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1. ECONOMY M D M de OPERATION c POWER TRM AND PROPELLER SELECTION suv aaia aa MOORING rc Ese BP EIL cate ENGINE OVERHEATING araar erm MRAILERING Se NAAA reaa Kanaari aaan ankaka Saaana anak AKAN N IMPACT DAMAGE E E E EE E E E E TET AE T E A T T SPECIAL OPERATING CONDITIONS MAINTE NA N CE tas edu bi Eu ENGINE EMISSIONS INFORMATION 10 OFF SEASON STORA GE eee ern PRE SEASON SERVICE E E Sus P LUBRICATION e WATER PRESSURE e Eee START ASSIST CIRCUIT FUSE Elixir POWER DISTRIBUTION PANEL PROPELLER Rc LP EM ANTIFPCORROSION enlm TROUBLE CHECK CHART aeree koe pa eni eo auseenssiedsacasernarborseniee
2. 2 PRODUCT REFERENCES ILLUSTRATIONS AND SPECIFICATIONS ressent nnne 4 BOMBARDIER LIMITED WARRANTY FOR EVINRUDE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND 5 BOMBARDIER LIMITED WARRANTY FOR EVINRUDE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT FEATUHES UIS POOR rut Qe nh Sia du ENGINE SPECIFICATIONS REMOTE CONTROL ENGINE MONITORING inniti tauri i x tel cca rr e nni FUEL AND OIL Eia eden AAEE d UE C Mm D n ELEM DI o pos BREAK IN 10 HOURS cessssssssssssssssssssssssssssesssssscsssssesssssesssssessssssessssessssueesssseesssseeessueesssuieesssseesssssesssseesssaeessaesses ENGINE STARTING BEFORE START UP A ENGINE STOPPING RE E SHIFTING AND SPEED CONTROL
3. 100 thru 250 HORSEPOWER FPL FSL FPX FCX FPZ BOMBARDIER FHL Our First Words to the Owner Operator This Operators Guide is an essential part of your Evinrude outboard It contains pertinent information which if followed will provide you with a thorough understanding needed for proper operation mainte nance care and above all safety The safety section of this Guide comes first because it is our first priority and it should be yours too It is strongly recommended that you read this Guide from front cover to rear cover Following this recommen dation will assure the completeness of the information that is essential to your safety the safety of any passengers and other boaters An Operators Readiness Test has been prepared on the last page of this Guide Be safe All passengers should be familiar with the proper operation of your boat and Evinrude outboard Be certain they fully understand and respect the controls and operation Each operator is responsible for the safety of all passengers and other boaters Please make safety your first priority and complete a boat ing safety course through your local Coast Guard Power Squadron Red Cross or State Boating Law Agency The pleasures of owning and operating an Evinrude outboard can be significant We strongly believe the rewards for following our recommendations will be worthwhile Remember that YOU are the key to safety Good safety practices not
4. To avoid difficulty when restarting never run the engine with the fuel hose disconnected or run the engine out of fuel If you must tilt the motor to remove it from the water lower it and allow the cooling system to drain com pletely as soon as you clear the launch area Between uses store your motor in a vertical posi tion For recommendations on extended periods of stor age refer to Storage SPECIAL OPERATING CONDITIONS Salt Water Flush the engine internally after use in salt polluted or brackish water to help prevent mineral deposits from clogging cooling passages Your outboard has a built in flushing port to facilitate flushing Refer to Flushing During use in salt or brackish water additional an odic protection for the boat and outboard may be re quired During long periods of mooring tilt the gearcase out of the water except in freezing temperatures Upon removal from salt water leave it in a vertical position until its cooling system has drained Weedy Water Weeds block water intakes and cause your out board to overheat Weeds on the propeller create vibration and reduce boat speed Run at slow speeds and in REVERSE frequently to clear weeds from the propeller and water intakes Check the water pump indicator often If REVERSE operation does not clear away weeds SHUT OFF the engine Remove weeds from pro peller area and water intakes before op
5. and in many confined areas such as the boat cabin cockpit swim platform and heads It can be worsened or caused by weather mooring and operating conditions and other boats Avoid exhaust fumes from your engine or other boats provide proper ventilation shut off your engine when not needed and be aware of the risk of backdrafting and condi tions that create CO accumulation In high concentrations CO can be fatal within min utes Lower concentrations are just as lethal over long periods of time AN Proceed with caution and at very low speed in shallow water Grounding or abrupt stops may result in personal injury or property damage Also be alert for debris and objects in the wa ter AN Be familiar with the waters you are operating in The gearcase of this outboard extends be low the water surface and could potentially come in contact with underwater obstructions Contact with underwater obstructions may re sult in loss of control and personal injury AN Avoid standing up or shifting weight suddenly in light weight boats AN Keep your passengers seated in seats The boat s bow gunwale transom and seat backs are not intended for use as seats AN Insist on the use of personal flotation devices approved by the U S Coast Guard by all pas sengers when boating conditions are hazard ous and by children and nonswimmers at all times AN Respect no wake zones rights of other water users and the environment As the
6. 48 Maintenance 100 FPL FSL and 115 FPL FSL models 1 Thrust washer 2 Spacer 3 Propeller nut 4 Cotter pin other models Install propeller nut and tighten to a torque of 70 80 ft Ibs 95 108 Install keeper on propeller nut align keeper slots and cotter pin hole Install new cotter pin and bend ends to secure 31 1 fa p 2 5 dr4028 All other models Thrust Washer Spacer Propeller nut Cotter pin Keeper Remove block of wood Make sure engine is in NEUTRAL give propeller a spin It must turn freely Repair If your propeller hits a solid object the impact 5 par tially absorbed by the rubber bushing in the hub to help prevent damage to the engine A strong impact can damage the hub and propeller blades Damage to blades can cause unusual and excessive vibra tion Damage to the hub can cause excessive en gine RPM with little forward movement IMPORTANT Avoid or limit operation using a dam aged propeller Carry a spare propeller Keep your propeller in good condition Use a file to smooth slight damage to blade edges See your DEALER for repair of serious damage ANTI CORROSION ANODES Your motor is equipped with one or more anodes that protect it from galvanic corrosion Refer to Fea tures section for anode location Disintegration of the anode is normal and indicates it is working Check each anode periodically Replace anodes smaller
7. Stop the engine and check the fuel system for leaks WARNING Failure to check for fuel leakage could allow a leak to go undetected resulting in fire or explosion BATTERY Each outboard needs one battery that is 12 volt heavy duty designated marine Vented refillable or maintenance free Rated according to the minimum requirements in Engine Specifications Deep cycle batteries are suitable IF they meet or exceed the minimum CCA requirements Ask your DEALER about your outboard s require ments before installing longer battery cables or a battery switch Never install an after market battery isolator Your outboard has a built in accessory battery charging feature Refer to Accessory Battery Connection Installation Read and understand the safety information sup plied with your battery BEFORE you begin installa tion IMPORTANT You must use the adapter clamps and starwashers supplied with this outboard when installing the main battery cables to the cranking battery Any other type of installation can damage the electrical system or EMM Make sure all components are clean and free of corrosion Connect the RED main cable to the positive battery post Connect the BLACK main cable to the negative battery post If you have marine battery posts install each main cable on the clamp adapter with a starwasher be low it Install all wires from accessories on the threaded portion
8. After any overheat have your DEALER Torque the cylinder head screws Inspect the water pump for excessive wear or dam age Inspect the thermostats Inspect the engine for leaks TRAILERING WARNING y Y Keep everyone clear of stern area when raising or lowering the outboard Personal injury or death can result from contact with moving parts of the outboard Trailering Bracket To engage bracket Tilt the motor fully using the tilt switch inside the boat or the trailering tilt switch dr3964 drc4014a 1 Trailering tilt switch 2 Tilt switch inside boat Pull down the trailering bracket A detent will hold the bracket in position Lower the motor until the trailering bracket locks into place in the stern brack ets dr5073 To disengage bracket Tilt the motor fully Re turn the trailering bracket to its stowed position Lower the motor to its vertical position dr5074 Trailer your boat with the motor in a vertical posi tion If your trailer does not provide adequate road clearance the motor can be trailered while tilted by using the motor s trailering bracket IMPORTANT DO NOT use the tilt support lever when trailering Operation 35 IMPACT DAMAGE Your engine has a shock absorption system de signed to help withstand damage from impact with underwater objects at low to moderate speeds However high speed impacts with rigid underwater objects like pilings or bo
9. ENGINE MAINTENANCE AND INSPECTION SCHEDULE 2003 Bombardier Motor Corporation of America All rights reserved TM Trademarks and registered trademarks of Bombardier Motor Corporation of America or its affiliates 1 GENERAL INFORMATION SAFETY THE RIGHT PLACE TO GET STARTED This Operators Guide contains essential informa tion to help prevent personal injury and damage to equipment It will acquaint the operator and pas sengers with the Evinrude outboard and its con trols operation maintenance and boating safety measures Make sure all operators read under stand and follow the contents This Guide should be kept in a waterproof bag with the product at all times during operation If the product ownership is trans ferred this Guide should be forwarded to the sub sequent owners This Operators Guide uses the following signal words identifying important safety messages These safety alert signal words mean ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED DANGER Indicates an imminently hazardous situa tion which if not avoided WILL result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided CAN result in severe injury or death CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or mode
10. Fuel Lines Fittings and Clamps A All Emission Component Gaskets General Information 9 The emission warranty covers damage to other engine components is caused by the failure of a war ranted part The Bombardier Operator s Guide provided contains written instructions for the proper maintenance and use of your outboard All emission warranty parts are warranted by Bombardier for the entire warranty pe riod of the outboard unless the part is scheduled for replacement as required maintenance in the Opera tor s Guide Emission warranty parts that are scheduled for replacement as required maintenance are warranted by Bombardier for the period of time before the first scheduled replacement date for that part Emission war ranty parts that are scheduled for regular inspection but not regular replacement are warranted by Bom bardier for the entire warranty period of the outboard Any emission warranty part repaired or replaced under the terms of this warranty statement is warranted by Bombardier for the remainder of the warranty period of the original part parts replaced under this limited warranty become the property of Bombar dier Maintenance receipts and records should be transferred to each subsequent owner of the outboard Owner s Warranty Responsibilities As the outboard owner you are responsible for the performance of the required maintenance listed in your Operator s Guide Bombardier recommends that you
11. Refer to Fuel and Oil Oil Evinrude direct injection oil Refer to Fuel and Oil Warning Signals Controlled by the engine s EMM Battery Minimum 500 CCA 620 MCA 12 volt Spark Plug Torque Refer to ECI Label 15 22 ft Ibs 20 30 N m Start Assist Circuit Fuse Evinrude P N 514768 Fuses Refer to Power Distribution Panel Fuel Filter Evinrude P N 502906 Alternator 35 Amp Fully Regulated Gearcase Lubricant Capacity Evinrude Ultra HPF gearcase lubricant L Models 26 fl oz 770 ml X Models 42 fl 1250 ml Pwr Trim Tilt Fluid Capacity 21 fl 622 ml Propeller 4 Refer to Propeller Selection Weight 2 L Models 365 Ibs 166 kg X Models 390 Ibs 177 kg Sound at Driver s Ear LpA ICOMIA 39 94 80 8 dB A Transom Height L Models 19 1 2 to 20 in 495 to 508 mm X Models 24 1 2 to 25 in 622 to 635 mm 14 General Information 135 150 175 Models Displacement 158 cu in 2589 cc Engine Type 609 V 6 Oylinder Two Cycle Direct Injection Full Throttle Operating Range 135 150 4750 to 5250 RPM 175 5250 to 5750 RPM Power 1 135 135 HP 100 7 kw 5000 RPM 150 150 HP 111 9 kw 5000 RPM 175 175 HP 130 5 kw 5500 RPM Idle RPM in Gear 2 650 50 Ignition Timing 2 Not Adjustable Emission Control System per SAE J1
12. Water that has leaked into the gear case or remained in the cooling system or other components can freeze causing serious engine damage IMPORTANT If your outboard s gearcase is equipped with an integral speedometer pickup all water must be cleared from the hose to prevent gearcase damage Refer to Off Season Storage Submerged Engine If your engine has been under water have it ser viced immediately upon recovery If immediate service is unavailable resubmerge it in fresh water to avoid prolonged exposure to the atmosphere After submersion all boat and engine electrical fuel and oiling systems must be inspected for signs of water intrusion Your DEALER should perform this service Dual Engine Operation When you are maneuvering at slow speed be sure both engines are running even if one or both are in NEUTRAL If itis necessary to return to harbor with one engine not running you should not attempt to operate the boat above planing speed Tilt the inoperative en gine high enough to keep its propeller out of the wa ter Under Tow Should you require a tow from another boat Shift your engine to NEUTRAL Tilt its gearcase out of the water Off load all persons into another boat Keep towing speed slower than planing speed Operation 37 MAINTENANCE Maintenance replacement or repair of the emission control devices and systems may be performed by any marine SI spark ignition en gine repair establishm
13. if needed repeat the procedure until steering effort is as equal as possible High motor installations The trim tab might be above the water when the motor is trimmed out Steering effort might increase Steering effort will be reduced if you trim the motor in and submerge the trim tab Dual standard rotation motors Move both trim tabs equally and in the same direction Dual motors one counter and one standard ro tation Set both trim tabs to the center position Tilt Limiter Cam If your outboard contacts the boat s motor well while tilting adjust the tilt limiter cam to limit maxi mum tilt up Place the outboard in its normal operating position Rotate the tilt limiter cam pull its tab forward and up to REDUCE the amount of tilt UP Check your adjustment tilt the outboard fully and adjust further if necessary Return the outboard to vertical position for each adjustment and repeat your check after each adjustment Adjusting the tilt limiter cam will NOT vent the outboard from tilting fully and con tacting the motor well if the gearcase hits an object at high speed Such contact could damage the outboard and boat and injure boat occupants Maintenance 43 LUBRICATION Gearcase Replace gearcase lubricant after first 10 hours of operation Check level and condition of lubricant af ter next 50 hours of operation Add lubricant if nec essary The
14. 1 Fuel hose and fuel fitting 3 8 in 9 mm 2 Oil supply fitting 1 4 in 6 mm Yellow stripe 3 Oil return fitting 5 16 in 8 mm Blue stripe 22 Fuel and Oil Prime the fuel system by holding the fuel primer bulb with its outlet end up and squeezing it until firm IMPORTANT Fuel distribution hoses in the boat must deliver fuel at the rate of flow needed by the engine Minimum inside diameter of fuel hoses must be 3 8 in 9 mm Fuel systems with built in tanks particularly those that include antisiphon valves and filter primer units may have restrictions that will not allow the engine fuel pump to deliver sufficient fuel under all conditions This can result in a loss of performance and possible engine damage If performance problem exists see your DEALER To avoid difficulty when restarting never run the engine with the fuel hose disconnected or run the engine out of fuel OIL SYSTEM If the oil hoses are disconnected for any reason seal them to prevent spillage Install caps on the oil fittings to prevent contamination You must use an oil tank equipped with a filter an oil supply hose and an oil return hose The oil sys tem must be purged if air is in the oil supply hose Refer to Installing the Oil Supply Hose Install the oil tank by following the instructions pro vided with the unit IMPORTANT Consider the installation location of the oil tank carefully The oil tank is vented to
15. consumer or the date the Product is first put to use whichever occurs first for a period of THIRTY SIX 36 CONSECUTIVE MONTHS for private recreational use or TWELVE 12 CONSECUTIVE MONTHS for commercial use except that emission related components providing input to emission controls e g sensors are warranted for twenty four 24 months or two hundred 200 hours of engine use whichever occurs first The Product is used commercially when it is used in connection with any work or employment that generates income during any part of the warranty period The Product is also used commercially when at any point dur ing the warranty period it is installed on a boat that has commercial tags or is licensed for commercial use The repair or replacement of parts or the performance of service to Product under this warranty does not extend the life of this limited warranty beyond its original expiration date All Evinrude Johnson Genuine Parts and accessories in stalled by an authorized dealer at the time of sale including but not limited to propellers bear the standard Bombardier parts and accessories one year limited warranty California residents who purchased or warranty registered a Product in California should refer to Bombardier s California Emissions Control Warranty Statement 3 CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only on Evinrude outboard engines purchased as new and unused from a dealer au tho
16. for engine maintenance and in spection scheduled to be performed by you and or by an authorized DEALER The schedule should be adjusted according to operating conditions and use The recommended lubricants have been formulated to protect bearings gears and engine components They must be used to avoid damage caused by improper lubrication IMPORTANT Schedules for rental operations commercial applications or high hour use will require greater frequency of inspection and maintenance Engine Maintenance and Inspection Schedule Frequency 2 2 5 3 c 22 58 o 2 55 Engine BE gt BS Care T 2 lt om 9 gt gt gt Description Product Mechanical steering lubricate 7 7 Every 60 days Every 30 in Saltwater Tilt tube inspect and lubricate 7 7 Every 60 days Every 30 in Saltwater Swivel bracket tilt support bracket inspect and 7 Every 60 days Every 30 in Saltwater lubricate Throttle and shift linkage inspect and lubricate 7 Every 60 days Every 30 in Saltwater Remote control cables lubricate 1 7 Every 60 days Every 30 in Saltwater Starter pinion shaft inspect and lubricate 200 250 9 Every 60 days Every 30 in Saltwater models 2 Lubrication and corrosion protection for metallic 4 Every 60 days Every 30 in Saltwater components Battery c
17. for use with the Product see the Operator s Guide Damage resulting from rust or corrosion Damage caused from cooling system blockage by foreign material Damage resulting from sand or debris in the water pump Cosmetic or paint changes due to exposure to the elements This warranty will be voided in its entirety and rendered null and void where Product has been altered or modified in such a way so as to adversely affect its operation performance or durability or change its intended use horsepower or emission levels or Product is or has been used for racing at any point even by a prior owner 7 LIMITATIONS OF LIABILITY ALL WARRANTIES EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MER CHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS LIMITED WARRANTY ALL INCIDENTAL CONSEQUENTIAL DIRECT INDIRECT OR OTHER DAMAGES OF ANY KIND ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY INCLUDING BUT NOT LIMITED TO expense for gasoline expense for transporting Product to and from Dealer removal of Product from a boat and reinstallation mechanic s travel time in and out of water charges slip or dock fees trailering or towing storage telephone cell phone fax or telegram charges rental of a like or replacement Product or boat during warranty services or down time taxi travel lodging loss of or dam age to personal property inconvenience cost of insurance
18. gearcase for leakage If leakage is evident the gearcase seals should be replaced See your DEALER Anticorrosion anodes Check condition Refer to Anti Corrosion Anodes Install the propeller unless you will run the engine on a flusher for your pre season servicing If so in stall the propeller after you shut off the engine and disconnect the flusher Refer to Flushing to use the engine s flushing sys tem Refer to Propeller to install the propeller WARNING Prevent accidental contact with a rotating propeller always remove it when using a flusher to run the engine Top off fuel tank with fresh fuel Battery Charge fully and install Refer to Bat tery WARNING Do not use a booster battery and jumper cables to start the engine Fumes vented can cause explosion and fire resulting in property damage serious injury or death Refer to Engine Monitoring and review your gine s warning system self test routine During your preseason start up make sure the warning system self tests properly If it doesn t see your DEALER Follow Engine Starting in the Engine Starting Section and start the engine Let it idle while you Observe running quality if poor refer to Trouble Check Chart or see your DEALER Observe water pump operation Water must flow from the water pump indicator in a steady stream If it doesn t shut off the engine and investigate Refer to Engine Overheating
19. imme diately to Engine Overheating A flashing WATER TEMP or HOT light The EMM has identified a progressive overheating con dition The engine will shut OFF and will not restart until the engine cools Engine Monitoring 19 CHECK ENGINE or CHK ENG The EMM has identified a potentially serious prob lem A flashing CHECK ENGINE or light The EMM has identified an abnormal operating condition related to the fuel system The engine will shut OFF and cannot be restarted VAN WARNING If the engine shuts OFF and the CHECK ENGINE or ENG light is flashing the engine cannot be restarted A hazardous fuel condition may exist Seek assistance to return to port 20 Engine Monitoring A continuous CHECK ENGINE or CHK ENG light with S L O W The EMM has identified a problem that will cause engine damage if it is not addressed Seek assistance and or return to safe harbor See your DEALER A continuous CHECK ENGINE or CHK ENG light without S L O W The EMM has identified a problem that should be addressed by your DEAL ER as soon as practical to avoid operational difficul ties LOW OIL Oil in the oil tank is at reserve level about 1 4 full Fill the oil tank with recommended oil as soon as possible to avoid emptying the tank Refer to Filling the Oil Tank FUEL AND OIL FUEL WARNING Gasoline is extremely flammable and highly explosive un
20. of the post dr6495 Main Cable Starwasher Accessory wires Maintenance 41 If you have automotive battery posts place a star Service washer on the clamp adapter first then the main ca ble and then the wires from the accessories Before servicing the battery or the outboard re move both battery cables from the battery BLACK cable first Keep metal objects from contacting either battery post IMPORTANT Service electrical components only while the outboard is NOT running Be careful when identifying positive and negative battery cables and posts If you touch the wrong post with a battery ca ELM briefly the charging system will be dam aged WARNING Battery electrolyte is acidic handle with care If electrolyte contacts any part of the dr6496 body immediately flush with water and seek medical attention 1 Starwasher 2 Main Cable 3 Accessory wires Accessory Battery Connection Tighten all connections securely and coat the in Your outboard is equipped with a feature to inde stallation with Triple Guard grease pendently charge an accessory battery The charg ing system can charge the cranking and accessory VAN WARNING batteries at the same time See your DEALER Keep the battery connections clean tight and insulated to prevent their shorting or arcing and causing an explosion If the bat tery mounting system does not cover the connections in
21. only protect you but also protect the people around you Having fun is what it s all about and with your cooperation the pertinent information in this Guide can en sure a safe and enjoyable experience Enjoy the great outdoors on the water VAN WARNING VAN Be careful Human error is caused by many factors carelessness fatigue overload preoccu pation unfamiliarity of operator with the product drugs and alcohol to name a few Damage to your boat and outboard can be fixed in a short period of time but injury or death has a lasting effect For your safety and the safety of others read this Guide from cover to cover and follow all safety warnings and recommendations Do not disregard any of the safety precautions and instructions Anyone operating your boat should first read and understand this Guide before they operate your boat and motor The following trademarks are the property of Bombardier Motor Corporation of America or its affiliates Evinrude amp 2440 fuel conditioner Evinrude direct injection oil S L O W Evinrude Johnson Genuine Parts System Check Evinrude Johnson XD25 formula Triple Guard grease Hi Vis gearcase lubricant Ultra HPF gearcase lubricant Johnson Contents GENERAL INFORMATION etant o Sea 2 SAFETY THE RIGHT PLACE TO GET STARTED
22. points 1 Shift Throttle lubrication points Maintenance 45 WATER PRESSURE An optional water pressure gauge is recommended to monitor cooling system pressures Noticing changes in water pressure can help prevent engine overheating The water pressure gauge must be connected at the correct point to ensure the most accurate pressure readings Follow the installation instructions included with the water pressure gauge drc49273a 135 250 models water pressure START ASSIST CIRCUIT FUSE The start assist circuit provides extra voltage to the fuel injectors during cranking Be sure that all active and spare fuses are in good condition Always carry spare fuses 46 Maintenance Fuse Failure A blown starter assist circuit fuse will not allow the engine to crank Replace it with a fuse of the same rating Repeated failures of fuse indicate a serious prob lem Do not replace it with higher rated fuse see your DEALER for service Fuse Replacement Remove cover install good fuse of the same rating IMPORTANT Failure to install cover securely will cause electrical problems SPARK PLUGS WARNING The ignition system presents a serious shock hazard The primary circuit operates in excess of 250 volts the secondary circuit operates in excess of 25 000 volts Use cau tion to avoid injury from shock or injury resulting from your reaction to shock Do not handle primary or secondary ignition compo
23. retain all receipts covering maintenance on your out board but Bombardier cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance However as the outboard owner you should be aware that Bombardier may deny you warranty coverage if your outboard or a part has failed due to abuse neglect improper maintenance or unapproved modifi cations You are responsible for presenting your outboard to an authorized Bombardier dealer as soon as a prob lem exists The warranty repairs will be completed in a reasonable amount of time not to exceed 30 days For any questions regarding your warranty rights and responsibilities or for the name and location of the nearest authorized Bombardier dealer contact Bombardier Customer Support Services 250 Sea Horse Drive Waukegan IL 60085 1 847 689 7090 or visit www evinrude com 10 General Information NOTES General Information 11 FEATURES oj N aj A Vj N 53 e N 1 Description Power Distribution Panel Fuses amp Spare Fuse Holder Starter Assist Circuit Fuse Accessory Battery Connection Tilt Support Anti Corrosion Anode Lubricant Drain Fill Plug Lubricant Level Plug Power Tilt amp Trim Reservoir Tilt Limiter Cam Engine Cover Latch Fuel Fitting not supplied with outboard 12 General Information WA
24. setting At intervals apply full throttle for periods of one to two minutes returning to three quarters throttle for a cooling period Change engine speed every 15 minutes 4 Next Eight Hours Avoid continuous throttle operation for extended periods Change engine speed every 15 minutes DO NOT exceed recommended maximum engine RPM Refer to Engine Specifications full Fuel and Oil 25 ENGINE STARTING DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas Engine exhaust contains carbon monoxide which if inhaled can cause serious brain damage or death WARNING The engine cover is machinery guard DO NOT operate your outboard with the cover off unless you are performing maintenance and then be careful to keep hands hair and clothing clear of all moving parts Contact with moving parts could cause injury Contact with a rotating propeller is likely to result in serious injury or death Assure the engine and prop area is clear of people and objects before starting engine or operating boat Do not allow anyone near a propeller even when the engine is off Blades can be sharp and the propeller can continue to turn even after the engine is off Always shut off the engine when near people in the water BEFORE START UP If the fuel hose and or oil hoses are not connected refer to
25. skipper and owner of a boat you are responsible for damage to other boats caused by the wake of your boat Allow no one to throw refuse over board AN Know the marine traffic laws and obey them AN Remember gasoline fumes are flammable and explosive Always adhere to the fueling procedure contained in this Operator s Guide and those given to you by the fueling station Always verify fuel level before use and during the ride Apply the principle of 1 3 fuel to des tination 1 3 back and 1 8 reserve fuel supply Do not carry spare fuel or flammable liquids in any storage or engine compartments Do not operate your boat if you are under the influence of drugs or alcohol High performance boats have high power to weight ratio If you are not experienced in the operation of a high performance boat do not attempt to operate one at or near its top speed until you have gained that experience AN For more information see your Evinrude Johnson DEALER for a copy of Introduction to High Performance Boating P N 335763 SAFETY MEASURES Installation and Maintenance Outboard Installation The outboard must be correctly installed Fail ure to correctly install the outboard could re sult in serious injury death or property damage We strongly recommend that your DEALER install your outboard to ensure prop er installation Do overpower your boat by using gine that exceeds the horsepow
26. than 2 3 their original size See your DEAL ER for replacements dr5082 Galvanic corrosion destroys underwater metal parts and can occur in fresh or salt water however salt brackish and polluted waters will accelerate corrosion Metal based antifouling paint on the boat or motor and the use of improperly installed shore power in the area of your moored boat will also accelerate corrosion IMPORTANT NEVER paint the anode its fasten ers or its mounting surface Painting will reduce its corrosion protection Maintenance 49 TROUBLE CHECK CHART IMPORTANT If you are unable to identify or solve the problem contact your DEALER SYMPTOM POSSIBLE CAUSE Starter motor will not operate Shift handle not in NEUTRAL Battery and electrical connections loose or corroded Fuse blown Refer to Power Distribution Panel Battery selector switch OFF Engine will not start Not following starting instructions Refer to Engine Starting Sec tion Battery voltage drops below 9 5 volts during cranking Fuel tank empty Fuel hose kinked Fuel system contaminated with water or dirt Fuel filter obstructed Spark plugs incorrect Refer to Engine Specifications Spark plugs improperly gapped carboned burned or wet Ignition system component failure Fuse blown Refer to Power Distribution Panel Fuse blown Refer to Start Assist Circuit Fuse Flashing WATER temp or hot light refer to Engine Monitoring and Eng
27. to keep on a straight path The trim tab can also be adjusted to compensate for steering wheel torque but adjust the trim tab only if bow up is commonly used Refer to Trim Tab When the motor is trimmed to full bow up position the boat s bow will tend to rise above the water Excessive bow up trim may cause propeller ventila tion resulting in propeller slippage WARNING When operating in rough water or crossing a wake excessive bow up trim may result in the boat s bow suddenly rising skyward possibly ejecting occupants WARNING Some boat motor propeller combinations may encounter boat instability and or high steering torque when operated at high speed at or near the motor s trim range lim its full bow up or bow down Boat stability and steering torque can also vary due to changing water conditions If any adverse conditions occur reduce throttle and or adjust trim angle to maintain control If you experience boat instability and or high steering torque see your DEALER to cor rect these conditions 9 3100 Bow Down BOW DOWN position will give the best accelera tion onto plane and the best towing power for skiing The bow down position is normally used for accel erating from a standing start or from idle speed Operating Conditions In the bow down position your boat may tend to pull to the right If this condition exists correct it by applying a counterclockwise force w
28. 167 8 kw 5750 RPM 250 250 HP 184 4 kw 5750 RPM Idle RPM in Gear 2 650 50 Ignition Timing 2 Not Adjustable Emission Control System per SAE J1930 2 ECM DFI Engine Control Module Direct Fuel Injection Fuel Requirements 2 87 Pump Posted AKI 90 RON Refer to Fuel and Oil Oil Evinrude Direct Injection oil Refer to Fuel and Oil Warning Signals Controlled by the engine s EMM Battery Minimum 675 CCA 845 MCA 12 volt OR 107 amp hour 6 Spark Plug 0 Torque Refer ECI Label 15 22 ft Ibs 20 30 N m Start Assist Circuit Fuse Evinrude P N 514768 Fuses Refer to Power Distribution Panel Fuel Filter Evinrude P N 502906 Alternator 35 Amp Fully Regulated Gearcase Lubricant Capacity Evinrude Ultra HPF gearcase lubricant 40 fl oz 1190 ml Counter Rotation 44 fl oz 1300 ml Standard Rotation Pwr Trim Tilt Fluid Capacity 21 fl 622 ml Propeller Refer to Propeller Selection Weight L Models 515 Ibs 234 kg X Models 537 105 244 kg Z Models 548 Ibs 249 kg Sound at Driver s Ear LpA ICOMIA 39 94 80 8 dB A Transom Height L Models 19 1 2 to 20 in 495 to 508 mm X Models 24 1 2 to 25 in 622 to 635 mm Z Models 29 1 2 to 30 in 749 to 762 mm Emission Control Information Rated following the standards of ICOMIA 28 83 ISO 3046 and NMMA
29. 930 2 ECM DFI Engine Control Module Direct Fuel Injection Fuel Requirements 2 87 Pump Posted AKI 90 RON Refer to Fuel and Oil Oil Evinrude Direct Injection oil Refer to Fuel and Oil Warning Signals Controlled by the engine s EMM Battery Minimum 675 CCA 845 MCA 12 volt 107 amp hour 9 Spark Plug 29 Torque Refer to ECI Labels 15 22 ft Ibs 20 30 N m Start Assist Circuit Fuse Evinrude P N 514768 Fuses Refer to Power Distribution Panel Fuel Filter Evinrude P N 502906 Alternator 35 Amp Fully Regulated Gearcase Lubricant Capacity Evinrude Ultra HPF gearcase lubricant 40 fl oz 1190 ml Counter Rotation 44 fl oz 1300 ml Standard Rotation Pwr Trim Tilt Fluid Capacity 21 fl 622 ml Propeller Refer to Propeller Selection Weight Models 423 16 192 kg X Models 443 Ibs 201 kg Sound at Driver s Ear LpA ICOMIA 39 94 78 2 dB A Transom Height L Models 19 1 2 to 20 in 495 to 508 mm X Models 24 1 2 to 25 in 622 to 635 mm General Information 15 200 225 250 Models 200 cu in 3279 cc Engine Type 90 V 6 Cylinder Two Cycle Direct Injection Full Throttle Operating Range 200 5000 to 6000 RPM 225 250 5500 to 6000 RPM Power 7 200 200 HP 149 2 kw 5750 RPM 225 225 HP
30. Any other spark plug will cause ignition problems Use a 750 CCA 940MCA battery when operating in temperatures below 32 F 0 C 4 Not supplied in all marketing areas Under extraordinary electrical load or environmental conditions use of a 107 amp hour minimum Generally available in group 29 size 7 Does not include propeller or fuel 16 General Information REMOTE CONTROL If you choose remote con trol be sure it has a start in gear prevention feature This feature can prevent injuries resulting from unexpected boat movement when the engine starts WARNING IMPORTANT When selecting the remote control system for your boat specify Evinrude compo nents Evinrude offers remote controls cables and wiring kits designed specifically for your Evinrude outboards Evinrude controls deliver the cable stroke your outboard needs for positive shift and throttle control and they incorporate such safety and convenience features as Start in gear prevention Plug in compatibility with Evinrude modular wir ing system 9 21155 Evinrude concealed side mount control Handle shift and throttle Trim tilt switch where equipped Neutral lock tab Fast idle button Throttle Friction Control o RON Evinrude Binnacle mount control Handle shift and throttle Trim tilt switch where equipped Fast idle button Throttle friction control Emergency stop clip and
31. Fuel System and Oil System to install them now Review and follow Break in 10 hours if the en gine is new You MUST supply water to the engine before at tempting to start it Engine damage can occur quickly Refer to Engine Overheating or Flushing Be sure the engine is in RUN position Refer to Power Trim and Tilt or Tilting 26 Engine Starting If the fuel tank has an operable vent open it Squeeze the fuel primer bulb outlet end up until firm b drc3915 If equipped with an electric fuel primer pump acti vate it for about 20 seconds Connect the clip to the emergency stop key switch Snap the lanyard to a secure place on the opera tor s clothing or life vest not where it might tear away instead of activating the stop switch PUSH KEY IN 9 FOR FULL CHOKE dr6819 dr5992a 1 Clip 2 Emergency Stop Clip key switch 3 Lanyard IMPORTANT The engine will start and run without the clip connected to the key switch However we strongly recommend that the operator use the clip and lanyard anytime the engine is running Refer to Emergency Stop Key Switch Move the remote control handle to NEUTRAL DR21155a DR5986aa 1 Concealed side mount control 2 Binnacle mount control DO NOT advance the throttle before start up Ad vancing the throttle overrides the electronic idle control system After the engine starts the engine management module EMM automatically increas es
32. Installing the Oil Return Hose Start the engine and run at idle only Restrict the oil return hose for about 15 20 seconds Shut off the engine Connect the oil return hose to the oil return hose fit ting on the motor Secure with the clamp 15 7 mm from the owner s kit 000068 1 Restrict Oil return hose 5 16 in 8 mm Blue stripe 1 Oil return hose 5 16 in 8 mm Blue stripe 2 Oil return hose fitting 5 16 in 8 mm Blue stripe 3 Clamp 15 7 mm from owner s kit Prevent injury from moving engine nents Before starting the engine Shift it to NEUTRAL Keep hands clothes hair clear of power head Remove the propeller if you use a flushing device Read Engine Starting ENGINE STOPPING 24 Fuel and Oil BREAK IN 10 HOURS IMPORTANT Follow this procedure to protect your new outboard during its initial hours of operation Careful break in allows internal engine components to seat properly resulting in maximum engine life and performance Failure to carefully follow the break in procedures can result in engine damage The engine management module EMM will auto matically supply extra oil to the engine during the first five hours of operation above 2000 RPM Perform the 10 hour break in procedure with the boat and engine in the water using an appropriate propeller DO NOT perform break in using a flushing device DO NOT start up
33. TER TEMP CHECK ENGINE LOW OIL DRC5206a DR44607a Description Oil Supply Fitting Oil Return Fitting LN Engine Wire Hamess m 9 a Fuel Filter 100HP 175HP Models 16 Item A OJN 1 000071 Description Trailering Tilt Switch 100HP 175HP Trailering Tilt Switch 200HP 250HP On Starboard Side Power Tilt amp Trim Manual Release Trailering Bracket Trim Limiter Rod Water Intake Trim Tab ECI Label not supplied with outboard Item 10 11 12 13 14 15 16 000062 Description Model amp Serial Number Plate Flushing Port Water Pump Indicator Fuel Filter 200HP 250HP Models Motor Cover Latch Remote Control 1 Steering Connector Kit Trim Gauge Oil Return Hose General Information 13 ENGINE SPECIFICATIONS 100 115 Models Displacement 105 4 cu in 1726 cc Engine Type 60 V 4 Cylinder Two Cycle Direct Injection Full Throttle Operating Range 100 115 5250 to 5750 RPM Power 7 100 100 HP 74 6 kw 5500 RPM 115 115 HP 85 8 kw 5500 RPM Idle RPM in Gear 2 650 50 Ignition Timing 2 Not Adjustable Emission Control System per SAE J1930 2 ECM DFI Engine Control Module Direct Fuel Injection Fuel Requirements 2 87 Pump Posted AKI 90 RON
34. address Previous owner Last name First name Address Zip code City Phone number Signature Date New address New owner Last name First name Address Zip code City Phone number Signature Date 000063 Maintenance 53 54 Maintenance BOMBARDIER Pe RECREATIONAL PRODUCTS E s EVINRUDE JOHNSON DEALER SUPPORT SERVICES 250 SEAHORSE DRIVE WAUKEGAN IL 60085 000064 RECREATIONAL PRODUCTS BOMBARDIER Maintenance 55 Operator s Guide Confirmation of Receipt Your DEALER Name Address Upon delivery of your new Evinrude amp Outboard complete and sign the form hereunder Your DEALER will take receipt of the form for their records Receipt Name Address Owner of model No Serial No To be completed by customer or selling DEALER The DEALER named on this document has instructed me on the operation maintenance safety features and warranty policy all of which understand and agree to be bound with am also satisfied with the predelivery set up and inspection of my Evinrude Outboard have also received a copy of the Operator s Guide Signature Date 56 Mainten
35. ance Readiness Test and Word to Owner Operator The Operator s Readiness Test 1 2 3 4 Did you read this Guide from front cover to rear cover Are you to take responsibility for the safe operation of your boat and motor Do you understand all the safety precautions and instructions contained in this Guide Do you understand that this Guide contains essential information to help prevent personal injury and damage to equipment Are you ready to follow the recommendations in this Guide and take a boating safety course before you operate your boat and motor Do you know who to ask if you have any questions about your boat and motor Do you know your local marine traffic laws Do you understand that human error can be caused by carelessness fatigue overload preoccupa tion unfamiliarity of operator with the product drugs and alcohol just to name a few WARNING It is impossible for this Guide to cover every hazardous situation you may encounter how ever your understanding of and adherence to essential information contained in this Guide will build good judgment when boating Always be alert and careful a good foundation for safety
36. ation 5 6 EXCLUSIONS The following are not warranted under any circumstances Replacement of parts due to normal wear and tear Routine maintenance parts and services including but not limited to maintenance requirements engine and lower unit oil changes lubrication valve and linkage adjustments and replacement of fuses zinc anodes thermostats timing belts starter motor bushings trim motor brushes filters propellers propeller bushings and spark plugs Damage caused by improper or lack of installation maintenance winterization and or storage failure to follow the pro cedures and recommendations in the Operator s Guide Damage resulting from removal of parts improper repairs service maintenance or modification or use of parts or accessories not manufactured or approved by Bombardier which in its reasonable judgment are either incompatible with Product or adversely affect its operation performance or durability or resulting from repairs done by a person that is not an authorized Dealer Damage caused by abuse misuse abnormal use neglect racing improper operation or operation of the Product in a manner inconsistent with the recommended operation described in the Operator s Guide Damage resulting from external damage accident submersion water ingestion fire theft vandalism or any act of God Operation without proper fuel oil or lubrication or with fuels oils or lubricants which are not suitable
37. be required to present proof of purchase to Dealer for warranty repairs Owner is required to sign the repair work order prior to the start of the repair in order to validate the warranty repair All parts replaced under this warranty become the property of Bombardier 5 WHAT BOMBARDIER WILL DO Bombardier s obligations under this warranty are limited to at its sole discretion repairing or replacing parts of Product found to be defective in material or workmanship in the reasonable judgment of Bombardier Such repair or replacement of parts will be done without charge for parts and labor at any authorized Dealer Bombardier s responsibility is limited to making the required repairs or replacements of parts with new or Bombardier certified re manufactured parts No claim of breach of warranty shall be cause for cancellation or rescission of the sale of Product to owner In the event that warranty service is required outside of the fifty United States or Canada owner will bear responsibility for any additional charges due to local practices and conditions such as but not limited to freight insurance taxes li cense fees import duties and any and all other financial charges including those levied by governments states territo ries and their respective agencies Bombardier reserves the right to improve modify or change Products from time to time without assuming any obligation to modify Products previously manufactured General Inform
38. coverage loan payments loss of time loss of income reve nue or profits or loss of enjoyment or use of Product SOME STATES PROVINCES OR JURISDICTIONS DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR OTHER EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM STATE TO STATE OR PROVINCE TO PROVINCE No distributor Dealer or any other person is authorized to make any affirmation representation or warranty regarding Product other than those contained in this limited warranty and if made shall not be enforceable against Bombardier Bombardier reserves the right to modify this warranty at any time being understood that such modification will not alter the warranty conditions applicable to the Products sold while this warranty is in effect 8 TRANSFER If the ownership of Product is transferred during the warranty coverage period this warranty shall also be transferred and be valid for the remaining coverage period provided that the former or new owner promptly contacts Bombardier or Dealer and gives the name and address of the new owner 9 CONSUMER ASSISTANCE Inthe event of a controversy or dispute in connection with this Bombardier limited warranty Bombardier recommends that you first try to resolve the issue at the dealership level by discussing the issue with Dealer s service
39. ct fill level and condition 5 D of lube Fuel and oil filter s replace D Propeller shaft splines inspect and lubricate 7 D Starter pinion shaft inspect and lubricate 100 175 9 D models Exhaust back pressure nipple decarbonize 9 we D Driveshaft splines inspect and lubricate 8 D p xp Water pump inspect and replace 1 Also recommended at 10 Hour Inspection 2 Do not use light duty penetrating lubricants 3 Emission related component Dealer Performed Service Operator Performed Service Evinrude anti corrosion spray or Evinrude 6 in 1 multi purpose lubricant Ultra HPF gearcase lubricant Power Trim Tilt Fluid Triple Guard grease Evinrude Moly Lube P N 175356 Starter Bendix Lube Only P N 337016 Noar 52 Maintenance CHANGE OF ADDRESS CHANGE OF OWNERSHIP If your address has changed or if there has been a change of ownership be sure to fill out and mail the card provided on this page Such notification is likewise necessary for your own safety even after expiration of the original warranty since Bombardier will be in a position to contact you if correction to your outboard becomes necessary Outside the U S and Canada this card should be sent to the Bombardier division where the outboard was registered Please contact your Dealer or Distributor a Change of address Change of ownership Model number Old
40. der certain conditions Follow the instructions in this section explicitly Improper handling of fuel could result in property damage serious injury or death Always turn off the engine before fueling Never permit anyone other than an adult to refill the fuel tank Do not fill the fuel tank all the way to the top or fuel may overflow when it expands due to heating by the sun Remove portable fuel tanks from the boat before fueling Always wipe off any fuel spillage Do not smoke or allow open flames or sparks or use electrical devices such as cel lular phones in the vicinity of a fuel leak or while fueling Always work in a well ventilated area Your outboard is certified to operate on unleaded automotive gasoline with an octane rating equal to or higher than that specified in Minimum Octane chart When using gasoline that contains MTBE or alcohol follow these guidelines Using unleaded gasoline that contains methyl ter tiary butyl ether MTBE is acceptable ONLY if the MTBE content does not exceed 15 by volume Using alcohol extended fuels is acceptable ONLY if the alcohol content does not exceed 10 ethanol by volume 5 methanol with 5 cosolvents by volume Minimum Octane Inside the U S Outside the U S 87 R M 2 AKI 90 RON Your outboard has been designed to operate using the above fuels however be aware of the follow ing The boat s fuel system may have different require ments r
41. e Biode gradable Outboard oil must be used IMPORTANT Failure to follow this recommenda tion could void the engine warranty if a lubrication related failure occurs Fuel and Oil 21 ADDITIVES IMPORTANT The only fuel additives approved by Bombardier for use in your Evinrude outboard are 2146 fuel conditioner and Evinrude Fuel System Cleaner Use of other fuel additives can result in poor performance or engine damage Evinrude 2 4 fuel conditioner will help prevent gum and varnish deposits from forming in fuel sys tem components and will remove moisture from the fuel system It can be used continuously and should be used during any period when your engine isn t being operated on a regular basis Its use will re duce spark plug fouling fuel system icing and fuel system component deterioration Evinrude Fuel System Cleaner will help keep fuel injectors in optimal operating condition FUEL SYSTEM Connecting the Fuel Hose A WARNING The outboard must be correctly installed Failure to correctly install the outboard could result in property damage serious injury or death We strongly recommend your DEALER install your outboard to ensure proper installation If the fuel hose is disconnected for any reason seal it to prevent spillage Cap the fuel fitting to prevent contamination Connect the fuel hose to the 3 8 in 9 mm fuel fit ting Fasten hose securely with clamp 18 5 mm from owner s kit
42. e from the engine if the fit ting is a quick disconnect If not and the hose is se cured to the engine leave it connected Secure the hose to protect it WARNING Store fuel tanks in well ventilated area away from heat and open flame Prevent escape of liquid or vapors which could acci dentally ignite Close the filler cap vent screw if equipped Be sure the disconnected fuel hose doesn t drip 40 Maintenance PRE SEASON SERVICE Remove your outboard from storage and prepare it for a season of reliable service by performing a gen eral check and a few preventive maintenance pro cedures Examine all loosened or removed hardware and any steering throttle and shift systems Replace damaged or missing parts with Evinrude Johnson Genuine Parts or equivalent VAN WARNING Failure to carefully reattach the outboard and its control systems with factory speci fied hardware can result in sudden unex pected loss of boat control Oil system Check for evidence of water in the oil tank If present see your DEALER If no water is evident top off the oil tank Refer to Fuel and Oil Section Oil System Disconnected oil hoses Follow the directions in Fuel and Oil Section Oil System to reinstall the hoses and reestablish oil flow Undisturbed oil hoses If the oil hoses were left connected no special attention to the oil system is required With the propeller removed check the
43. egarding the use of alcohol fuels Refer to the boat s owner guide Alcohol attracts and holds moisture that can cause corrosion of metallic parts in the fuel system Alcohol blended fuel can cause engine perfor mance problems IMPORTANT Always use fresh gasoline Gasoline will oxidize and weather the result is loss of octane volatile compounds and the production of gum and varnish deposits which can damage the outboard WARNING Leaking fuel is and explosion hazard All parts in the fuel system should be inspected frequently and replaced if signs of deterioration or leakage are found Inspect the fuel system each time you refuel each time you remove the engine cover and annually OIL Evinrude direct injection oil is recommended for your Evinrude outboard It is formulated with special additives for the cleaning power a direct in jection outboard needs for longer life This synthetic blend oil also provides superior lubrication to re duce engine component wear and maintain top per formance Evinrude brand oils are formulated to give best en gine performance while controlling piston and com bustion chamber deposits providing superior lubrication and ensuring maximum spark plug life If Evinrude direct injection oil is not available you must use an NMMA certified TC W3 oil such as Evinrude Johnson XD25 formula or Evinrude Bio degradable Outboard oil When operating under 32 F 0 C Evinrud
44. ents or individual ENGINE EMISSIONS INFORMATION Manufacturer s Responsibility Beginning with 1999 model year engines manufac turers of marine engines must determine the ex haust emission levels for each engine horsepower family and certify these engines with the United States of America Environmental Protection Agen cy EPA An emissions control information label showing emission levels and engine specifications must be placed on each engine at the time of man ufacture Dealer s Responsibility When performing service on all 1999 and more re cent Evinrude outboards that carry an emissions control information label adjustments must be kept within published factory specifications Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed cer tification standards Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory speci fications Exceptions include manufacturers prescribed changes such as altitude adjustments for exam ple Owner Responsibility The owner operator is required to have engine maintenance performed to maintain emission levels within prescribed certification standards The owner operator is not to and should not allow anyone to modify the engine in any manner that would alter the horsepower or allow emissions lev els to e
45. er indicated on the boat s capacity plate Overpowering could result in loss of control If your boat has no capacity plate contact your DEALER or the boat s manufacturer Maintenance When replacement parts are required use Evinrude Johnson Genuine Parts or parts with equivalent characteristics including type strength and material Using substandard parts could result in injury or product malfunc tion Only perform service procedures which are detailed in this Operators Guide Attempting to perform maintenance or repair on your out board if you are not familiar with the correct service and safety procedure could cause per sonal injury or death Further information can be obtained from your authorized Evinrude Johnson DEALER In many instances proper tools and training are required for certain ser vice or repair procedures Maintain your boat and engine in top condition at all times Adhere to the Engine Mainte nance and Inspection Schedule Operate your boat and outboard prudently and have fun Do not forget that all persons must assist other boaters in case of emergen Prevent injury from contact with rotating pro peller remove propeller before flushing or be fore performing any maintenance General Information 3 PRODUCT REFERENCES ILLUSTRATIONS AND SPECIFICATIONS A WARNING When replacement parts are required use Evinrude Johnson Genuine Par s or parts with eq
46. erating at higher speed Boat Bottom and Engine External Finish The condition of your boat s bottom affects perfor mance A covering of marine growth reduces speed For maximum performance keep the boat s running surface clean by wiping it dry after each use and washing it occasionally After operating your outboard rinse it with fresh wa ter and wipe it dry Apply Evinrude Anti Corrosion Spray to any surface subject to corrosion but avoid the anti corrosion anode s Periodically wash the entire boat and outboard with soapy water and apply a coat of automotive wax Leave the engine cover in place when washing the outboard High Altitude Your engine s EMM will automatically compensate for changes in altitude However if you consistently boat above 3000 ft 900 m you will experience a slight loss of power due to reduced air density If your engine drops below the recommended RPM operating range at full throttle have your DEALER select a lower pitch propeller If you return to sea level have your DEALER install the original propeller and verify correct RPM oper ating range Shallow Water IMPORTANT Serious engine damage will occur if the gearcase is allowed to drag on the waterway bottom Freezing Weather DURING operation in freezing weather keep the gearcase submerged at all times Upon removing your motor from the water leave it in a vertical position until its cooling system is drained IMPORTANT
47. eration One Star Low Emission The one star label identifies Personal Watercraft Outboard Sterndrive and Inboard engines that meet the Air Resource Board s Personal Watercraft and Outboard marine engine 2001 exhaust emission stan dards Engines meeting these standards have 75 lower emissions than conventional carbureted two stroke engines These engines are equivalent to the U S EPA s 2006 standards for marine engines Two Stars Very Low Emission The two star label identifies Personal Watercraft Outboard Sterndrive and Inboard engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2004 exhaust emission stan dards Engines meeting these standards have 20 lower emissions than One Star Low Emission en gines Three Stars Ultra Low Emission The three star label identified engines that meet the Air Resources Board s Personal Watercraft and Out board marine engine 2008 exhaust emission standards Engines meeting these standards have 65 low er emissions than One Star Low Emission engines Four Stars Super Ultra Low Emission The four star label identifies engines that meet the Air Resources Board s Sterndrive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engines meeting these standards have 90 lower emissions than One Star Low Emission engines For more information Cleaner Wa
48. idle speed Idle speed will decrease as the en gine warms up Wait until idle speed decreases before you shift into gear WARNING DO NOT attempt to shift the engine into FORWARD or REVERSE while it is running at fast idle Shifting under this condition can result in sudden boat movement resulting in injury A Turn the key switch fully clockwise to the START position Crank the engine no longer than 10 sec onds IMPORTANT The starter motor can be damaged if operated continuously for more than 10 seconds Upon start up release the key If the engine did not start release the key momen tarily then try again Each time the key switch is turned from OFF to ON the warning system will self test Refer to Engine Monitoring If the warning system fails to self test during start up see your DEALER If your outboard doesn t react normally to this start ing procedure or if it fails to start refer to Trouble Check Chart After Engine Starts IMPORTANT DO NOT advance the throttle when operating the engine in NEUTRAL Advancing the throttle can cause the engine to over rev which can result in severe engine damage Check the water pump indicator A steady stream of water indicates the water pump is working If a steady stream of water from the water pump indica tor is not visible stop the engine Refer to Engine Overheating 9 4952 Engine temperature will determine the length of the pe
49. il the switch is released or the engine reaches the end of its travel drc4014a 1 Bow Up 2 Bow Down 30 Operation If the tilted engine s cover contacts the boat s motor well limit the maximum tilt by following the proce dures in Adjustments Tilt Limiter Cam Trimming To operate the power trim push and hold the trim tilt switch in the desired bow direction either bow up or bow down The engine will move until the switch is released or the engine reaches its maxi mum position The boat will be properly trimmed when the trim an gle provides a bow position that results in the best boat performance for your operating conditions You must use a speedometer and tachometer to determine boat and engine performance at different trim positions To help maintain steering stability and good performance always maintain the proper trim angle which varies depending on the combina tion of boat motor propeller and operating condi tions To familiarize yourself with power trim make test runs with the boat s bow at various positions Note the time it takes for the boat to plane the tachome ter and speedometer readings and the ride and ac tion of the boat Bow Up BOW UP position will give the best fuel economy and highest top speed Operating Conditions In the bow up position your boat may tend to pull to the left If this condition exists correct it by applying a clockwise force with the steering wheel
50. ilt support lever up Lower the motor to operating position FLUSHING DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas Engine exhaust contains carbon monoxide which if inhaled can cause serious brain damage or death Flush your engine with fresh water as soon as pos sible after each use in salty polluted or brackish water to minimize the formation of deposits that can clog cooling passages Flush the engine on the trailer or at dockside while it is tilted or vertical running or stopped Outboard Running WARNING Prevent injury from contact with rotating propeller remove the propeller before flushing 1 Place the engine in vertical position in a well ventilated area with good drainage 2 Remove the plug from the flushing port 3 Install flushing device if needed and garden hose 4 Start the water keep pressure between 20 40 psi 140 300 kPa dr5077 5 Startthe engine run it at idle only and flush it for at least five minutes 6 Shut off the engine remove the flusher if used and install the plug If the plug is also the water pump indicator turn it so the water streams out to the side where it can be seen easily from the helm 7 Leave the outboard in vertical position long enough to completely drain the powerhead Outboard Not Running 1 The ou
51. ine damage it will also limit engine speed to 1200 RPM This additional protection feature is referred to as S L O W If the engine was running faster than 1200 RPM when the S L O W system activat ed it will shake noticeably Under certain operating conditions the EMM will shut OFF the engine VAN CAUTION In the S L O W mode the engine speed is limited Under certain conditions the engine s limited speed may reduce maneu verability of your boat If the S L O W mode is activated and you are unable to correct the problem seek assistance and or return to safe harbor Serious engine damage engine shutoff and or reduced maneuverability may be imminent NO WATER 5 TEMP CHECK ENGINE LOW OIL dr5206 dr5364 1 System Check Gauge 2 System Check Gauge with Tachometer NO OIL There is an oil delivery problem Serious engine damage can occur quickly The EMM will activate S L O W If the oil tank is empty add the recommended oil If the oil tank is not empty seek assistance and or return to safe harbor DO NOT exceed 1000 RPM See your DEALER WATER TEMP or HOT The engine is overheating Serious engine damage can occur quickly The EMM will activate S L O W Under certain conditions the EMM will shut OFF the engine A continuous WATER TEMP or light with S L O W The EMM has identified an overheat ing condition Shut OFF the engine and refer
52. ine Overheating Flashing check engine chk eng light refer to Engine Monitor ing Engine will not idle properly Motor angle excessive Spark plugs damaged or incorrect Refer to Engine Specifica tions Fuel system contaminated with water or dirt Fuse blown Refer to Power Distribution Panel Engine loses power shale plugs damaged or incorrect Refer to Engine Specifica ions Fuel filter obstructed Fuel system contaminated with water or dirt Water intakes obstructed and cooling system not operating cor rectly Refer to Operation Section Engine Overheating Oiling system malfunction Fuse blown Refer to Power Distribution Panel S L O W protection mode activated Refer to Engine Monitor ing Propeller shaft bent Propeller fouled and restricted blades bent or broken Fuel system contaminated with water or dirt Engine mounts s damaged S L O W protection mode activated Refer to Engine Monitor ing Propeller hub loose slipping Propeller blades bent or missing Propeller shaft bent Propeller fouled and restricted Engine vibrates excessively Engine runs but makes little or no progress Warning System Activates Refer to Engine Monitoring 50 Maintenance ENGINE MAINTENANCE AND INSPECTION SCHEDULE Routine maintenance is necessary for all mechanized products Periodic maintenance contributes to the product s life span The following maintenance chart provides guidelines
53. ion to increase speed FUEL ECONOMY The economy throttle range can save fuel depend ing on boat load and hull design When boat reach es top speed throttle back from FULL SPEED to the economy throttle range You will save fuel with out a noticeable loss of speed DR6472 DR6506 Concealed Side Mount Control Binnacle Mount Control OPERATION DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas Engine exhaust contains carbon monoxide which if inhaled can cause serious brain damage or death Contact with a rotating propeller is likely to result in serious injury or death Assure the engine and prop area is clear of people and objects before starting engine or operating boat Do not allow anyone near a propeller even when the engine is off Blades can be sharp and the propeller can continue to turn even after the engine is off Always shut off the engine when near people in the water POWER TRIM AND TILT WARNING Any malfunction of the power trim and tilt unit could result in loss of shock absorber protection if an underwater obstruction is hit Malfunction can also result in loss of reverse thrust capability The trim system features a trim range of 21 You can pivot the engine to any position within this range while underway and at any boat speed The power trim
54. is normally used to improve accel eration speed and ride quality and to adjust for changing water conditions The tilt system will tilt your engine an additional 54 While positioned within the tilt range DO NOT run the engine faster than idle speed If idling a tilted engine keep its water intakes submerged at all times The power tilt is often used to tilt the engine for clearance when beaching mooring or launching 1 Trim Range 2 Tilt Range Trim Gauge The trim gauge indicates the bow position that is achieved by the trim angle of your motor drc3908 Operation 29 Manual Release VAN WARNING A Keep everyone clear of a tilted engine when backing out the manual release screw The engine could drop suddenly and forcibly Be sure to tighten the manual release screw after manually repositioning the engine Tightening the screw also reactivates the engine s shock absorber protection and reverse thrust capability If needed the outboard will tilt up or down manually Turn the manual release screw counterclockwise slowly until it lightly contacts its retaining ring about 3 and 1 2 turns Reposition the engine Tighten the manual release screw to hold the en gine in its new position dr5076 1 Manual Release Screw Tilting To operate the power tilt push and hold the trim tilt switch in the bow up or bow down position The en gine will tilt up or down unt
55. ith the steering wheel to keep on a straight path The trim tab can also be adjusted to compensate for this steering wheel torque but adjust the trim tab only if bow down is commonly used Refer to Trim Tab When the motor is trimmed to full bow down posi tion the boat s bow will tend to go deeper into the water plow IMPORTANT Some boats plow or are difficult to plane when operated in the trim s lowest position If your boat handles unsuitably when trimmed fully bow down set the angle adjusting rod or trim limiter rod to limit the travel of the power trim If your motor is not equipped with this rod purchase one from your DEALER WARNING y Y If the bow of the boat plows the water at high speeds the boat may bow steer or spin suddenly possibly ejecting occupants Operation 31 PROPELLER SELECTION To select the correct propeller for your boating ap plication your boat and motor MUST be water test ed See your DEALER for assistance Refer to Propeller before removing or installing propeller IMPORTANT The correct propeller for your boat under normal load conditions will allow the engine to run near the midpoint of the RPM operating range at full throttle Refer to Engine Specifica tions Right hand propellers are considered standard ro tation propellers When propelling a boat forward the propeller rotates in a right hand clockwise di rection as viewed from the rear Left hand propel
56. ke noticeably The protection system must be RESET before the engine will op erate at speeds over 1200 RPM Under certain con ditions the EMM will shut off the engine The following conditions must be met to RESET the system The engine must be shut off and the cooling tem perature restored 34 Operation IF the S L O W protection system activates and the stream from the water pump indicator becomes in termittent or stops reduce speed to idle and Shift to NEUTRAL SHUT OFF the engine Tilt the motor up Clean the intake screens of any blockage Clean the water pump indicator of any blockage Lower the motor Restart the engine and run at idle IF cleaning the screens and indicator does not re store the water pump indicator s steady discharge SHUT OFF the engine and do not attempt to oper ate it See your DEALER IF cleaning the screens and indicator does restore the water pump indicator s steady discharge you might have to run for two minutes in NEUTRAL to allow the engine to cool and the light to go off If the warning light stays on after two minutes STOP the engine and see your DEALER IMPORTANT You must restore cooling to the en gine to avoid serious engine damage If you do not restore cooling to the engine the EMM will identify a progressive overheating condition and shut off the engine The WATER TEMP or HOT light will flash The engine will not restart until the engine is al lowed to cool
57. kup after all the water has been removed Maintenance 39 Lubrication Refer to Lubrication to drain and refill the gearcase and for lubricating points on the engine Touch up painted surfaces and wax the engine s exterior Store the engine on the boat or an engine stand in a vertical self draining position If you cannot store the engine in the recommended vertical position be sure the cooling system is drained completely Never place the gearcase high er than the powerhead Any water remaining in the exhaust passages can run into the cylinders and cause serious damage If you remove an installed engine examine all hardware you loosened or removed from the en gine and its steering throttle and shift systems Replace damaged or missing parts with Evinrude Johnson Genuine Parts or equivalent Battery Remove it clean it check its condition and water level then charge it Store it in a place that s cool and dry out of direct sunlight Check the water level and charge it periodically during the storage period Oil system Leave the oil hoses connected If you must disconnect them to remove the engine from the boat for storage cap the fittings and plug the hoses Oil tank Inspect the oil tank for contamination and or water Fill with recommended oil to reduce or prevent condensation from forming in the tank during storage Portable fuel tank Disconnect the hose from the tank Remove the hos
58. lanyard gie Evinrude Side mount control Handle shift and throttle Trim tilt switch where equipped Neutral lock tab Fast idle lever Emergency stop clip and lanyard General Information 17 Emergency Stop Key Switch A combination emergency stop switch and key Switch is a feature of Evinrude prewired remote controls and all Evinrude control wiring kits Use of the emergency stop feature is highly recommended on all boats Connect the clip to the emergency stop key switch Snap the lanyard to a secure place on the opera tor s clothing or life vest not where it might tear away instead of activating the stop switch Discon necting the clip and lanyard will stop the engine and prevent the boat from becoming a runaway if the driver moves beyond the range of the lanyard If the lanyard is too long it can be shortened by knotting or looping it DO NOT cut and retie the lanyard In an emergency situation the engine can be started without the clip in place Follow the normal starting procedure Reinstall a clip as soon as possible PUSH KEY IN FOR FULL CHOKE dr6819 dr5992a 1 Clip 2 Emergency stop key switch 3 Lanyard 18 General Information WARNING Avoid knocking or pulling the clip off the stop switch during normal boating Avoid bumping the key if operating without the clip on the switch The resulting unexpected loss of forward motion can throw occu
59. lers are considered counter rota tion propellers When propelling a boat forward the propeller rotates in a left hand counterclockwise direction as viewed from the rear 000033 1 Right Hand clockwise 2 Left Hand counterclockwise WARNING VAN If you have a dual engine installation that includes a counter rotating engine and you remove the propellers always check to be sure they are installed on the correct engines before aggressively operating your boat Shift each motor individually into FORWARD or REVERSE at idle speed only If the boat moves opposite the direction indicated by the remote control handle the wrong propeller has been installed on the motor being checked Install the correct propeller and confirm your installation using the above method before any attempt is made to operate the boat 32 Operation MOORING You may moor your boat with the motor s gearcase out of the water by using its tilt feature Depending on the model refer to Tilting or Power Trim and Tilt IMPORTANT DO NOT use the tilt support lever while trailering Refer to Trailering Engage the tilt support lever if you intend to leave the motor tilted for a period of time Tilt the motor UP using the trailering tilt switch Flip the tilt support lever down Lower the motor until the tilt support lever rests sol idly on the stern brackets Disengage the tilt support lever Tilt the motor UP Flip the t
60. manager or owner f further assistance is required please contact the Bombardier Customer Support Services 250 Sea Horse Drive Waukegan IL 60085 1 847 689 7090 Revision April 2003 Engines sold in Canada are distributed and serviced by Bombardier Inc 6 General Information BOMBARDIER LIMITED WARRANTY FOR EVINRUDE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA For a copy of the Limited Warranty see your Bombardier distributor dealer authorized to distribute Evinrude products in the country in which the sale occurs If further assistance is required please contact Bombardier Customer Support Services 250 Sea Horse Drive Waukeg an Illinois 60085 or the affiliate of Bombardier where the Product was registered for warranty General Information 7 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT Your Evinrude outboard with Direct Injection has a special environmental label required by the California Air Resources Board The label has one two three or four stars A hangtag provided with your outboard describes the meaning of the star rating system The Star Label means Cleaner Marine Engines The Symbol for Cleaner Marine Engines Cleaner Air and Water For a healthier lifestyle and environment Better Fuel Economy Burns up to 30 to 40 percent less gas and oil than conventional carbureted two stroke engines saving money and resources Longer Emission Warranty Protects consumer for worry free op
61. nents while the engine is cranking or running IMPORTANT The spark plugs should be serviced by an Evinrude DEALER to insure correct orienta tion of the spark plug to fuel injector Incorrect spark plug maintenance can lead to engine damage Re fer to Engine Maintenance and Inspection Schedule POWER DISTRIBUTION PANEL A power distribution panel on your outboard con trols and protects the electrical systems The panel includes 7 mini fuses and 4 power relays The cov er holds spare fuses and a puller Refer to Fuse Panel Chart for rating color position and circuit information Be sure that all active and spare fuses are in good condition Always carry spare fuses Fuse Failure A minor electrical problem can blow a fuse Re place it with a fuse of the same rating Repeated failures of fuses in the same position in dicate a serious problem Do not replace with high er rated fuses see your DEALER for service Fuse Replacement Remove the retaining screws and panel cover Identify and remove the failed fuse install a good fuse of the same rating Install the panel cover and screws tighten securely IMPORTANT Failure to install the panel cover se curely will cause electrical problems Fuse Panel Chart dr47566 drc6497 Pos Rating Circuit P N amp Color 1 10 Amp Oil Injector 514766 Red 2 10 Amp V4 No 1 amp Injectors 514766 Red V6 No 184 Injecto
62. of operation your new engine will be broken in and its mechanical parts will have seated At that time all systems should be checked and any adjustments needed should be made Your DEALER will perform this 10 hour Inspection at your request and expense based on local rates according to what your engine needs refer to En gine Maintenance and Inspection Schedule 10 Hour Inspection for a partial list Follow consistent preventive maintenance by hav ing your DEALER check and service your engine once a year or after each 100 hours of operation whichever comes first OFF SEASON STORAGE You must protect against natural environmental conditions that can be damaging to an outboard motor Temperature and humidity changes while your outboard motor is not in use can cause corro sion of internal engine parts when they are not pro tected Fuel remaining in your fuel tank and in the engine will oxidize and weather which can result in loss of octane and can cause gum deposits in the fuel system Your warranty does not cover engine failure caused by these conditions We strongly rec ommend that you have your DEALER prepare your outboard for the off season To do the off season storage preparations yourself the supplies and perform the steps that fol OW 244 fuel conditioner Triple Guard grease Ultra HPF gearcase lubricant Storage Fogging Oil spray can Stabilize the engine s fuel supply with 2 4 fuel con ditioner during
63. onnections and condition verify 7 D SystemCheck self test and warning horn verify D operation Anticorrosion anodes verify operation D Water intake screens verify condition D Overboard water pump indicator verify operation D Steering system check verify function D Throttle and shift operation verify function D Emergency stop circuit and lanyard verify function D Flush cooling system Operator s Guide onboard Engine upper and lower motor covers clean and Operator s Guide review Fuel and oil system components inspect and repair D D leaks Fastener inspection tighten loosened components D D Air silencer clean and inspect D D Thermostat inspect and verify D ew Power tilt trim fluid inspect fluid level 6 D m Maintenance 51 Engine Maintenance and Inspection Schedule Frequency 2 2 5 5 gt gt 5 Iz oS Le ot eS oc 5 5 10 Tre Ne Engine BE gt BS Care mures mm Description Product r Engine to transom mounting hardware re torque D D 40 ft Ibs Electrical and ignition wires and connections D D inspect Gearcase lubricant replace 5 D D Powerhead synchronization and linkage inspect 3 7 D D Access EMM information resolve any service D D codes Fuel filter and oil filter s inspection eliminate contamination Gearcase lubricant inspe
64. or run the engine out of the water DO NOT leave a running engine unattended IMPORTANT BEFORE the first start up of your new engine Read Engine Starting Engine Stopping and Shifting and Speed Control Perform prelaunch check of all equipment Launch the boat and start the engine according to the procedures in Engine Starting AFTER start up Verify water pump operation often Look for a steady stream of water from the water pump indica tor If the stream of water stops shut off the engine to prevent damage Find and correct the cause or see your DEALER before you continue Verify shift function by shifting into gear and observ ing that the boat moves and that the movement is in the same direction as the shifter Refer to Shifting and Speed Control Change engine RPM often Avoid holding a throttle setting longer than 15 minutes 1 First 10 minutes of operation Operate the engine in gear at fast idle ONLY 2 Next 50 minutes Operate engine in gear below 3500 RPM DO NOT hold a constant throttle setting Change engine speed every 15 minutes With easy planing boats use full throttle to quickly accelerate boat onto plane Immediately reduce throttle to one half as soon as boat is on plane BE SURE boat remains on plane at this throttle setting 3 Second Hour Use Full throttle to accelerate boat onto plane then reduce throttle setting to three quarters BE SURE boat remains on plane at this throttle
65. pants forward causing injury Your emergency stop switch can be effec tive only when in good working condition At each outing inspect clip and lanyard for cuts breaks or wear Replace worn or dam aged parts Keep the lanyard free from obstructions and entanglements At each outing test the system s operation With the engine running remove the clip from the switch by pulling the lanyard If the engine does not stop running see your DEALER ENGINE MONITORING IMPORTANT Your outboard must be equipped with the System Check engine monitor Operating your outboard without the System Check engine monitor will void your warranty for failures related to the functions monitored on your engine When you turn the key switch ON the System Check engine monitor horn performs a self test by sounding a 1 2 second beep The gauge self tests by turning the warning lights on then off in se quence During engine start up pause with the key switch in the ON position to observe the horn and gauge perform the self test If the self test does not happen as stated see your DEALER The System Check engine monitor alerts the oper ator with a 10 second beep of the horn and a warn ing light on the gauge when certain engine problems occur The appropriate warning light will stay on until the problem is corrected or the key switch is turned OFF If the engine management module EMM senses that the problem could cause permanent eng
66. ram during installation Periodic regreasing of the steering cable ram with Triple Guard grease is required Refer to Engine Maintenance and In spection Schedule for lubrication frequency Refer to steering system manufacturer s information when servicing boat s steering system 9 29546 Failure to regrease as recommended could result in steering system corrosion Corro sion can affect steering effort making oper ator control difficult Power Trim and Tilt Fluid Reservoir Tilt the motor up and engage the tilt support De pending on your model refer to Tilting or Power Trim and Tilt Remove filler cap and check fluid level If necessary add enough Evinrude Johnson Power Trim Tilt and Power Steering Fluid to bring the fluid level even with the bottom of the fill cap hole when the unit is at full tilt IMPORTANT Correct fluid level must be main tained to ensure operation of the impact protection built into this unit Lubrication Points Refer to Engine Maintenance and Inspection Schedule for lubrication frequency and recom mended lubricant dr48607 200 250 models 1 Throttle linkage lubrication points 1 Trailering bracket lubrication points 200 250 models 1 Throttle linkage lubrication points 2 Starter Bendix lubrication points drc6500 dr44295 200 250 models 100 175 models 1 Shift Throttle lubrication
67. rate personal injury or property dam age It also may be used to alert against unsafe practices IMPORTANT Identifies information that will help prevent damage to machinery and appears next to information that controls correct assembly and op eration of the product Although the mere reading of such information does not eliminate the hazard the understanding and application of the information will promote the correct use of your outboard engine 2 General Information A responsible educated boater will fully appreciate the pleasures of boating and will be a safe boater Boating Safety Classes are conducted by the U S Coast Guard Auxiliary the U S Power Squadron and some Red Cross Chapters For information about classes call toll free 1 800 336 BOAT For additional information about boating safety and reg ulations call U S Coast Guard Boating Safety Hot line 1 800 368 5647 Outside North America please contact your DEALER or distributor for de tails about boating safety SAFETY MEASURES General AN To fully appreciate the pleasures enjoyment and excitement of boating there are some ba sic rules that should be observed and followed by any boater Some rules may be new to you and others may be common sense or obvi OUS irrespective take them seriously Fail ure to follow this safety information and safe boating rules could result in injury to you your passengers or other water users Become comple
68. reafter check level and condition of lubricant every 50 hours Replace lubricant every 100 hours of operation or once each season whichever oc curs first Refill with Ultra HPF gearcase lubricant If not available Hi Vis or other marine gearcase lube can be used however long term durability may be affected with continued use See your DEALER IMPORTANT The recommended gear lubricants include special additives for marine applications Do not use automotive gear lubricants 2 stroke or 4 stroke engine oil or any other oil or grease for gearcase applications With motor in normal operating position Remove drain fill plug and lubricant level plug from side of gearcase and completely drain gearcase of old lubricant Examine drained lubricant for metal filings milky appearance or black color with burnt odor If old lu bricant has any of those characteristics see your DEALER If drained lubricant is in good condition continue Place tube of lubricant in drain fill hole and fill slowly until lubricant appears at lubricant level hole See Engine Specifications for gearcase capacity Install lubricant level plug before removing tube from drain fill hole Drain fill plug can then be in stalled without loss of lubricant Securely tighten both plugs LUBRICANT 1 Drain fill Plu 2 Lubricant Level Plug dr33681 44 Maintenance Steering System The installer was instructed to grease the steering cable
69. riod of fast idle after start up the warmer the engine the shorter the period of fast idle Engine Starting 27 ENGINE STOPPING Move control handle to NEUTRAL Turn key switch counterclockwise to the OFF posi tion Remove the key when the boat will be unat tended To avoid difficulty when restarting never stop the engine by running it with the fuel hose disconnected or otherwise running it out of fuel SHIFTING AND SPEED CONTROL IMPORTANT Carefully check the function of all control and engine systems before leaving the dock DO NOT shift the engine into FORWARD or REVERSE while it is shut off If the following directions are not suitable for your boat s control see your DEALER before proceed ing Shifting With engine running and control handle in NEU RAL Concealed Side Mount Control Unlock the control handle lift the neutral lock tab by squeezing the hand grip Briskly and decisively move the control handle fore or aft until it engag es the gear detent 1 NEUTRAL Lock Tab Hand Grip 28 Engine Starting Binnacle Mount Control Briskly and decisively move the control handle fore or aft until it engages the gear detent DR5986 IMPORTANT When shifting from FORWARD to REVERSE or from REVERSE to FORWARD pause at NEUTRAL until the engine is at idle speed and the boat has slowed Speed Control After gear engagement move the control handle slowly in the same direct
70. rized to distribute Evinrude products in the country in which the sale occurred Dealer and then only after the Bom bardier specified pre delivery inspection process has been completed and documented by the purchaser and Dealer Warranty coverage only becomes available upon proper registration of Product by Dealer or owner Only the original purchaser and any subsequent owners who reside in the United States and Canada and have pur chased Product from a U S or Canadian Dealer are eligible for warranty registration and warranty coverage hereunder Such limitations are necessary in order to allow Bombardier to protect the safety of its products its consumers and the general public As outlined in the Operator s Guide timely routine required maintenance must be performed to maintain warranty cover age Bombardier may require proof of proper maintenance prior to authorizing warranty coverage 4 WHAT TO DO TO OBTAIN WARRANTY COVERAGE The registered owner must notify an authorized Dealer within two 2 days of the appearance of a defect Owner must bring Product including any defective part therein to Dealer promptly after the appearance of the defect and in any event within the warranty period and must provide Dealer with reasonable opportunity to repair the defect The expenses of transporting Product to and from Dealer for warranty service are to be borne by the owner If the Product has not previously been registered the owner may also
71. rs 3 10 Amp V4 Spare Fuse 514766 Red V6 No 3 amp 6 Injectors 4 10 Amp Fuel Pump 514766 Red 5 10 Amp Ignition Circuit 514766 Red 6 10 Amp V4 2 amp 4 Injectors 514766 Red V6 No 2 amp 5 Injectors 7 10 Amp Key Switch EMM 514766 Red Accessories 8 Relay EMM Ignition and Stop 586224 Circuits 9 Relay Power Trim Tilt 586224 11 10 Relay Fuel Pump 586224 Maintenance 47 PROPELLER WARNING When servicing the propeller always shift the outboard to NEUTRAL position turn the key switch OFF and disconnect battery pos itive cable so the engine cannot be started accidentally IMPORTANT Apply Triple Guard grease to the en tire propeller shaft before installing the propeller At least annually remove the propeller and check for debris Clean the shaft and regrease it before rein stalling a propeller Installation Slide thrust washer onto shaft with shoulder facing aft Slide propeller onto shaft engaging the splines and seating it on the thrust bushing Slide spacer onto the shaft and engage the propel ler shaft splines Wedge a block of wood between the propeller blade and the anti ventilation plate dr3984 100 FPL FSL and 115 FPL FSL models Install Propeller nut and tighten to a torque of 120 in Ibs 14 N m Continue to tighten propeller nut until nut slots and cotter pin hole are aligned Install new cotter pin and bend ends to secure
72. s stolen to Customer and Dealer Support Services 250 Seahorse Drive Waukegan IL 60085 U S A Give the outboard s model and serial numbers and en close a copy of the police report Outside North America Report the theft to the Bombardier distributor where the outboard was reg istered Technical Literature Bombardier Motor Corporation of America offers technical literature specifically for your outboard A service manual a parts catalog or an extra Opera tors Guide can be purchased from your selling DEALER For the name and location of the nearest Evinrude DEALER in the United States and Cana da visit www evinrude com Declaration of Conformity Bombardier Motor Corporation of America declares that the outboard to which this Operators Manual applies conforms to the essential requirements out lined in CE Machinery Directive 98 37 EC as amended George Broughton Director of Outboards BOMBARDIER LIMITED WARRANTY FOR 2004 EVINRUDE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA 1 SCOPE OF THE LIMITED WARRANTY Bombardier Motor Corporation of America Bombardier warrants its Evinrude amp outboard engines sold by authorized Evinrude dealers in the fifty United States and Canada Product from defects in material or workmanship for the period and under the conditions described below 2 WARRANTY COVERAGE PERIOD This limited warranty will be in effect from the date of purchase by the first retail
73. stall covers Check often to see that connections stay clean and tight IMPORTANT The accessory battery connection must only be used to charge a single 12 volt battery or two 12 volt batteries wired in parallel The acces connection must not be used to charge either battery in a 24 volt system IMPORTANT DO NOT use wing nuts on battery connections even if they came with the battery Wing nuts can loosen and cause errant warning signals or electrical system damage 42 Maintenance ADJUSTMENTS Trim Tab WARNING Improper trim tab adjustment can cause dif ficult steering A propeller will generate steering torque when the propeller shaft is not running parallel to the water s surface The trim tab is adjustable to compensate for this steering torque IMPORTANT A single trim tab adjustment will re lieve steering effort under only one set of speed motor angle and load conditions No single adjust ment can relieve steering effort under all speed motor angle and load conditions If the boat pulls to the left or right when its load is evenly distributed adjust the trim tab as follows With the motor shut OFF loosen the trim tab screw If the boat pulled to the right move the rear of the trim tab slightly to the right If the boat pulled to the left move the rear of the trim tab slightly to the left Tighten the trim tab screw to a torque of 35 40 ft Ibs 47 54 N m Test the boat and
74. tboard may be in a tilted or vertical posi tion 2 Remove the plug from the flushing port 3 Install flushing device if needed and garden hose 4 Start the water and flush the engine for at least five minutes keep pressure between 20 40 psi 140 300 kPa 5 Remove the flusher if used install the plug If the plug is also the water pump indicator turn it so the water streams out to the side where it can be seen easily from the helm 6 Lower the outboard to vertical position long enough to completely drain the powerhead Operation 33 ENGINE OVERHEATING IMPORTANT Do not run your engine even for a brief start up without supplying water to it Refer to Flushing While boating the engine s water intakes must stay completely submerged and unobstructed Observe proper transom height and trim angle While the en gine is running the engine s water pump indicator must discharge a steady stream of water Check the indicator often especially when operating in weeds mud and debris laden water and at extreme trim angles DRC4952rev 1 Water intake screens 2 Water pump indicator If the engine overheats its System Check engine monitor will sound the warning horn and turn on the WATER TEMP or HOT light Also the S L O W protection system will immediately limit the engine s speed to 1200 RPM If the engine was running fast er than 1200 RPM when the S L O W system acti vated it will sha
75. tely familiar with the control and operation of your boat and motor before embarking on your first trip or taking on a pas senger s If you have not had the opportunity to do so with your DEALER practice driving in a suitable area and feel the response of each control Be familiar with all controls before ap plying the throttle above idle speed As the op erator you are in control and responsible for safe operation SAFETY MEASURES Operation AN Be sure at least one of your passengers knows how to handle your boat in case of an emergency AN All passengers should know the location of emergency equipment and how to use it AN All safety equipment and personal flotation devices must be in good condition and suit able for your type of boat Always comply with the regulations that apply to your boat AN Contact with rotating propeller is likely to result in serious injury or death Do not allow anyone near a propeller even when the engine is off Propeller blades can be sharp and can contin ue to turn even after the engine is shut off Al ways shut off the engine when boat is near people in the water AN Whenever running the engine assure there is proper ventilation to avoid the accumulation of carbon monoxide CO which is odorless col orless and tasteless and can lead to uncon Sciousness brain damage or death if inhaled in sufficient concentrations CO accumulation can occur while docked anchored or under
76. tercraft Get the Facts 1 800 END SMOG www arb ca gov 8 General Information YOUR EMISSION CONTROL WARRANTY RIGHTS AND OBLIGATION The California Air Resources Board and Bombardier Motor Corporation of America Bombardier are pleased to explain the emission control system warranty on your Evinrude outboard with Direct Injection In California new outboard engines must be designed built and equipped to meet the State s stringent anti smog standards Bombardier must warrant the emission control system on your outboard for the pe riods of time listed below provided there has been no abuse neglect or improper maintenance of your outboard Your emission control system may include parts such as the carburetor or fuel injection system the igni tion system and catalytic converter Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Bombardier will repair your outboard at no cost to you including diagnosis parts and labor provided that such work is performed by an authorized Bombardier dealer Manufacturer s Limited Warranty Coverage This emission limited warranty covers Evinrude outboards with Direct Injection certified and produced by Bombardier for sale in California that are originally sold in California to a California resident or subse quently warranty registered to a California resident The Bombardier North America Limited Warranty con ditions for E
77. the at mosphere To avoid serious powerhead damage be sure the oil tank is installed in a location that does not allow constant exposure to sunlight rain bilge water or spray Periodically inspect the oil tank for evidence of water Filling the Oil Tank Remove the filler cap and fill the tank with recom mended outboard lubricant as specified in Fuel and Oil Replace the filler cap and tighten securely IMPORTANT Always keep a supply of oil in the tank If you run the tank dry you MUST purge the oil system of air before using the engine Installing the Oil Supply Hose IMPORTANT To avoid engine damage from lack of lubrication make sure you purge the system Make sure all connections are airtight Anytime the oil supply hose has been disconnected you must prime the oil system before reconnecting the supply hose and operating the engine Connect the oil supply hose to the oil inlet fitting on the motor Secure with the small clamp 13 8 mm from the owner s kit 1 Oil supply hose 1 4 in 6 mm Yellow stripe 2 Oil inlet fitting 1 4 in 6 mm Yellow stripe 3 Clamp 13 8 mm from owner s kit Hold the open end of the oil return hose fitting over a container With its outlet end up squeeze the oil fill bulb repeatedly until about 8 oz 250 ml of oil have been pumped and the supply hose is purged of all air 000067 1 Oil return hose fitting 5 16 in 8 mm Blue stripe Fuel and Oil 23
78. the last hours of operation to ensure proper stabilization following instructions on the container for mixture Be sure to run the engine long enough for the treated fuel to reach the en gine WARNING Prevent injury from moving engine compo nents Before starting the engine Shift it to NEUTRAL Keep hands clothes hair clear of power head Remove the propeller if you use a flushing device IMPORTANT Provide a water supply to the engine and start it run it at idle only To run the engine on a flusher refer to Flushing To avoid difficulty when restarting never run the engine with the fuel hose disconnected or run the engine out of fuel Storage Fogging Oil Following instructions on the can fog the engine by spraying through the holes in the throttle plates in the throttle bodies dr46041a Ignition oil and fuel systems Check for mis placed leads and damaged or deteriorated parts Be sure starter solenoid terminal boot and all con nectors are in place Screws bolts nuts Tighten that are loose any Propeller Remove and examine If damaged see your DEALER Clean the propeller shaft and lu bricate it Refer to Propeller Gearcase speedometer pickup if equipped Disconnect the speedometer hose at the upper connection With air pressure no more than 25 psi 167 kPa blow all water from the gearcase speed ometer pickup system Reconnect speedometer pic
79. uivalent characteristics including type strength and material Using substan dard parts could result in injury or product malfunction Bombardier Motor Corporation of America reserves the right to make changes at any time without no tice to features specifications and model availabil ity The right is also reserved to change any specification or part at any time without incurring any obligation to update older models The informa tion in the Guide is based on the latest specifica tions available at the time of publication Photographs and illustrations used in this Guide might not depict actual models or equipment but are intended as representative views for reference only The continuing accuracy of this Guide cannot be guaranteed Certain features of systems discussed in this Guide might not be found on all models in all marketing ar eas Owner s Identification North America At the time of purchase your DEALER will complete your outboard registration forms Your portion provides proof of ownership and date of purchase Outside North America See your DEALER or distributor for details Model and Serial Numbers The model and serial numbers appear on a plate at tached to the stern bracket or swivel bracket Record your outboard s Model Number Serial Number Purchase Date Ignition Key Number 4 General Information Stolen Outboards North America Report your outboard a
80. ulders can be beyond the capability of the absorption system Such impacts can result in serious damage to your engine and in jury to boat occupants from the engine or its parts entering the boat Occupants can also be ejected or injured by falling against portions of the boat as a result of rapid deceleration following impacts When boating in unfamiliar shallow or debris laden wa ters seek information on safe boating areas and navigation hazards from a reliable local source Re duce your speed and keep a sharp lookout dr4411 The engine s shock absorption system does not work while operating in reverse If you back into an object either in the water or while trailering your boat and engine can be seriously damaged dr4412 36 Operation If you hit any object stop immediately and examine the engine for loosening of attaching hardware and clamp screws if equipped Inspect for damage to Swivel and stern brackets steering components and components in the area of impact Also exam ine the boat for structural damage Tighten any loosened hardware If the collision occurred in the water proceed slowly to harbor Before boating again have your DEALER thoroughly inspect all components WARNING A Failure to inspect for damage could result in sudden unexpected component failure loss of boat control and personal injury Unrepaired damage could reduce your boat and engine s ability to resist future impacts
81. vinrude outboards with Direct Injection are still applicable to these models with the necessary modifications Select emission control parts of your Evinrude outboard with Direct Injection are warranted from the date of purchase by the first retail consumer or the date the product is first put to use whichever occurs first for a period of 4 years or for 250 hours of use whichever occurs first However warranty coverage based on the hourly period is only permitted for outboards equipped with the appropriate hour meters or their equivalent If any emission related part on your engine is defective under warranty the part will be repaired or replaced by Bombardier Parts covered are 1 Electrical System 4 Air Induction System A EMM Engine Management Module A Reed Valves B Spark Plugs and Wires B Throttle Body Assembly C Ignition Coils C Throttle Linkage D Wiring Harness 5 Oil System 2 Exhaust System A Oil Injector A Powerhead to Lower Unit Adapter Plate B Oil Lift Pump B Exhaust Pressure Fitting C Oil Lines Fittings and Clamps C Inner Exhaust Housing D Exhaust Back Pressure Hose and Diaphragm 6 Sensors E Intake Manifold and Exhaust Manifold A Air Temperature Sensor B Crank Position Sensor 3 Fuel System C Throttle Position Sensor A Fuel Lift Pump D Water Temperature Sensor Port Cylinder Head B Fuel Supply Pump E Thermostat C Fuel Injectors D Vapor Separator 7 Gaskets E
82. xceed their predetermined factory specifica tions Tampering with the fuel system to change horse power or modify emission levels beyond factory settings or specifications will void the product war ranty 38 Maintenance EPA Emission Regulations All new 1999 and more recent Evinrude outboards manufactured by Bombardier are certified to the EPA as conforming to the requirements of the reg ulations for the control of air pollution from new wa tercraft marine spark ignition engines This certification is contingent on certain adjustments being set to factory standards For this reason the factory procedure for servicing the product must be strictly followed and whenever practicable re turned to the original intent of the design The re sponsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA requirements on exhaust emissions for marine products For more detailed information on this subject you may contact the fol lowing locations VIA U S POSTAL SERVICE Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group 6403 401 M St NW Washington DC 20460 VIA EXPRESS or COURIER MAIL Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group 6403 501 3 rd St NW Washington DC 20001 EPA INTERNET WEB SITE WWW epa gov 10 HOUR INSPECTION After 10 hours

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