82 96 89 103 96 110 103 117 110 124 250 HO 300 HP 4 6 7 11 9 12 10 14 12 15 14 16 15 18 16 19 18 20 18 25 20 30 90 V6 3 4L 27 41 48 75 62 82 68 96 82 103 96 110 103
54. ith XD 100 oil 2009 Oiling Systems extreme applications Mulipoitoling 2009 Oiling Systems Electrical test adaptors 12010 Service Tips Water vapor from exhaust relief 12010 Service Tips Engecovercae 7 2010 gt Service Tips a control system and engine management Soin unidas CON Sdn enl ICON remote control trim plates 2010 Evinrude ICON Remote Control ICON accessory power relay 2010 Evinrude ICON Remote Control 95 VELG Model ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control ICON Control I Command 96 Other References Parts amp Accessories Device net style connectors 2009 Bulletin 2008 01 P Water pressure sensor kit P N 5006214 2009 I Command Water pressure sensor kit P N 764195 2009 Parts amp Accessories Pre programmed water pressure sensor kits 2009 Bulletin 2008 03 P Parts amp Accessories Pre programmed fuel level converter kits 2009 Bulletin 2008 04 P Fluid level converter kit P N 764166 2009 I Command How to se
55. loppy drive necessary for injector coefficient file installations but not required if user has internet access to DealerPort or BOSSWeb Refer to Service Bulletin 2010 07 S Display resolution 800 x 600 1024 x 768 preferred font size 96 dpi Interface Port Computer RS 232 9 pin Serial Port USB to RS 232 9 pin Serial Adapter Configured to ComPort 1 through 9 CardBus PCMCIA to RS 232 9 pin Serial Adapter Configured to ComPort 1 through 9 Communications Cable Use Interface Cable P N 437955 IMPORTANT Version 5 1 software MUST be installed using the program CD P N 5008689 Version 5 1 software is NOT available online 40 Evinrude Diagnostics Software Program Initial Setup Automatically Connect To Engine When Application Starts Automatically Record Engine Values History Upon Engine Connection Automatically Save Engine Data File EDF Upon Engine Connection v v Display Confirm Close Message When Closing The Application C Use Automatic Website Updates Select Assigned Website O BOSSWeb DealerPort OK Initial Setup Software Registration For Dealer User Number Name Address City State Province Zip Postal Code Country ALL FIELDS must be completed Software Registration EVINRUDE DIAGNOSTICS SOFTWARE Important Information for Evinrude Diagnostics Software Version 5 1 Program Installation Initial Setup The first
56. o Red connectors I Command and NMEA This bulletin provides information related to the dif 2008 01 P 2000 Network Connec ALL ferences in compatible DeviceNet tors style connectors Command Water This bulletin provides information related to the 2008 03 P 2 ALL selection and installation of Command water pressure sensors kits 2008 04 P Fuel Level ALL This bulletin provides information related to the Converter Kits configuration of fuel level converters l Command Diaital This bulletin provides recommended service pro 2010 01 P ae 0 cedures and information to update software and to Gauges submit warranty allowance requests 56 PARTS AND ACCESSORIES P amp A INFORMATION Tiller Handle Kits Evinrude E TEC 15 30 HP Models Tiller Handle Kits for 15 30 HP models are available as follows Color Blue White Note Model Year 2009 2010 5007834 not available 5 pin electrical connector 2011 amp newer 5008256 5008237 6 pin electrical connector Uses a 5 pin electrical connector The neutral switch is attached Refer to the 2009 or 2010 Accessory Parts Catalog for parts information Uses a 6 pin electrical connector Refer to the 2011 Parts Catalog for order information Refer to the 2011 Accessory Parts Catalog for service parts infor mation Tiller handle kits for 2009 10 models are not interchangeable with
57. onal information and recommendations These problems can occur with all brands and types of outboards and are related to fuel blending contaminants and atmospheric conditions 34 F e Deteriorated fuel hose and primer bulb Blockage in the fuel system SERVICE INFORMATION OILING SYSTEM Code 36 Rear Oil Injection Pump Circuit OPEN Code 36 is a new service code for Evinrude E TEC 250 300 HP 90 V6 3 4L models with the new rear oil pump The rear oil pump is powered by the 12 V electrical circuit The EMM controls pump operation by rapidly connecting and disconnecting the pump s internal coil to ground Refer to the 2011 Service Manual for code description Possible Causes Damaged wire harness or electrical connector between EMM and oil pump Failed internal coil of oil pump Failed circuit in EMM Troubleshooting procedure Use the correct service manual to check the fol lowing Rear oil pump voltage and control signal Refer to Cylinder Oil Pump Voltage Tests Oil injection pump circuit resistance Refer to Cylinder Oil Pump Resistance Test 1 Rear oil injection pump 35 A SRP COOLING SYSTEM Gearcase Flushing Adapter Cover auxiliary water inlet holes on the gearcase when a gearcase flushing adapter is used to flush the outboard If auxiliary water inlet holes on the gear case are not covered water can drain from them resulting in engine o
58. onnector neutral switch 14 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 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
59. ontact 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 1 847 689 6902 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 1 847 689 7235 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 1 847 689 6902 Non authorized dealers consumers Parts amp Accessories Support North American dealers may call 1 800 888 4662 for technical assistance with parts and accessories e Select option for ordering assistance pricing and back order or returns information e 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 1 847 689 7510 Dealers Outside
60. r Remove the fitting and inspect for damage or blockage Replace if damaged Clean or replace the exhaust back pressure fitting if it is blocked Clean it by soaking in Engine Tuner After soaking use an appropriate size pick or drill bit to open blocked holes 27 A 200 300 HP 90 V6 MODELS Ordering Replacement Gearcases The L2 Type gearcase with the 58 1 71 1 gear ratio is no longer available Use an M2 Type gearcase with the 54 1 85 1 gear ratio if replacement is needed Because a gearcase conversion kit is required existing part numbers do not supersede Dealers who enter an order for a 58 gear ratio L2 Type gearcase will receive an invoice with a Note to call the After Sales Service Department This will result in delays receiving the correct replacement gearcase Order the following parts e Select the correct M2 Type replacement gearcase Refer to the Parts Catalog for replacement gearcase part numbers Select the correct gearcase conversion kit order P N 5008535 for 20 inch models eorder P N 5008536 for 25 inch models Gearcase conversion kits include the correct shift rod a new exhaust grommet new gearcase mounting screws and installation instructions Refer to the installation instructions for the following Exhaust grommet and Oetiker clamp installation Shift rod installation and shift rod height adjustment Correct water inlet screen selection Correc
61. r shaft by the thrust bushing The area that is scored by the thrust bushing will weaken Because the loose propeller puts an abnormal amount of stress on the propeller shaft the failure occurs at the weak point created by the insufficient clamp load on the thrust bushing This type of failure also results in the loss of the propeller and propeller hardware Note Incorrect installation of any manufacturer s propeller and propeller hard ware that results in the failure of the propeller shaft is not a condition which will be covered under the BRP Limited Warranty 59 14 27 NOTES PARTS AND ACCESSORIES 60 SERVICE TOOLS rer New service tools have been developed for 2011 Model Year outboards New tools were announced in Service Bulletin 2010 09 S Fuel Flow Test Kit P N 5008371 The Fuel Flow Test Kit P N 5008371 is used to check a boat s fuel system for e fuel flow restrictions and air leaks without having to start the outboard or run the vessel through the water Developed for Evinrude E TEC 115 300 HP out boards pam This tool was shipped automatically as part of the essential tool program bi enm Refer to Service Bulletin 2010 09 S and the instructions for additional informa tion Fuel Flow Test Kit P N 5008371 62 I Command Software Update Kit P N 765357 Use Command Software Update Kit P N 765357 to update Command digital gauge software So
62. range wire of the ignition coil connector Refer to Ignition Control Circuit Tests in the appropriate service manual The black wire of the ignition coil connector provides continuity to ground The secondary spark plug lead provides continuity Refer to Ignition Output Tests in the appropriate service manual for other igni tion system test procedures 32 CDI Multi Strike Ignition 1 Fastrise time 2 Short spark duration 3 No spark in gap Evinrude E TEC IDI 1 Fastrise time 2 Long spark duration PN 5006328 1 SN 10110080142864 PCN 98999 2 CS 42425 Injector Serial Number Label 1 Serial number 2 Checksum number Usage of mis tool is Reserved for Authorized BRP A Dealers Only Unauthorized une is Sry Prohibited 1 Click here for options SERVICE INFORMATION FUEL SYSTEM Injector Coefficient Database Dealers can now download the coefficient files for new service fuel injectors from a database available on the internet This process eliminates the need for a 3 5 inch floppy drive on the service laptop computer and the problems created when the disk is packaged with a service fuel injector is damaged Refer to the serial number label attached to the fuel injector electrical connector ACCURATELY record the 14 digit Serial Number SN and the 5 digit Checksum CS number from the injector serial number label Log on to DealerPor
63. t or BossWeb to download injector coefficient files from the internet Refer to Service Bulletin 2010 07 S for complete instructions A copy of this bulletin is packaged with each service fuel injector Internet Browser Blocks Download of Injector Coefficient File The problem After entering injector serial number and checksum nothing hap pens after pressing the Download Injector Coefficient File button The cause Internet browser security settings are blocking download of the coef ficient file and displays a security message bar above the screen The fix Click on the security message bar that reads Click here for options Select Download File to start the download process 33 Fuel Issues Reports received by the After Sales Department indicate fuel related problems persist in areas where alcohol extended fuels are used These problems include Excessive alcohol content in fuel Water or other contaminants in the fuel tank Phase separation These problems can result in Corrosion of fuel system metal parts Deteriorated fuel hoses Blockage in the fuel system Engine damage As part of routine maintenance inspect fuel hoses from the tank to the outboard Make sure fuel supply hoses have not deteriorated Replace deteriorated fuel hoses Routine inspection of fuel hoses can help prevent expensive repairs Refer Service Bulletin 2006 06 S and to the 2008 and 2009 Product Service Update books for additi
64. t trim tab selection and installation Gearcase mounting screw torque The change of gear ratio requires a change of propeller pitch 28 ee ST i B M2 Type Gearcase Gearcase Conversion Kit Typical MAINTENANCE SERVICE INFORMATION Maintenance Recommendations 26 Point Inspection Checklist Use the 26 Point Inspection Checklist to explain required service for the Evinrude E TEC 300 hour 3 year service and to help sell a maintenance plan to your customer The parts department can use the checklist to stock service supplies Service technicians can use the checklist to check off service items as they are completed Description Engine Every 300 Description Engine Every 300 Care hours or Care hours or Product 3 years Product 3 years Emergency stop circuit and lanyard check operation X Fuel filter replace 2 X Controls steering and tilting check operation X Gearcase lubricant replace A X Engine mounting hardware re tighten X Spark plugs inspect or replace 9 X Fasteners tighten any loosened components X Thermostats inspect and check operation 3 X Water intake screens check condition X Grease fittings lubricate C X Cooling system check water pump indicator X Power trim tilt and fluid level inspect B X Anticorrosion anodes check condition X Propeller shaft splines
65. t up fuel management options 2009 I Command gauge installation dashboard hole size 2009 Model I Command I Command I Command I Command I Command I Command I Command P amp A P amp A P amp A P amp A P amp A P amp A P amp A Propeller Propeller Propeller Propeller Propeller Propeller Propeller Software Software APPENDIX Where to Find Book Year Section Other References How to reset gauge to factory default settings 2009 Command Avoid radar antenna when installing GPS module 2009 a sender resistance different in North America and 5609 T Cammang Rectifier regulator no purple wire 2009 Parts amp Accessories Frequently requested part numbers 2010 Parts amp Accessories Reverse gear availability 2010 Parts amp Accessories Hydrus propeller exhaust ring 2009 Rigging Gear ratio and propeller selection 54 vs 58 ratio 2009 Rigging gearcases 2008 Diagnostic Software USB to serial adapters for diagnostic software 2008 Diagnostic Software PC Specifications for diagnostic software Parts amp Accessories Bulletin 2001 01 P Parts amp Accessories Bulletin 2005 01 P 97 LEG Model Software Software Software Software Software Software Software Software Software Software Software Software Soft
66. tate the connectors to align pins to sockets This can damage the pins of the connector A damaged connector can cause an electrical short in the net work resulting in a failed 3 Amp fuse at the master power key switch It is possible for the pins of one connector to enter the sockets of the other con nector when the tabs and grooves of the connector are misaligned This dam ages the connector housing and makes an extra groove in the misaligned connector Misaligned connectors can cause the 3 Amp fuse at the master power key switch to blow and disrupt or eliminate communication on the network Improper network communication can create non recoverable fault codes and activate S A F E 47 A 150 200 HP 60 V6 Models Code 152 Shift Actuator Motion Fault The problem After installing an ICON conversion kit P N 765304 on a 150 200 HP 60 V6 Code 152 Shift Actuator Motion Fault occurs when the engine is shifted into forward gear due to incorrect shift actuator calibration The fix Use Evinrude Diagnostic software version 4 0 or higher to verify shift actuator calibration Refer to the installation instructions provided with the con version kit If the problem persists perform the following adjustment Turn the master power key switch to the ON position Position control levers to the NEUTRAL detent e Move the control lever to the FORWARD detent Manually turn the propeller shaft to confirm FO
67. tware Monitor screen or a NMEA 2000 gauge or ICON to monitor voltage Perform the following steps if ICON network voltage is below 13 25 VDC Identify which battery is powering the CON network Test battery connections and charge Run the engine connected to the battery for the CON network or use a battery charger to support the battery voltage Visually inspect the 3A fuse for the master power key switch and the 10A fuse for the power supply cable Check network voltage at the 10A fuse of the ICON power supply cable Look for an Accessory Power Relay Kit P N 765296 in the CON network This optional power relay kit connects to one of the 6 port hubs and is required to power any accessory controlled by the master power key switch Connect only the positive lead of an accessory to the terminal board provided with the accessory power relay kit Do NOT connect accessory wiring to the master power key switch 51 A Failed 3 Amp Fuse Master Power Key Switch A failed 3 amp fuse for the master power key switch is normally caused by one of the following Failed or damaged master power key switch Damaged master power key switch wire harness Damaged or faulty buss cable or back bone cable e Damaged or faulty hub Follow these steps to troubleshoot a failed 3 amp fuse Step 1 Inspect master power key switch for damage Test key switch function with an ohm meter Refer to MWS Key Switch Dia
68. umbers are used to represent similar devices on a common network When adding devices to the NMEA 2000 network Unconfigured devices MUST be added one device at a time Preconfigured device kits can be added to the network all at one time n either case if a device is associated with an engine the device instance number MUST match the engine instance number Ruse Engine Device Association oe Port Kad Center pe Starboard Outboards Instance Numbers 1 0 2 0 1 3 0 1 2 4 0 1 2 3 5 0 1 2 3 4 Use Evinrude Diagnostics software to confirm engine instance or transom posi tion 54 Engine Instance Transom Position Information I COMMAND I Command Water Pressure Sensor Kit P N 5008300 Use this kit to provide water pressure data to Command or other instruments on a NMEA 2000 network Install this kit on Evinrude E TEC 115 300 HP out boards only The water pressure sensor used in this kit is capable of providing water pressure readings from 0 to 30 psi 0 to 206 kPA Refer to the installation instructions provided with the kit for correct installation The water pressure sensor MUST be installed in a vertical position Hose instal lation MUST provide complete drainage of water from the sensor Software for Devices Software is available to update Command digital gauge and device software Lo
69. unger BIP 2008 Fuel System Unleaded gasoline 2008 Fuel System Service Bulletin 9 2009 Fuel System 2006 06 S Alcohol extended fuels 2009 Fuel System 91 VELG Model Other References a All Fuel system maintenance OB PURI y 2009 Fuel System All Fuel flow compensation 2008 Fuel System All 25 mix and match fuel injectors Nozzle and seat 2008 Fuel System A Al Al Al Al Al Al Al Al Al Al 2008 Ignition amp Electrical in Spa DIENEN 2009 Ignition amp Electrical All Spark plug life 2008 Ignition amp Electrical All No lubricant on TPS linkage 2008 Ignition amp Electrical All TPS installation tip 2008 Ignition amp Electrical m 2008 Ignition amp Electrical i ene 2009 Ignition amp Electrical Service Bulletin 2006 01 S 2008 Ignition amp Electrical 2009 Ignition amp Electrical All Neutral switch and shift interrupt switch functions 2008 Ignition amp Electrical All Circuit testing with inductive pick up timing light 2008 Ignition amp Electrical All Starter motor service parts 92 All All All All All All All All All All All All All All All All All All All All All All Model APPENDIX Topic Where Find Book Year Section Other References 2003 Ong System TAS 2008 Powerhead model fi mor ne Powerhead replacement rebuild 2009 Powerhead 2009 Power
70. ver 60 MPH High Flow P N 5005063 350264 350265 0 060 General Ultra High Flow P N 5006337 M2 Standard 350946 350945 0 160 Aerated Ultra High Flow 1 4 P N 5007081 350790 350791 0 410 Severely aerated Screws P N 337061 T Note Kits include both screens screws and instruction sheet O Type Gearcase Individual Water Screens tt Port Starboard Height Application Standard 337778 337778 0 023 General Optional 339247 339247 0 055 Aerated Screws P N 337061 Tt Note Screens are symmetrical use two per outboard S Type and S2 Type Gearcases Individual Water Screens tt Port Starboard Height Application Standard through 2006 340495 340495 Flush General Standard 2007 and newer 337778 337778 0 058 Aerated Weedy Optional 339247 339247 0 200 Severely aerated Screws P N 340665 Tt Note Screens are symmetrical use two per outboard 75 4 27 2011 RPM QUICK REFERENCE CHART Model Recommended Optimum RPM Operating Range RPM Range Rated HP 15 H O 5500 6100 5400 5800 5800 25 HP 5500 6100 5400 5800 5800 30 HP 5500 6100 5400 5800 5800 40 HP 5000 6000 5400 5600 5500 50 HP 5500 6000 5600 5750 5750 60 HP 5500 6000 5600 5750 5750 65 HP Commercial 5500 6000 5600 5750 5750 75 HP 4500 5500 5000 5200 5000 90 HP 4500 5500 5000 5200 5000 115 130 HP 60 V4 5500 6000 55
71. verheat To insure enough water travels to the powerhead from the water intakes tempo rarily cover auxiliary water inlets as follows 15 30 HP Models Temporarily cover the two small auxiliary water inlet holes on each side of the gearcase with waterproof tape 150 300 HP Models equipped with an M2 Type gearcase Temporarily cover the six auxiliary water inlet holes on the front of the gearcase with water proof tape Be sure to remove waterproof tape from auxiliary water inlets when flushing is complete 36 15 30 HP Models 1 Auxiliary water inlets 150 300 HP Models M2 Type Gearcase 1 Auxiliary water inlets Hydraulic Trim and Tilt Assembly 1 P N 5007776 Black anodized manifold SERVICE INFORMATION TRIM AND TILT Single Piston Hydraulic Trim and Tilt Assemblies Identification Dealers must correctly identify single piston hydraulic trim and tilt assemblies to order the correct service parts The single piston hydraulic trim and tilt assembly is used on 75 90 HP 20 inch models in 2005 and on 115 130 HP V4 20 inch models in 2007 Hydraulic Trim and Tilt Assembly P N 5005756 superseded to P N 5007776 starting in 2008 Some service parts for these hydraulic trim and tilt assemblies are NOT inter changeable Use the table below and the appropriate Parts Catalog to correctly ident
72. ware Software Software Software Software Stern Drive 98 Where to Find Book Vear Section Other References New USB to serial adapters for diagnostic software 2009 Diagnostic Software USB to serial adapter set up 2008 Diagnostic Software Evinrude Diagnostic software program update v 2 0 2008 Diagnostic Software ease men mann CC vene ans an fonr nern nee ren Stern drive parts inquiries 2009 Parts amp Accessories APPENDIX Model Where to Find Book Year Section Other References Service e Tools Gearcase alignment pin kit 2008 Gearcase 2006 03 S Service Tools S 2 driveshaft tools 2008 Gearcase 2005 06 S Tools 60 models Powerhead alignment tool 2008 Powerhead Serve Slt Tools New tools for M2 Type and L2 Type gearcases 2009 Gearcase o Propeller shaft seal tools allow replacement of seals Service a 19085 without gearcase disassembly ed 2008 02 S Service GE Tools Gearcase alignment gauge 2008 Gearcase 2004 0115 pe Teens 99 VELG NOTES APPENDIX 100 De Lu mi Z e ei 1 oc e lt lt Lil a 140 DIU e
73. ype Gearcase 54 Ratio on 225 300 HP 90 Models The L2 Type gearcase with 58 gear ratio has been replaced by the M2 Type gearcase with 54 gear ratio on all 225 300 HP models The larger gear set used in the M2 Type gearcase improves durability Front water inlets provide additional cooling water for the powerhead and can boost water pressure in excess of 40 psi 275 kPa Also see Exhaust Housing to Gearcase Alignment Pins on p 38 Additional benefits of the M2 Type gearcase Improved acceleration due to 542 1 85 1 gear ratio Front and side water inlets Wider propeller selection available to optimize performance ST sf M 2 B gt M2 Type Gearcase 1 Front water inlet 2 Side water inlet 21 1 Strengthening ribs Fuel Rail Typical 22 Exhaust Grommet 115 300 HP Models A new exhaust grommet is used on all V4 and V6 models The new exhaust grommet features ribs to strengthen the grommet and reduce flexing around the insert area This improves retention of the overboard indicator hose When installing an exhaust grommet clean and dry all parts Make sure the Oet iker clamp that retains the overboard indicator hose is correctly positioned Refer to the appropriate Service Manual for installation instructions Exhaust grommet P N 5008518 services all 2005 and newer 115 300 HP Evinrude E T

2011 Product Service Update, P/N 5008496

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