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Operator`s Guide

1. N 006995 006996 Item Description Item Description 16 Oil Tank 23 Spark Plugs 17 Oil Fill Cap 24 EMM Engine Management Module 18 Fuse 25 Rewind Starter Flywheel Guard 19 Spare Fuse 26 Throttle Friction Screw 20 Air Silencer 27 Emergency Start Clip 21 Battery Cable electric start models only 28 Tiller Arm Tilt Release 22 Fuel Connector 29 Steering Friction Lever Continue to Oil and Fuel on page 16 13 Using Your E TEC Outboard COMPONENT IDENTIFICATION REMOTE CONTROL MODELS 7 4 5 006997 Item Description Item Description 1 Air Inlet Tilt Handle 5 Trim Tab 2 Engine Cover Latch 6 Water Intake Screens 3 Water Pump Indicator Flushing Port 7 Rope Pull Start Handle 4 Anti Corrosion Anodes gt COMPONENT IDENTIFICATION 006998 Starboard 006999 Item Description Item Description 8 Oil Tank 14 Battery Cables 9 Oil Fill Cap 15 Spark Plugs 10 Fuse 16 EMM Engine Management Module 11 Spar
2. 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 Johnson outboard have also received a copy of the Operator s Guide Signature Date 75
3. IMPORTANT When trailering your outboard DO NOT cover the engine with canvas it will dull the finish of the outboard s engine covers gt MAINTENANCE SCHEDULE Anti Corrosion Anodes Your outboard is equipped with one or more anodes that protect it from galvanic corrosion Disintegration of the anode is normal and in dicates it is working Check each anode peri odically Replace anodes smaller than 2 3 their original size See your Dealer for re placements 007035 Galvanic corrosion destroys underwater met al 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 outboard 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 fasteners or its mounting surface Painting will reduce its corrosion protection SUBMERGED OUTBOARD If your outboard has been under water have it serviced immediately upon recovery If immediate service is unavailable resub merge it in fresh water to avoid prolonged ex posure to the atmosphere After submersion all boat and engine electri cal fuel and oiling systems must be inspect ed for signs of water intrusion Your Dealer should perform this service 49 Maintenance TRANSPORTING THE OUTBOARD If the outboard is laid down for transportation or stora
4. Owner s Identification United States and Canada At the time of purchase your Dealer will complete your out board registration forms Your portion provides proof of ownership and date of purchase Outside United States and Canada See your Dealer or distributor for details Model and Serial Numbers The model and serial numbers appear on a plate attached to the stern bracket or swivel brack et Record your outboard s Model Number Serial Number Purchase Date Ignition Key Number Stolen Outboards United States and Canada Report stolen outboards to your local dealer or distributor Outside United States and Canada Report the theft to the Bombardier Recreational Prod ucts distributor where the outboard was registered Technical Literature BRP offers technical literature specifically for your outboard A service manual a parts cata log or an extra Operators Guide can be purchased from your selling Dealer For the name and location of the nearest Evinrude Dealer in the United States and Canada visit www evinrude com Declaration of Conformity Application of Council Directives Directive 94 25 EC as amended by 2003 44 EC Recreational Craft Relevant Directive s Directive 89 336 EC as amended by 2004 108 EC Electromagnetic Compatibility Relevant Harmonized Standard s As referenced by Council and Relevant Directives Product Type Marine Outboard 2 Stroke Cycle SI Engine Manu
5. These safety notices mean ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Additionally Bombardier Recreational Prod ucts BRP has identified key information that is essential to the operation of your Evinrude E TEC outboard Key information appears throughout this Guide in gray boxes with a key above the text This highlighted information is a vital ref erence when using your outboard IMPORTANT SAFETY MESSAGES This Operator s Guide contains essential in formation to help prevent personal injury and damage to equipment Safety messages ap pear throughout this Guide in the applicable A All safety equipment and personal floatation devices must be in good con dition and suitable for your type of boat section A WARNING A Be careful Human error is caused by many factors carelessness fatigue overload preoccupation 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 oth ers follow all safety warnings and rec ommendations Do not disregard any of the safety precautions and instruc tions Anyone operating your boat should first read and understand this Guide before they operate your boat and out board SAFETY MEASURES General A To fully appreciate the pleasures enjoy ment and excitement of boating t
6. 1 Tilt lever and swivel bracket lubrication points annually 007033 1 Tilt tube lubrication points annually 2 Tilt lever shaft annually 007020 1 Tiller handle lubrication points annually WEEDY WATER Weeds block water intakes and may cause your outboard to overheat Weeds on the pro peller create vibration and reduce boat speed When operating in weedy water 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 propeller area and water intakes before operating at higher speed HIGH ALTITUDE Your outboard s EMM will automatically com pensate for changes in altitude However if you boat above 3000 ft 900 m you will ex perience 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 in stall the original propeller and verify correct RPM operating range 42 COLD AND FREEZING WEATHER IMPORTANT When operating in conditions under 40 F 4 C Evinrude Johnson XD100 oil is recommended When operating in condi tions under 32 F 0 C Evinrude Johnson XD100 oil must be used During operation in freezing weather keep the gearcase subm
7. ALL WARRANTIES EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRAN TY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURA TION 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 damage to personal property inconvenience cost of insurance coverage loan payments loss of time loss of income revenue or prof its or loss of enjoyment or use of Product SOME STATES PROVINCES OR JURISDICTIONS DO NOT ALLOW FOR THE DISCLAIMERS LIM ITATIONS OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR OTHER EXCLUSIONS IDENTI FIED 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 war ranty regarding Product other than those contained in this limited warranty a
8. Evinrude Johnson XD100 oil is recommended When operating in conditions under 32 F 0 C Evinrude Johnson XD100 oil must be used REMOVING THE ENGINE COVER Release rear engine cover latch by pulling the handle back and turning downward 007000 Pull up on the tilt handle to release the engine cover seal on the engine cover 007001 1 Tilt handle Release the hook from its catch in the front and remove the engine cover to access the oil tank 007002 OIL AND FUEL FILLING THE OIL TANK Remove the filler cap and fill the tank with the recommended outboard lubricant as speci fied in Oil Requirements on page 16 Replace the filler cap and tighten securely Reinstall the engine cover IMPORTANT The oil tank capacity is 1 5 quarts 1 4 liters PRIMING THE OIL SYSTEM The oiling system must be primed before us ing the outboard if The outboard is new check with your deal er to ensure oil system was primed You run completely out of oil Prime the oiling system by performing winter ization Refer to Long Term Storage Win terization on page 52 Using Your E TEC Outboard FUEL REQUIREMENTS A WARNING A Gasoline is extremely flammable and highly explosive under certain condi tions Follow the instructions in this section explicitly Improper handling of fuel could result in property damage serious injury or death Leaking fuel is a fire and explosio
9. 48 SCRATCH REPAIR C Surface scratches on the upper and lower engine covers can be polished out with buff ing compound Treat affected areas using these steps 1 Sand the affected area with 800 grit sand paper 2 Wet sand the area with 1200 grit sandpa per 3 Using a composite material buffing com pound polish the area closely following the product directions IMPORTANT Your Dealer has the profes sional materials to properly repair scratches Do not attempt to paint over marks or scratches in the composite material See your Dealer to repair any deep scratches or gouges HULL FINISH The condition of your boat s bottom affects performance Marine growth or bottom paint ing may reduce speed and fuel efficiency For maximum performance keep the boat s running surface clean by rinsing it with fresh water and wiping it dry Apply Evinrude anti corrosion spray to any surface subject to cor rosion but avoid the anti corrosion anode s OUTBOARD EXTERNAL FINISH Your outboard s upper and lower engine cov ers use molded in color technology provid ing a deep durable gloss with maximum ultraviolet sunlight protection The high gloss finish will show polish marks when viewed closely in certain light condi tions This glossing is NORMAL Periodically wash the entire boat and out board with soapy water and apply a coat of automotive wax Leave the engine cover in place when washing the outboard
10. inspect and lubricate 9 C Y Spark plugs inspect and replace if necessary 2 v Starter pinion shaft inspect and lubricate D Y Steering system inspect and lubricate v Thermostat inspect and pressure relief valve 1 Average recreational use Commercial use heavy use or use in salt or polluted water requires more frequent inspection and maintenance annual checks are recommended 2 Emission related component Refer to Owner Responsibility on page 46 Product Warrant Information on page 65 and if applicable California Emission Control Warranty Statement on page 3 Annually in salt water applications Refer to Salt Water Lubrication Points on page 42 A HPF XR Gearcase Lubricant HPF Pro Gearcase Lubricant in high performance or commercial applications B Evinrude Johnson Biodegradeable TNT Fluid Triple Guard Grease D Starter Bendix Lube ONLY P N 337016 o 47 Maintenance SPARK PLUGS A WARNING A The ignition system presents a serious shock hazard Use caution to avoid injury from shock or injury resulting from your reaction to shock Do not handle primary or secondary ignition components while the engine is crank ing or running Spark plugs should be serviced by an Evinrude E TEC Dealer Incorrect spark plug maintenance can lead to engine damage IMPORTANT Replacement spark plugs MUST be indexed correctly Marine Engine Duty Cycles The International Council of Marine
11. 4 hours the engine will shut down and will not be able to be restarted See your Dealer WARNING STARTING MODE CHARGING OKAY RUNNING MODE CHARGING FAULT CRANK POSITION OKAY IN ECTOR IGNITION FAULT O SENSORS OKAY SENSOR FAULT O LANYARD STOP OKAY EMMDIAGNOSTICS EMM Diagnostics Label NOOIL OVERHEAT 007057 Start Mode If any of the LEDs does NOT light during start ing it may indicate an engine problem Refer to EMM Diagnostics Label LED 1 2 or 3 OFF seek assistance to return to port See your Dealer LED 3 flashing indicates a hazardous fuel condition may exist Seek assistance to return to port See your Dealer LED 4 OFF indicates the stop circuit is activat ed make sure the stop lanyard is attached LED 4 flashing indicates engine shut down EMM temp OVER range refer to Engine Overheating on page 41 Engine temp OVER range refer to Engine Overheating on page 41 Excessive No Oil condition Seek assis tance to return to port gt ENGINE MONITORING ENGINE MONITOR SYSTEM OPTIONAL This outboard can be equipped with an op tional engine monitoring system such as I Command SystemCheck or equivalent Use a monitoring system to provide visual and audible warnings IMPORTANT Evinrude E TEC 25 and 30 HP outboards require an optional module and wire harness to support and Sys temCheck warning functions A dash mounted
12. E This outboard is equipped with Speed Adjust ing Failsafe Electronics S A F E S A F E is an engine warning system con trolled by the Engine Management Module EMM The EMM monitors engine sensors If conditions which could cause permanent en gine damage exist the EMM limits engine speed to 1200 RPM If engine is in S A F E mode the outboard will shake noticeably when accelerated above 1200 RPM For additional protection during severe oper ating conditions the EMM will shut OFF the engine A CAUTION A In the S A F E mode the engine speed is limited Under certain conditions the engine s limited speed may reduce maneuverability of your boat If the S A F E 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 maneuverabil ity may be imminent The EMM activates S A F E mode for NO OIL warning indicates a nearly empty oil tank Refer to Filling the Oil Tank and Priming the Oil System on page 17 OVERHEAT warning indicates an engine or EMM overheat condition Refer to En gine Overheating on page 41 FAULT warning indicates a problem exists The EMM has identified a problem with the outboard Seek assistance and or return to harbor immediately See your Dealer DIAGNOSTIC LEDS The Engine Management Module EMM has four LED indicators located on the top corner of the c
13. Evinrude Johnson Genuine Parts and accessories installed by an authorized dealer at the time of sale including but not limited to pro pellers bear the standard BRP parts and accessories one year limited warranty California residents who purchased or warranty registered a Product in California should refer to BRP s California Emissions Control Warranty Statement 5 CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only on Evinrude outboard engines purchased as new and unused from a dealer authorized to distribute Evinrude products in the country in which the sale occurred Deal er and then only after the BRP specified pre delivery inspection process has been completed and doc umented 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 purchased Product from a U S or Canadian Dealer are eligible for warranty registration and warran ty coverage hereunder Such limitations are necessary in order to allow BRP 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 coverage BRP may require proof of proper maintenance prior to authorizing warranty coverage 6 WHAT TO DO TO OBTAIN WARRANTY COVERAGE The
14. Industry Associations ICOMIA Standard No 36 88 specifies a marine engine duty cycle based on documented studies A duty cycle is a profile of engine running and usage This duty cycle is used to determine average spark plug lon gevity and maintenance requirements for Evinrude E TEC outboards ICOMIA Marine Engine Duty Cycle Engine Speed as Time at Specified RPM Percentage of Rated Percentage of total Speed RPM engine running time IDLE 40 40 25 60 15 80 14 100 6 IMPORTANT Some running profiles and conditions can lead to spark plug wear sooner than expected Depending on your specific usage the spark plug maintenance schedule may require adjustment FUSE C On outboards equipped with an accesso ry electric starter a blown fuse will not allow the engine to start Replace it with a fuse of the same rating A spare fuse is provided Repeated fuse failures indicate a potentially serious problem Do not replace it with higher rated fuse see your Dealer for service In an emergency the engine may be rope started and run this will not harm the engine Fuse Replacement IMPORTANT Use only fuses of the same rat ing Your Evinrude E TEC outboard uses 10 amp fuses Remove engine cover Install spare fuse in place of failed fuse 007034 1 Fuse 2 Spare fuse IMPORTANT Failure to install cover securely may cause electrical problems
15. Refer to Tilt UP on page 31 Graspthe tilt rod retainer and squeeze to re lease Slide rod assembly all the way out Insert rod in desired position Make sure rod passes through both stern brackets Push in against retainer Make sure the catch is locked on the stern bracket 32 SHALLOW WATER DRIVE You can tilt the outboard to any position within the tilt range If idling a tilted outboard keep its water intakes submerged at all times Engaging Shallow Water Drive Slow the engine and shift to NEUTRAL before engaging or disengaging shallow water drive Move tilt run lever to TILT position Grasp tilt grip on engine cover and tilt out board until shallow water drive link engages trim angle adjustment rod Relocate the motor angle adjusting rod if nec essary Refer to Trim Angle Adjustment on page 32 007025 1 Shallow water drive link 2 Trim angle adjustment rod 3 Retainer gt TILTING AND TRIM A WARNING A When in shallow water drive your motor has no protection from the effects of underwater impact Operate the motor in FORWARD and ONLY at slow speed The motor can tilt up forcibly and drop suddenly if it hits an underwater object or if you shift to REVERSE and apply throttle You could lose control Disengaging Shallow Water Drive Move tilt run lever to RUN position Grasp tilt grip on engine cover and raise out board slightly The shallow water drive link will automa
16. Start the outboard Outboard runs at slow idle speed Tiller Control Typical 2 After outboard runs for about 15 seconds move throttle grip to IDLE position Out board continues to run at slow idle speed 3 After outboard runs for another 15 sec onds advance throttle grip to HALF THROTTLE position Outboard will accel erate to fast idle speed and fog itself 4 Allow outboard to run until it shuts itself OFF automatically less than one minute Winterization is complete when outboard shuts itself off f the outboard DOES NOT shut itself off you may not have properly advanced throttle grip If the engine exceeds 3000 RPM the out board may have been shifted into gear In either event immediately press STOP button to turn outboard OFF and re start the procedure 53 Maintenance After Winterization All Outboards 1 After the outboard shuts itself off turn key switch OFF For tiller models remove emergency stop clip key switch Do not start the outboard again after winterization is completed 2 If winterizing on a trailer turn off water and detach garden hose Grease propeller shaft splines with recommended lubricant and re install propeller IMPORTANT When winterizing is finished leave the outboard in vertical position long enough to completely drain the powerhead If equipped disconnect the speedometer pick up at the upper connection and blow all water o
17. by the Safety Alert Symbol It is imperative to read understand and follow these com ments This Guide should be kept in a waterproof bag with the outboard at all times during opera tion If the product ownership is transferred this Guide should be forwarded to the new owners A responsible educated boater will fully ap preciate the pleasures of boating and will be a safe boater Boating Safety Classes are con ducted 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 safe ty and regulations call U S Coast Guard Boating Safety Hotline 1 800 368 5647 Outside North America please contact your Dealer or distributor for details about boating safety This Operator s Guide uses the following sig nal words identifying important safety mes sages A DANGER Indicates an imminently hazardous sit uation which if not avoided WILL result in death or serious injury A WARNING Indicates a hazardous situation which if not avoided could result in death or severe injury A CAUTION A Indicates a hazardous situation which if not avoided could result in minor or moderate injury IMPORTANT Identifies information that will help prevent damage to machinery and ap pears next to information that controls correct assembly and operation of the product
18. distributor dealer authorized to distribute Evinrude products in the country in which the sale occurs If further assistance is required please contact BRP US Inc Outboard Engines Division After Sales Support P O Box 597 Sturtevant WI 53177 1 847 689 7090 or the affiliate of BRP where the Product was registered for warranty Engines sold in Canada are distributed and serviced by Bombardier Recreational Products Inc Limited Warranty Revision February 2008 67 Product Information CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT Your Evinrude E TEC outboard 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 operation 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 tha
19. gauge a warning horn a CANmodule and related wiring are required Gauges Gauges are available in several styles such as a digital Command gauge with LCD dis plays or a basic SystemCheck gauge 1 Typical I Command Digital gauge 2 Typical SystemCheck gauge For and other gauges refer to the gauge user s guide for gauge displays oper ation warnings and monitoring instructions Self Test During engine start up pause with the key switch in the ON position The monitoring sys tem self tests by sounding a half second beep SystemCheck gauges self test by turn ing the indicator lights on simultaneously then off in sequence IMPORTANT If the self test does not happen as stated see your Dealer 39 Using Your E TEC Outboard Warnings Engine monitor system warnings activate the horn for 10 seconds and the appropriate gauge light for a minimum of 30 seconds If the unsafe operating condition continues a light or dis play remains ON until the key is turned OFF or the failure is corrected The warning will reoccur at the next startup if the problem is not corrected NO OIL Symptom The oil tank is empty or nearly empty Result EMM will activate S A F E mode 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 Action Your outboard is designed to run in S A F E mode for up to five hou
20. out board unless the part is scheduled for replacement as required maintenance in the Operator s Guide Emission warranty parts that are scheduled for replacement as required maintenance are warranted by BRP for the period of time before the first scheduled replacement date for that part Emission warranty parts that are scheduled for regular inspection but not regular replacement are warranted by BRP 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 BRP for the remainder of the warranty period of the original part All parts replaced under this limited warranty become the property of BRP 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 BRP recommends that you retain all receipts covering maintenance on your outboard but BRP cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance As the outboard owner you should however be aware that BRP may deny you warranty coverage if your outboard or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your outboard to an authorized BRP dealer as soon as a
21. performance boats have a high power to weight ratio If you are not ex perienced in the operation of a high per formance boat do not attempt to operate one at or near its top speed un til you have gained that experience A Become completely familiar with the control and operation of your boat and outboard before embarking on your first trip or taking on a passenger 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 applying the throttle above idle speed As the operator you are in con trol and responsible for safe operation SAFETY MEASURES Installation and Maintenance Z The outboard must be correctly in stalled Failure to correctly install the outboard could result in serious injury death or property damage We strongly recommend that your Dealer install your outboard to ensure proper installation AN Do not overpower your boat by using an engine that exceeds the horsepower in dicated 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 AN When replacement parts are required use Evinrude Johnson Genuine Parts or parts with equivalent characteristics in cluding type strength and material Us ing substandard parts could result in injury or product malfunction AN Only p
22. problem ex ists 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 BRP dealer contact BRP US Inc Outboard Engines Division After Sales Support P O Box 597 Sturtevant WI 53177 1 847 689 7090 or visit www evinrude com 70 Readiness Test The Operator s Readiness Test 1 2 3 4 Did you read this Guide from front cover to rear cover Are you ready to take responsibility for the safe operation of your boat and outboard 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 outboard Do you know who to ask if you have any questions about your boat and outboard Do you know your local marine traffic laws Do you understand that human error can be caused by carelessness fatigue overload preoccupation 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 encoun ter however your understanding of and adherence to essential information con tained in this Gu
23. 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 007044 Tighten the trim tab screw to a torque of 35 40 ft lbs 47 54 N m Test the boat and if need ed repeat the procedure until steering effort is as equal as possible High outboard installations The trim tab might be above the water when the out board is trimmed out Steering effort might in crease Steering effort will be reduced if you E the outboard in and submerge the trim tab Friction 007041 1 Throttle friction screw 2 Steering friction lever Throttle Friction Adjust until a slight drag is felt when accelerating or decelerating only DO NOT overtighten Steering Friction The steering friction was set on your outboard at the factory A slight drag should be felt when turning the out board with the steering handle If adjustment is necessary turn the adjustment screw Clockwise to increase friction or Counterclockwise to decrease friction A WARNING A DO NOT overtighten for hands off steering Reduced steering control could result 63 Product Information SPECIFICATIONS 25 30 Models Displacement 35 1 cu in 576 cc Engine Type In line 2 Cylinder Two Cycle E TEC Full Throttle Operating Range 25 HP 5000 to 6000 RPM 30 HP 5000 to 6000 RPM Power 25 HP
24. to se cure 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 is partially absorbed by the rubber bushing in the hub to help prevent damage to the out board A strong impact can damage the hub and propeller blades Damage to blades can cause unusual and excessive vibration Dam age to the hub can cause excessive engine RPM with little forward movement IMPORTANT Avoid or limit operation using a damaged 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 62 gt ADJUSTMENTS ADJUSTMENTS Trim Tab Improper trim tab adjustment can cause difficult steering WARNING 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 relieve steering effort under only one set of speed outboard angle and load conditions No single adjustment can relieve steering ef fort under all speed outboard 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 outboard shut OFF loosen the trim tab screw If the boat pulled to the right move
25. 0 rpm Press the of the button to increase or press the side of the button to decrease idle Idle speed may be adjusted up to 1500 rpm or down to 550 rpm If the engine is shut off it will return to the de fault idle speed when restarted 007018 1 Troll Control button TILLER HANDLE RATCHET Tiller models feature a ratchet which holds the tiller arm at approximately 30 or 90 posi tions To release the tiller arm press up on the release lever 007019 1 Release lever gt OPERATION TILLER HANDLE ANGLE Tiller handle angle can be raised or lowered by turning the adjustment screw under the handle 007020 1 Adjustment screw TRIM TILT SWITCH If equipped the trim tilt switch is located in the end of tiller handle Press switch as indicated for UP and DOWN operation 1 Trim tilt switch UP 2 Trim tilt switch DOWN Continue to Fuel Economy on page 30 27 Using Your E TEC Outboard SHIFTING AND SPEED CONTROL REMOTE MODELS WARNING If you choose a non Evinrude remote control it must have a start in gear prevention feature This feature can prevent injuries resulting from unexpected boat movement when the engine starts IMPORTANT When selecting the remote control system for your boat specify Evinrude com ponents Evinrude controls deliver the cable stroke your outboard needs for positive shift and throttle control and they incorporate such safet
26. 25 HP 18 4 kw 5500 RPM 30 HP 30 HP 22 1 kw 5500 RPM Idle RPM in Neutral 700 50 Ignition Timing Not Adjustable per SAE J1930 2 Emission Control System ECM E TEC Engine Control Module E TEC Fuel Requirements 2 87 Pump Posted AKI 90 RON Refer to Fuel Requirements on page 18 Oil Lubricant Capacity TC W3 NMMA certified oil or Evinrude Johnson XD100 oil Refer to Oil Requirements on page 16 1 5 qt 1 41 Warning Signals Controlled by the outboard s EMM Battery Minimum 640 CCA 800 MCA 12 volt or 800 CCA 1000 MCA 12 volt below 32 F 0 C Spark Plug Refer to ECI Label Fuses Refer to Fuse on page 48 Fuel Filter In line Replaceable Battery Charging 15 Amp Fully Regulated Gearcase Lubricant Capacity Evinrude HPF XR 11 fl oz 825 ml Power Trim Tilt Fluid Capacity 11 7 fl oz 345 ml Propeller Refer to Propeller Selection on page 61 Weight DR RL Models 142 148 lbs 64 67 Kg DTE DTEL Models 148 154 Ibs 67 70 Kg EL PL Models 169 178 lbs 77 81 Kg Sound at Drivers Ear LpA ICOMIA 39 94 76 8 dB A Transom Height R TE Models 14 1 2 to 15 in 368 to 381 mm RL TEL DPL Models 19 1 2 to 20 in 495 to 508 mm Rated following the standards of ICOMIA 28 83 ISO 3046 and NMMA Emission Control Information Use a 800 CCA 1000 MCA battery whe
27. 6 23 Using Your E TEC Outboard ENGINESTARTING STOPPING REMOTE CONTROL MODELS Refer to the Routine Inspection Checklist on page 44 for pre launch checks before us ing your Evinrude E TEC outboard You MUST supply water to the engine before attempting to start it Engine damage can oc cur quickly Be sure the water intake screens are below the water surface Connect the clip to the emergency stop key switch Snap the lanyard to a secure place on the operators clothing or life vest not where it might tear away instead of activating the stop switch PUSH KEY IN FOR FULL CHOKE imm dr6819 dr5992a 1 Clip 2 Emergency stop clip key switch 3 Lanyard IMPORTANT In an emergency situation the engine will start and run without the clip con nected to the key switch The operator should always use the clip and lanyard anytime the engine is running Refer to Emergency Stop Key Switch on page 29 A WARNING Always use the safety lanyard when operating your boat to help prevent a runaway boat and reduce the risk of personal injury or death Move the remote control handle to NEU TRAL WARNING If are using a remote control that does not have start in gear prevention the outboard can be started while it is in gear Protect against unexpected boat movement by always starting your outboard in NEUTRAL DO NOT advance the throttle before start up Advanc
28. ANT Be sure that outboard water pressure is not adversely affected by the mounting height of the outboard 58 A WARNING A The outboard must be correctly installed Failure to correctly install the outboard could result in serious injury death or property damage We strongly recommend that your Dealer install your outboard to ensure proper instal lation IMPORTANT Follow all directions carefully The outboard s warranty will not cover prod uct damage or failure that results from incor rect outboard installation WARNING Even if equipped with clamp screws your outboard must be bolted to the boat to prevent it from working off the transom during operation Center the outboard on the transom mounting bracket and tighten clamp screws by hand Use the outboard stern brackets as a tem plate for location and size of holes to drill in the transom Use each stern bracket s mounting holes as a guide to drill TWO 5 16 in 7 9 mm holes through the transom 007040 1 Drilled transom holes INSTALLATION Use the supplied hardware to securely mount the outboard Install the mounting bolts through the stern brackets and transom Install large washers and locknuts onto bolts and tighten securely P d N 4 2 to 18961 1 Large washers 2 Bolts WARNING When replacing bolts screws or other fasteners use Evinrude Johnson parts or parts of equivalent st
29. Add 2 4 Fuel Conditioner following instructions on container Fill fuel tank 2 If winterizing on a trailer remove the pro peller Attach a garden hose to flushing port and turn on the water Refer to Flush ing on page 50 3 Outboard must be in NEUTRAL and re mote control and shift linkage must be in NEUTRAL position at all times during win terization procedure 51 Maintenance LONG TERM STORAGE WINTERIZATION A WARNING A Outboard must be in NEUTRAL before performing winterization Starting out board in gear can cause personal injury If winterizing on a trailer the propeller must be removed before performing procedure Failure to remove propeller can cause personal injury or death Winterization prepares your outboard for long term off season storage During winter ization the engine is fogged and extra oil is used to coat internal engine components Winterization requires a specific process of steps Closely follow the applicable winterization procedure for your outboard Remote control Tiller control Remote control with foot throttle If you are unsure which procedure is right for you contact your Dealer for assistance You can confirm your outboard enters winter ization mode when the engine runs at fast idle and The SystemCheck gauge lights flash if equipped The Command gauge displays winteriza tion message if equipped Remote Control Outboar
30. Control Tiller Models 26 Tiller Handle lt lt 27 Idle Speed 27 Trim Tilt Switch ataca cct ln 27 Shifting and Speed Control Remote Models 28 Fuel Economy nenn 30 Tilting and 31 Manual Models eee eee eee eee n nn nnn 31 Trim Angle Adjustment 32 Shallow Water Drive 33 Power Trim and Tilt Models 34 Trailering iieii ee e ck e aie ihe Roe qn 36 Impact Damage Protection 37 Engine Monitoring 38 Warning System S A F E 38 Diagnostic LEDs hm n 38 Engine Monitor System Optional 39 Engine Overheating 41 Special Operating Conditions 42 Salt Water ina ra wade Ree ee 42 Weedy Water eee eee n n nnn 42 High Altitude 2 secs reni tee nde Eu Gilet a acct 42 Cold and Freezing Weather 43 Shallow Water er a a eee ee E 43 Under TOW a den
31. EVINRUDE gt 25 30 HORSEPOWER R RL TE TEL PL 2009 Model Year 011111 WARNING Read this Operator Guide thoroughly It contains important safety information When operating your boat always have this Operator Guide onboard 25 30 HORSEPOWER RL TE TEL EL PL 2009 Model Year FEATURES AT A GLANCE Easy to Own and Operate Three Year Limited Warranty No Scheduled Dealer Maintenance for Three Years of Normal Recreational Use No Operational Break In Procedure Easy Starts no choking or priming Digital Engine Management Self Flushing Cooling System Long Term Storage Design Simplified Winterization Procedure Digital Diagnostics Low Oil Usage CANbus Capable Durable and Reliable Full Corrosion Protection Evinrude E TEC Lubrication System Auto Calibrated Linkage Robust Heavy Duty Design Posi Lock Latches Extra Capacity Water Pump Iridium Spark Plugs Vibration Isolated Electronics Beltless 15 Amp Charging System Stainless Steel Thermostat Nickel Chrome Faced Piston Rings Micro Finished Connecting Rods Crankshaft Cleaner and Quieter EPA Emissions Compliance European Union Emissions Compliance California 3 Star Emissions Compliance Sealed Fuel System Low Friction Design No powerhead gears belts cams oil scraping rings or mechanical oil pump Full Length Insulated Lower Pans Quiet Signature Sound Air Intake Silencer Idle Air Bypass The following trademarks are the pro
32. En gine Monitoring on page 38 Water intakes obstructed and cooling system not operating correctly Refer to Engine Overheating on page 41 Spark plugs damaged or incorrect Refer to Spark Plugs on page 48 Fuel filter obstructed Fuel system contaminated with water or dirt Oiling system malfunction Engine runs but makes little or Throttle needs to be reset refer to Refer to En no progress gine Starting Tiller Models on page 20 Remote Control Models on page 24 Propeller hub loose slipping Propeller blades bent or missing Propeller shaft bent Propeller debris Warning system activates Refer to Engine Overheating on page 41 55 Maintenance 56 gt TROUBLESHOOTING PRODUCT INFORMATION Product Information INSTALLATION A WARNING A Your outboard must not exceed the maximum horsepower indicated on the boat s capacity plate Such overpower ing can cause loss of control Contact your Dealer or the boat s manufacturer if your boat lacks a capacity plate Boats designed for remote steered out boards might be overpowered by a tiller steered outboard of the maximum rated horsepower Ask your Dealer or boat manufacturer if you are unsure about your boat s suitability Incorrectly matched boat and outboard transom heights can cause boat insta bility and loss of control Refer to Tran som Height Prevent lateral movement and possible outb
33. NG If the bow of the boat plows the water at high speeds the boat may bow steer or spin suddenly possibly ejecting or otherwise seriously injuring occupants 34 gt TILTING AND TRIM C Trim In most operating conditions it is recom mended to trim the outboard to the full down position when accelerating Once on plane trim the outboard up for best performance Over trimming increases engine RPM while decreasing speed The best trim setting is when the highest speed is achieved with the lowest engine RPM Tilt The full tilt is often used to tilt the outboard for clearance when beaching mooring launching 007028 1 Trim range 2 Tilt range Tilt Lock Lever If you intend to leave the outboard tilted for a period of time engage the tilt lock lever 1 Tilt the outboard UP using the trailering tilt Switch 2 Flip the tilt lock lever down 3 Lower the outboard until the tilt lock lever rests solidly on the stern brackets 1 007029 1 Tilt lock lever When you are finished tilting the outboard disengage the tilt lock lever 1 Tilt the outboard UP 2 Flip the tilt lock lever up 3 Lower the outboard to operating position 35 Using Your E TEC Outboard Manual Release Valve If needed the outboard will tilt up or down manually using the manual release valve A WARNING A Keep everyone clear of a tilted out board when backing out the manual release screw T
34. Your E TEC Outboard SHIFTING AND SPEED CONTROL TILLER MODELS IMPORTANT Carefully check the function of all control and engine systems before leaving the dock DO NOT shift the outboard into FORWARD or REVERSE while it is shut OFF Shifting With engine running twist the throttle grip to SHIFT or slower Move the shift lever briskly and decisively to FORWARD or REVERSE 1 Shift lever 2 FORWARD 3 REVERSE WARNING operate the outboard in Do not REVERSE with the tilt run lever in TILT The outboard may tilt out of the water resulting in loss of control IMPORTANT When shifting from FOR WARD to REVERSE or from REVERSE to FORWARD pause at NEUTRAL until the en gine is at idle speed and the boat has slowed Speed Control With the outboard running twist throttle grip Clockwise to decrease speed or Counterclockwise to increase speed 1 Decrease speed 2 Shift 3 Increase speed Tiller is equipped with a throttle friction screw Tighten the screw to reduce the effort re quired to hold a throttle setting 007017 1 Throttle friction screw WARNING Tighten knob only enough to hold throttle at a constant engine speed Overtightening will prevent quick throt tle change in case of emergency 26 TILLER HANDLE ADJUSTMENTS IDLE SPEED CONTROL Tiller models feature Troll Contro which al lows adjusting the idle speed for trolling The default idle speed is 70
35. an result in a loss of performance If a performance prob lem exists see your Dealer FUEL SYSTEM PRIMING If the outboard is run out of fuel refill the fuel tank and squeeze the primer bulb until firm Prime the electric fuel pump by first removing the emergency stop switch clip and then pull ing the rope at least two times This will cause the fuel pump to fill the injectors Replace the emergency stop switch clip and follow the normal starting procedure FUEL ADDITIVES The only fuel additives approved for use in your Evinrude E TEC outboard are Evinrude Johnson 244 Fuel Conditioner Evinrude Johnson Fuel System Cleaner Use of other fuel additives can result in poor performance or engine damage Evinrude Johnson 2 4 Fuel Conditioner will help prevent gum and varnish deposits from forming in fuel system components and will remove moisture from the fuel system It can be used continuously and should be used during any period when the outboard is not being operated on a regular basis Its use will reduce spark plug fouling fuel system icing and fuel system component deterioration Evinrude Johnson Fuel System Cleaner will help keep fuel injectors in optimal operating condition 19 Using Your E TEC Outboard OPERATION SAFETY INFORMATION A DANGER A DO NOT run the engine indoors or with out adequate ventilation or permit exhaust fumes to accumulate in con fined areas Engine exhaust contains carbon m
36. anty Information 65 California Emission Control Warranty Statement 68 Readiness Test 12 522 ou ELE RET a 71 Frequently Asked Questions 72 Change of Address Change of Ownership 73 Confirmation of Receipt 75 ABOUT THIS GUIDE This Operator s Guide is an essential part of your Evinrude E TEC outboard It contains pertinent information which if followed will provide you with a thorough understanding needed for proper operation maintenance care and above all safety Safety is our first priority and it should be yours too It is strongly recommended you read this Guide from cover to cover The more you know and understand about your Evinrude E TEC out board the greater the safety and pleasure you will get from using it Following this rec ommendation will assure the completeness of the information essential to your safety the safety of any passengers and other water us ers This Operators Guide identifies important safety messages Although the mere reading of such informa tion does not eliminate the hazard the under standing and application of the information will promote the correct use of your outboard engine ry Warning Symbols in this Guide How can you reduce the risk of death per sonal injury and possible property damage This Operators Guide answers such ques tions and are contained in boxes highlighted
37. anty does not cover engine failure caused by these conditions Temperature and humidity changes during storage period can cause corrosion of internal engine components Winterization prepares your outboard for long term off season storage During winter ization the engine is fogged and extra oil is used to coat internal engine components Re fer to Long Term Storage Winterization on page 52 Stabilize the fuel supply Fuel remaining in your fuel tank can oxidize resulting in loss of octane and fuel system deposits Use Evinrude Johnson 2 4 Fuel Conditioner to prevent gum and varnish deposits from forming in fuel system components Refer to Fuel Additives on page 19 A WARNING Prevent injury from moving engine components Before starting the out board e Shift it to NEUTRAL Keep hands clothes and hair clear of powerhead Remove the propeller Store fuel tanks in a well ventilated area away from heat and open flame Prevent escape of liquid or vapors which could accidentally ignite Close filler cap vent screws if equipped and be sure any disconnected fuel hoses do not drip SHORT TERM STORAGE Between uses store your outboard in a verti cal position to allow the cooling system to drain completely Preparation Your outboard can be winterized in the water If winterizing in water make sure the water intake screens are completely submerged 1 Stabilize the engine s fuel supply
38. anyard 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 Rein stall a clip as soon as possible IMPORTANT Your emergency stop switch can be effective only when in good working condition At each outing inspect clip and lan yard for cuts breaks or wear Replace worn or damaged parts FOR FULL CHOKE a dr6819 dr5992a 1 Clip 2 Emergency stop key switch 3 Lanyard WARNING Always use the safety lanyard when operating your boat to help prevent a runaway boat and reduce the risk of personal injury or death OPERATION WARNING de 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 occupants forward causing injury Keep the lanyard free from obstruc tions and entanglements At each outing test the system s oper ation With the engine running remove the clip from the switch by pulling the lanyard If the engine does not stop running see your Dealer IMPORTANT Carefully check the function of all control and engine systems before leaving the dock DO NOT shift the engine into FOR WARD or REVERSE while it is shut off If the following
39. directions are not suitable for your boat s control see your Dealer before proceeding Shifting IMPORTANT When shifting from FOR WARD to REVERSE or from REVERSE to FORWARD pause at NEUTRAL until the en gine is at idle speed and the boat has slowed With engine running and control handle in NEUTRAL Side Mount Controls Unlock the control handle by lifting the neutral lock lever on the hand grip With a firm quick motion move the control handle fore or aft un til it engages the forward or reverse gear de tent Binnacle Mount Controls With a firm quick motion move the control handle fore or aft until it engages the forward or reverse gear detent Speed Control After gear engagement move the control handle slowly in the same direction to in crease speed Continue to Fuel Economy on page 30 29 Using Your E TEC Outboard FUEL ECONOMY Fuel economy can vary depending on boat load hull design and throttle setting When boat reaches top speed throttle back from FULL SPEED to a lower throttle setting You will save fuel with a minimal loss of speed Typical Fuel Economy Throttle Range 1 Side mount control 2 Binnacle mount control 30 gt TILTING AND TRIM TILTING AND TRIM MANUAL MODELS IMPORTANT Use the tilt grip to tilt your out board Do not use the tiller handle as a lever Tilt UP Move tilt run lever to TILT position 1 Tilt support bracket Whil
40. ds 1 For side mount controls lift fast idle le ver Start the outboard Outboard runs at slow idle speed Side Mount Control Typical For binnacle or concealed side mount controls press fast idle button and ad vance throttle handle to HALF throttle posi tion Start the outboard Outboard runs at slow idle speed Concealed Side Mount Control Typical 52 2 After outboard runs for about 15 seconds For side mount controls lower fast idle lever For binnacle or concealed side mount controls return throttle handle to IDLE po sition Outboard continues to run at slow idle speed 3 After outboard runs for another 15 sec onds For side mount controls raise fast idle lever again For binnacle or concealed side mount controls advance throttle handle to HALF THROTTLE position Outboard will accelerate to fast idle speed and fog itself 4 Allow outboard to run until it shuts itself OFF automatically less than one minute Winterization is complete when outboard shuts itself off If the outboard DOES NOT shut itself off you may not have used the fast idle le ver or button and the outboard was shifted into gear If the engine exceeds 3000 RPM the out board may have been shifted into gear In either event immediately turn key switch OFF and re start the procedure STORAGE Tiller Control Outboards 1 Advance throttle grip to HALF THROTTLE position
41. e Fuse 17 Rewind Starter Flywheel Guard 12 Air Silencer 18 Rope Pull Start Handle 13 Fuel Connector Continue to Oil and Fuel on page 16 15 Using Your E TEC Outboard OIL AND FUEL OIL REQUIREMENTS e Evinrude Johnson Brand Oils Evinrude Johnson outboard oils are formulat ed to give best engine performance while controlling piston and combustion chamber deposits providing superior lubrication and ensuring maximum spark plug life The following outboard oils are recommend ed for use in your Evinrude E TEC outboard e Evinrude Johnson XD1 00 Evinrude Johnson XD50 or Evinrude Johnson XD30 Evinrude Johnson XD100 Oil Evinrude Johnson XD100 oil is preferred for your Evinrude E TEC outboard This synthetic formula oil provides uncompro mised lubrication and superior performance even in extreme conditions especially in cold temperatures down to 0 F 17 C em Other Oils If Evinrude Johnson brand oils are not avail able you must use an oil that meets NMMA TC WS certification standards IMPORTANT Failure to follow oil specifica tions could void the engine warranty if a lubri cation related failure occurs OILING SYSTEM Always top off your oil tank prior to pro longed usage or long trips New outboards are programmed to use addi tional oil during the first two hours of opera tion above 2000 RPM IMPORTANT When operating in conditions under 40 F 4 C
42. e outboard is tilted leave tilt lever in the TILT position When the tilt run 007022 lever is in the RUN position tilt support 1 TILT positi can release unexpectedly and allow positon outboard to drop creating a risk of Grasp tilt grip on engine cover and tilt out Serious personal injury or loss of con board to the full tilt position trol Tilt DOWN Move tilt run lever to RUN position 1 Tilt grip Tilt support will automatically engage 1 RUN position Grasp tilt grip on engine cover and raise out board slightly Tilt support will automatically disengage Slowly lower outboard to its normal operating position 31 Using Your E TEC Outboard TRIM ANGLE ADJUSTMENT A WARNING A Boat stability and steering torque can vary due to changing water conditions If any adverse conditions occur reduce throttle and or adjust tilt angle to main tain control If you experience boat instability and or high steering torque see your Dealer to correct these condi tions If the bow of the boat plows the water at high speeds the boat may bow steer or spin suddenly possibly ejecting or otherwise seriously injuring occupants The outboard should be perpendicular to the water when the boat is underway at full speed This adjustment can only be deter mined by water testing the boat Set angle ad justment for your normal load Place the outboard in full TILT position
43. eading Evinrude E TEC outboard engine We thank you for your business and wish you many years of enjoyable use Happy Boating AN n f uL Mae 1 yt D err BES Mu 1 Roch Lambert Vice President General Manager Outboard Engines TABLE OF CONTENTS About This Guide 6 Important Safety Messages 7 UsiNG YOUR EVINRUDE E TEC OUTBOARD 11 Component 12 Component Identification Tiller Models 12 Component Identification Remote Control Models 14 Oikand Fuel occiso ario ts 16 Oil Requirements nennen n nn nnn 16 Qiling Systemi 3242 a da il xr reis 16 Filling the Oil 17 Priming the Oil System 17 Fuel 1 lt 1 18 Fuel System Operation 19 Fuel System Priming 19 Fuel Additives gt dol 19 Operation i sr te rhe lou obo Boe dd woo e el 20 Safety Information 20 Engine Starting Stopping Tiller 20 Engine Starting Stopping Remote Control Models 24 Shifting and Speed
44. erform service procedures which are detailed in this Operator s Guide At tempting to perform maintenance or re pair on your outboard if you are not familiar with the correct service and safety procedure could cause personal injury or death Further information can be obtained from your authorized Evinrude Johnson Dealer In many in stances proper tools and training are re quired for certain service or repair procedures Maintain your boat and engine in top condition at all times Adhere to the Maintenance Schedule on page 47 Operate your boat and outboard pru dently and have fun Do not forget that all persons must assist other boaters in case of emergency AN Prevent injury from contact with rotating propeller remove propeller before flush ing or before performing any mainte nance PRODUCT REFERENCES ILLUSTRATIONS AND SPECIFICATIONS BRP reserves the right to make changes at any time without notice to features specifications and model availability and to change any specification or part at any time without incurring any obligation to update older models The information in the Guide is based on the latest specifications 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 Certain features of systems discussed in this Guide might not be found on all models in all marketing areas
45. erged at all times Upon removing your outboard from the water leave it in a vertical position until its cooling system is drained Store the outboard verti cally If the outboard s gearcase is equipped with an integral speedometer pickup all water must be cleared from the hose to prevent gearcase damage Refer to Storage on page 51 CAUTION A Water remaining in the gearcase cool ing system or other components can freeze causing serious engine dam age SPECIAL OPERATING CONDITIONS SHALLOW WATER Gearcase damage can occur if the gearcase is allowed to drag on the waterway bottom Use caution when operating in shallow water IMPORTANT Impact damage is NOT cov ered by the outboard warranty 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 and Keep speed slower than planing speed 43 Using Your E TEC Outboard ROUTINE INSPECTION CHECKLIST Pre Launch Checks Each Use a a Check fuel level Check oil level Check function of steering handle throttle shift and emergency stop circuit and lanyard Check condition of propeller Confirm the cooling system is operational water intake screens and water pump indicator Confirm this Operator s Guide is onboard and readily accessible Periodic Checks a Check condition of anti co
46. facturer BRP US Inc 10101 Science Drive Sturtevant WI 53177 EC Type Certificate Exhaust Emissions Sound Emissions Engine Model s Certificate Number Certificate Number E25RSES E25DRLSES E25DTESES E25DTELSES E25DELSES E25DPLSES ESORSES E30DRLSES E30DTELSES E30DELSES E30DPLSEW E30DPLSES 1 the undersigned hereby declare that the product specified above conforms to the above Di rective s and Standard s uel Fernando Garcia Director of Regulatory Affairs and Public Relations USING YOUR Evinrude E TEC OUTBOARD Using Your E TEC Outboard COMPONENT IDENTIFICATION TILLER MODELS ar 15 3 2 2 8 9 10 11 y 3 4 ye X 5 Go 006994 Item Description Item Description 1 Air Inlet Tilt Handle 9 Clip and Lanyard Assembly 2 Engine Cover Latch 10 Start Button Electric Start Models Only 3 Water Pump Indicator Flushing Port 11 Throttle Friction Adjustment 4 Anti Corrosion Anodes 12 Steering Handle Twist Grip Throttle 5 Trim Tab 13 Touch Troll Idle Speed Adjustment 6 Water Intake Screens 14 Shift Lever 7 Steering Friction Adjustment 15 Rope Pull Start Handle 8 Stop Button Emergency Stop Switch Port Starboard 25 gt COMPONENT IDENTIFICATION
47. ge the oiling system must be primed before reusing the outboard Refer to Prim ing the Oil System on page 17 If the outboard is laid down for transportation or storage it should be laid on its back If the engine is transported laying on its side protect the motor covers by laying it on an old blanket or other soft cloth 007043 1 Transport outboard resting on bumpers FLUSHING If desired the outboard can be flushed after each use on a trailer or at dockside while it is vertical 1 Place the outboard in an area with good drainage 2 Connect garden hose to flushing port 3 Turn on the water It is not necessary to run the engine for a good flushing 4 Leave the outboard in vertical position long enough to completely drain the power head IMPORTANT If you cannot store the out board in the recommended vertical position be sure the cooling system is drained com pletely Never place the gearcase higher than the powerhead Any water remaining in the exhaust passages can run into the cylinders and cause serious damage 50 STORAGE STORAGE DANGER A DO NOT run the engine indoors or with out adequate ventilation or permit exhaust fumes to accumulate in con fined areas Engine exhaust contains carbon monoxide which if inhaled can cause serious brain damage or death You must protect against natural environmen tal conditions that can be damaging to an out board Your warr
48. he boat ramp or in your driveway We are proud of how easy we have made it for you to own this outboard Hopefully it means you will be spending more time on the water each year POWER amp PERFORMANCE Evinrude E TEC outboards have been engineered to outperform anything on the wa ter acceleration top end speed any size any horsepower across the line And for your buddies who own a four stroke Well they cannot touch our power to weight ratio And you can tell them that no four stroke comes close to the pure power and torque of an Evinrude E TEC outboard DURABILITY QUALITY RELIABILITY Fewer parts Fewer problems Every Evinrude E TEC outboard component is tested and retested for maximum performance and longer life Parts are bigger and stronger to work harder and last longer CLEAN amp QUIET You do not even have to think about emissions anywhere in the country anywhere in the world Evinrude E TEC outboards are the only outboard marine engines to have received a Clean Air Excellence Award from the United States Environmental Protection Agency EPA The entire Evinrude E TEC line meets or exceeds all worldwide emission standards We have even got 3 Star certification from the tough est of the tough the California Air Resources Board And thanks to the sophisticated acoustically tuned air intake and exhaust systems you will not be filling the air with a lot of noise either BRP is proud you have purchased this technology l
49. he outboard could drop suddenly and forcibly Be sure to tighten the manual release screw after manually repositioning the outboard Tightening the screw also reactivates the outboard s impact protection and reverse thrust capability 1 Turn the manual release screw counter clockwise slowly about 3 1 2 turns until it lightly contacts its retaining ring 2 Reposition the outboard 3 Tighten the manual release valve to hold the outboard in its new position 1 Manual release screw TRAILERING Trailer your boat with the outboard in a verti cal position If your trailer does not provide ad equate road clearance support the outboard with an accessory trailering bracket IMPORTANT The outboard must be re strained when trailering Bouncing during transport may damage the outboard and the boat s transom IMPORTANT Use of the tilt support bracket or tilt lock lever when trailering may cause damage to the outboard Continue to Impact Damage Protection on page 37 36 IMPACT DAMAGE PROTECTION Your outboard has a shock absorption system designed to help withstand damage from im pact with underwater objects at low to moder ate speeds High speed impacts with rigid underwater objects like pilings or boulders can be beyond the capability of the absorption system Such impacts can result in serious damage to your outboard and injury to boat occupants from the outboard or its parts en teri
50. here are some basic rules that should be ob served and followed by any boater Some rules may be new to you and oth ers may be common sense or obvious irrespective take them seriously AA Be sure at least one of your passengers knows how to handle your boat in case of an emergency AA All passengers should know the location of emergency equipment and how to use it Know the marine traffic laws and obey them Always comply with the regulations that apply to your boat Remember gasoline fumes are flamma ble and explosive Always adhere to the fueling procedure contained in this Op erator s Guide and those given to you by the fueling station Always verify fuel lev el before use and during the ride Apply the principle of 1 3 fuel to destination 1 3 back and 1 3 reserve fuel supply Do not carry spare fuel or flammable liquids in any storage or engine compartments Whenever running the engine assure there is proper ventilation to avoid the accumulation of carbon monoxide CO which is odorless colorless and taste less and can lead to unconsciousness brain damage or death if inhaled in suf ficient concentrations CO accumulation can occur while docked anchored or underway 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 op erating conditions and other boats Avoid exhaust fumes from your engine or other boats prov
51. ide proper ventila tion shut off your engine when not needed and be aware of the risk of backdrafting and conditions that create CO accumulation In high concentra tions CO can be fatal within minutes Lower concentrations are just as lethal over long periods of time Avoid standing up or shifting weight sud denly in light weight boats Keep your passengers seated in seats The boat s bow gunwale transom and seat backs are not intended for use as seats Insist on the use of personal floatation devices approved by the U S Coast Guard by all passengers when boating conditions are hazardous and by chil dren and nonswimmers at all times Proceed with caution and at very low speed in shallow water Grounding or abrupt stops may result in personal inju ry or property damage Also be alert for debris and objects in the water A Be familiar with the waters you are oper ating in The gearcase of this outboard extends below the water surface and could potentially come in contact with underwater obstructions Contact with underwater obstructions may result in loss of control and personal injury AA Respect no wake zones rights of other water users and the environment As the 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 overboard A Do not operate your boat if you are un der the influence of drugs or alcohol As High
52. ide will build good judgment when boating Always be alert and careful a good foundation for safety 71 Product Information FREQUENTLY ASKED QUESTIONS No dealer scheduled maintenance for the first three years of normal recreational use Really Yes BRP knows you want to spend your time out on the water not servicing your Evinrude E TEC outboard There are no valves to adjust belts to service chains to replace or oil to change We do recommend pre launch inspections of your outboard at each use and at reg ular intervals Salt water applications require minimal additional inspections and lubrication What fuel octane is recommended for my Evinrude E TEC outboard Evinrude E TEC outboards require a minimum octane of 87 U S Use of higher octane fu els is not harmful but also not necessary What kind of oil does my Evinrude E TEC outboard require Any TC W3RL oil may be used The outboard can be programmed by your Dealer to run on Evinrude Johnson XD100 oil for lower oil consumption and reduced operating cost Refer to Removing the Engine Cover on page 17 see also Oil Requirements on page 16 Do I need to mix oil into my fuel No Evinrude E TEC outboards do not require any mixing of oil and fuel Where should I take my Evinrude E TEC outboard for service For repairs covered under warranty you must take your Evinrude E TEC outboard to an au thorized dealer BRP approved dealers and distributors have rece
53. ing the throttle overrides the electron ic idle control system If the outboard is started with the throttle ad vanced the outboard will be in a safety mode It will not respond to throttle until the throttle is returned to slowest IDLE position 24 Turn the key switch fully clockwise to the START position Crank the engine no longer than 20 seconds 007015 IMPORTANT The starter motor can be dam aged if operated continuously for more than 20 seconds Upon start up release the key If the engine did not start release the key mo mentarily then try again Each time the key switch is turned from OFF to ON the warning system will self test Refer to Engine Monitoring on page 38 If the warning system fails to self test during start up see your Dealer If your outboard does not react normally to this starting procedure or if it fails to start re fer to Troubleshooting on page 55 gt OPERATION After Engine Starts 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 indicator is not visible stop the engine Refer to Engine Overheating on page 41 007016 ENGINE STOPPING Move control handle to NEUTRAL Turn key switch counterclockwise to the OFF position Remove the key when the boat will be unattended Continue to Shifting and Speed Control Remote Models on page 28 25 Using
54. ircuit board The LEDs provide quick reference to the sta tus of several outboard systems The LEDs can be used to identify specific warning functions of S A F E mode activation without ending a day on the water IMPORTANT LED 1 is closest to the center of the EMM To view the LEDs the engine cover must be removed Refer to Removing the Engine Cover on page 17 The engine cover and flywheel guard are machinery guards Use caution when the engine is running WARNING DO NOT wear jewelry or loose clothing Keep hair hands and clothing away from rotating parts 1 EMM 2 LEDs 3 LED 1 The LEDs identify system functions in two modes Start Mode and Running Mode As the outboard is being started all four LEDs should light and then go OFF in sequence When the outboard is running all LEDs should be OFF 38 Running Mode If any LED is ON while the outboard is run ning it may indicate a system problem Refer to EMM Diagnostics Label LED 1 2 or 3 ON return to port as soon as practical to avoid operational difficulties See your Dealer LED 4 ON indicates EMM temp ABOVE range refer to Engine Overheating on page 41 Engine temp ABOVE range refer to En gine Overheating on page 41 Low No Oil condition Refer to Filling the Oil Tank and Priming the Oil System on page 17 Do the engine in low oil con dition If run in excess of
55. ived the necessary train ing to properly service your outboard Contact BRP for an authorized Evinrude E TEC dealer near you order replacement parts and accessories for my Evinrude E TEC outboard Yes When replacement parts are required use Evinrude Johnson Genuine Parts or parts with equivalent characteristics including type strength and material Using substandard parts could result in injury or product malfunction Your dealer can order the parts and ac cessories you desire Do need to complete any paperwork when I move or sell my Evinrude E TEC outboard Yes In order to maintain contact with you or the new Evinrude E TEC owner BRP requests you complete the form outlining Change of Address Change of Ownership on page 73 This will ensure you or the new owner is made aware of any product announcements and keep the warranty coverage up to date What do need to do before storing my Evinrude E TEC outboard for the winter Winterization is minimal Refer to Storage on page 51 for step by step instructions to store your Evinrude E TEC outboard for the off season 72 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 form provided on this page This notification is necessary for your own safety even after expiration of the original warranty since BRP will be in a position to contact you if correction to your outb
56. le while you Observe running quality If poor refer to Troubleshooting on page 55 or see your Dealer Confirm water pump operation Water must flow from the water pump indicator in a steady stream If it does not shut off the outboard and investigate Refer to Engine Overheat ing on page 41 Stop the outboard and check the fuel system for leaks WARNING A Failure to check for fuel leakage could allow a leak to go undetected resulting in fire or explosion 4 gt TROUBLESHOOTING TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE Starter motor will not operate Shift handle not in NEUTRAL Fuse blown Engine will not start Fuel system not primed after running out of fuel Refer to Fuel System Priming on page 19 Not following starting instructions Refer to En gine Starting Tiller Models on page 20 Remote Control Models on page 24 Fuel tank empty Fuel hose kinked Fuel system contaminated with water or dirt Fuel filter obstructed S A F E protection mode activated Refer to En gine Monitoring on page 38 e Spark plugs improperly gapped carboned burned or wet Spark plugs incorrect Refer to Spark Plugs on page 48 Fuse blown Engine will not idle properly Debris on propeller Spark plugs damaged or incorrect Refer to Spark Plugs on page 48 Fuel system contaminated with water or dirt Engine loses power S A F E protection mode activated Refer to
57. mmended on all boats Connect the clip to the emergency stop switch Snap the lanyard to a secure place on the operators clothing or life vest not where it might tear away instead of activating the stop switch Disconnecting 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 007013 1 Clip 2 Emergency stop clip switch WARNING Always use the safety lanyard when operating your boat to help prevent a runaway boat and reduce the risk of personal injury or death gt OPERATION An extra clip is provided on the tiller handle If the operator is thrown from the boat another person can insert the extra clip in the stop Switch and start the outboard 007014 1 Extra clip A WARNING A Avoid knocking or pulling the clip off the stop switch during normal boating The resulting unexpected loss of for ward motion can throw occupants for ward causing injury Keep the lanyard free from obstruc tions and entanglements At each outing test the system s oper ation With the engine running remove the clip from the switch by pulling the lanyard If the engine does not stop running see your Dealer Continue to Shifting and Speed Control Tiller Models on page 2
58. n 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 identifies engines that meet the Air Resources Board s Personal Watercraft and Out board marine engine 2009 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exhaust emission standards Engines meeting these standards have 65 lower 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 9096 lower emission than One Star Low Emission engines For more information Cleaner Watercraft Get the Facts 1 800 END SMOG www arb ca gov 68 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR EMISSION CONTROL WARRANTY RIGHTS AND OBLIGATION The California Air Resources Board and Bombardier Recrea
59. n haz ard 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 Follow these instructions to ensure safety when handing fuel Always turn off the engine before fuel ing 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 cellular phones in the vicinity of a fuel leak or while fueling Always work in a well ventilated area Minimum Octane Your outboard is certified to operate on un leaded automotive gasoline with an octane rating equal to or higher than 87 R M 2 AKI Inside the U S 90 RON Outside the U S Using unleaded gasoline that contains methyl tertiary butyl ether MTBE is acceptable ONLY if the MTBE content does not exceed 1596 by volume Alcohol Fuels Your outboard has been designed to operate using the specified fuels however be aware of the following The boat s fuel system may have different requirements regarding the use of alcohol fuels Refer to the boat s owner guide Alcohol attracts and holds moistu
60. n operating in temperatures below 32 F 0 C Use Evinrude Johnson HPF Pro Gearcase Lubricant for high performance outboards and commercial applications Evinrude Johnson HPF Pro Gearcase Lubricant delivers exceptional durability and reliability and promotes long gearcase life in marine use 64 PRODUCT WARRANTY INFORMATION PRODUCT WARRANTY INFORMATION BOMBARDIER RECREATIONAL PRODUCTS LIMITED WARRANTY FOR 2009 EVINRUDE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA 1 SCOPE OF THE LIMITED WARRANTY Bombardier Recreational Products BRP warrants its 2009 Evinrude outboard engines sold by au thorized 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 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 propel ler bushings and spark plugs Damage caused by improper or lack of installation maintenance winterization and or storage failure to follow the procedures and recommendations in the Operator s Guide Damage resulti
61. nd if made shall not be en forceable against BRP BRP reserves the right to modify this warranty at any time being understood that such modiicaton will not alter the warranty conditions applicable to the Products sold while this warranty is in effect 65 Product Information 4 WARRANTY COVERAGE PERIOD This limited warranty will be in effect from the date of delivery to the first retail 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 hun dred 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 during the warranty period it is installed on a boat that has commercial tags or is licensed for commercial use In cases where the delivery date is not established to BRP s satisfaction the date of sale will be used to determine the warranty start date 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
62. ng from removal of parts improper repairs service maintenance or modification or use of parts or accessories not manufactured or approved by BRP 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 A Met in a manner inconsistent with the recommended operation described in the Operator s uide 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 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 o 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 3 LIMITATIONS OF LIABILITY
63. ng the boat Occupants can also be eject ed or injured by falling against portions of the boat as a result of rapid deceleration following impacts When boating in unfamiliar shallow or de bris laden waters seek information on safe boating areas and navigation hazards from a reliable local source Reduce your speed and keep a sharp lookout IMPORTANT Impact damage is NOT cov ered by the outboard warranty 007021 gt TILTING AND TRIM The outboard 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 outboard can be seriously damaged dr4412 If you hit any object STOP immediately and examine the out board for loosening of attaching hardware INSPECT for damage to swivel and stern brackets and steering components EXAMINE 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 compo nents A WARNING Failure to inspect for damage after an accident or striking an object could result in sudden unexpected compo nent failure loss of boat control and personal injury Unrepaired damage could reduce your boat and outboard s ability to resist future impacts 37 Using Your E TEC Outboard ENGINE MONITORING WARNING SYSTEM S A F
64. o return to port See your Dealer 40 ENGINE OVERHEATING IMPORTANT Do not run your outboard even for a brief start up without supplying water to it Refer to Flushing on page 50 While boating the outboard s water intakes must stay completely submerged and unob structed Observe proper transom height and tilt angle While the outboard is running the outboard s water pump indicator must dis charge a steady stream of water Check the indicator often especially when operating in weeds muddy and debris laden water and at extreme trim angles 007031 1 Water intake screens 2 Water pump indicator If the engine overheats the S A F E Speed Adjusting Failsafe Electronics mode will im mediately limit the engine s speed to 1200 RPM If the engine was running faster than 1200 RPM when the S A F E mode activat ed it will shake noticeably The protection system must be RESET before the engine will operate at speeds over 1200 RPM Under certain conditions the EMM will shut off the engine gt ENGINE MONITORING em To RESET the system The engine must be shut off and the cooling temperature restored IF the S A F E mode activates and the stream from the water pump indicator be comes intermittent or stops reduce speed to idle and 1 Shift to NEUTRAL 2 SHUT OFF the engine 3 Tilt the outboard up 4 Clean the intake screens of any blockage 5 Clean the water pump indicator of an
65. oard is required Outside the U S and Canada this card should be sent to the Bombardier Recreational Products divi sion where the outboard was registered Please contact your Dealer or Distributor Change of Address Change of Ownership Model number Serial Number Old Address Previous Owner Last name First name Address City State Zip code Country Phone number Signature Date New Address New Owner Last name First name Address City State Zip code Country Phone number Signature Date Dealer Information Dealer name Dealer number Phone number Contact name In the U S or Canada mail completed form to BRP US Inc Outboard Engines Division After Sales Support P O Box 597 Sturtevant WI 53177 73 CONFIRMATION OF RECEIPT Your Dealer Name Address Upon delivery of your new Evinrude Johnson outboard complete and sign the form below Your Dealer will take receipt of the form for their records E Receipt Name Address Owner of Model No
66. oard loss by using the mounting hardware supplied or hardware of suffi cient size strength and quality Refer to Installing the Outboard on page 58 A mounting surface that is damaged or too thin to support your outboard while underway might fail during operation causing a loss of control Be sure the boat s transom or mounting bracket is structurally sound and between 1 5 8 in 41 mm and 2 3 4 in 70 mm in thickness IMPORTANT Use an appropriate hoist to lift the engine Refer to Specifications on page 64 for engine weight INSTALLING THE OUTBOARD TRANSOM HEIGHT Make sure the transom height matches the length of the outboard to be installed A 19 to 21 in 48 3 to 53 3 cm transom height uses a 20 in 50 8 cm shaft out board The shaft length of the outboard being in stalled should come close to matching the transom height of the boat Determine transom height by measuring from the top edge of the transom along the center line 1 Centerline 2 Antiventilation plate 3 Transom Height Boat performance depends on outboard mounting height Generally the anti ventilation plate of the gearcase should align with the bottom of the hull Conventional V hulls often perform well with the anti ventilation plate approximately 1 in 25 mm above the bottom of the hull Test outboard and boat performance at differ ent heights until the best performance is achieved IMPORT
67. 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 BRP 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 Intake Manifold D Wiring Harness 5 Oil System 2 Exhaust System A Oil Injector A Inner Exhaust Housing B Oil Lines Fittings and Clamps B Adaptor Exhaust Manifold C Megaphone Inner Exhaust 6 Sensors A Air Temperature Sensor 3 Fuel System B Crank Position Sensor A Fuel Lift Pump C Throttle Position Sensor B Fuel Supply Pump D Water Temperature Sensor C Fuel Injectors E Thermostat D Vapor Separator E Fuel Lines Fittings and Clamps 7 Gaskets A All Emission Component Gaskets The emission warranty covers damage to other engine components that is caused by the failure of a war ranted part 69 Product Information The BRP Operator s Guide provided contains written instructions for the proper maintenance and use of your outboard All emission warranty parts are warranted by BRP for the entire warranty period of the
68. oes not react normally to this starting procedure or if it fails to start re fer to Troubleshooting on page 55 TILLER ELECTRIC MODELS Start Button While seated press the start button If equipped with a key switch it must be in the ON position Crank the engine no longer than 20 seconds 007010 1 Start button IMPORTANT The starter motor can be dam aged if operated continuously for more than 20 seconds 21 Using Your E TEC Outboard Upon start up release the button If the engine did not start release the button momentarily then try again IMPORTANT Engine will not start if outboard is in gear if lanyard is not in place If your outboard does not react normally to this starting procedure or if it fails to start re fer to Troubleshooting on page 55 After Engine Starts 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 indicator is not visible stop the engine Refer to Engine Overheating on page 41 007011 ENGINE STOPPING Twist the throttle grip to SHIFT position or slower Move shift lever to NEUTRAL Press the STOP button until the outboard stops running If equipped close the vent screw on the fuel tank s filler cap 007012 1 STOP button 22 Emergency Stop Switch The emergency stop switch is on the steering handle Use of the emergency stop feature is highly reco
69. on fase a E esos a mox CR een ae tala mage 43 Routine Inspection Checklist 44 MAINTENANCE 45 Engine Emissions Information 46 Maintenance Schedule 47 Spark PLUGS ge neta ee tal as 48 PUSC pote cad a NE a acl ee RARE ae a 48 Scratch Repair osos iere da ole RES MIR eee a 49 Hull Finish cece eerie wa nen as 49 Outboard External Finish 0 0 cece eee eee 49 Submerged Outboard ooooocooccoc nennen nennen nn nn 49 Transporting the Outboard 50 Flushlng rr a een a 50 Slorage ci due S ue Dine Bee son dees ww his Peele 51 Short Term Storage 51 Long Term Storage Winterization 52 Pre Season Check 54 Troubleshooting 55 PRODUCT INFORMATION 57 Installation cocidos E as 58 Installing the 58 Transom Height cece ee eee eee 58 Battery Electric Start Models 60 Propeller un xy crow el ae ed t exci je laca anal ac dva Ge cakes 61 Adjustments 63 Specifications 64 Product Warr
70. onoxide 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 WARNING The engine cover is a machinery guard DO NOT operate your outboard with the cover off unless you are performing maintenance or emergency starting and then be careful to keep hands hair and clothing clear of all moving parts Contact with moving parts could cause injury Always shut off the outboard when your boat is near people who are in the water A Be familiar with the waters you are oper ating in The gearcase of this outboard extends below the water surface and could potentially come in contact with underwater obstructions Contact with underwater obstructions may result in loss of control and personal injury ENGINE STARTING STOPPING TILLER MODELS Refer to the Routine Inspection Checklist on page 44 for pre launch checks before us ing your Evinrude E TEC outboard You MUST supply water to the engine before attempting to start it Engine damage can oc cur quickly Be sure the water intake screens are below the water su
71. ot to modify the outboard in any manner that would alter the horsepower or al low emission levels to exceed their predeter mined factory specifications Exceptions include manufacturer s prescribed changes such as altitude adjustments for ex ample Owner Responsibility The owner operator is required to have en gine 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 al low emissions levels to exceed their predeter mined factory specifications Tampering with the fuel system to change horsepower or modify emission levels beyond factory settings or specifications will void the product warranty EPA Emission Regulations All new 1999 and more recent Evinrude out boards manufactured by BRP are certified to the EPA as conforming to the requirements of the regulations for the control of air pollution from new watercraft marine spark ignition en gines This certification is contingent on cer tain adjustments being set to factory standards For this reason the factory proce dure for servicing the product must be strictly followed and whenever practicable returned 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 reg ulations pertaining to the EPA requirements on exhaus
72. perty of Bombardier Recreational Products Inc or its affiliates Evinrude Evinrude E TEC Evinrude Johnson Genuine Parts Evinrude Johnson XD100 Evinrude Johnson XD50 2007 BRP US Inc All rights reserved Evinrude Johnson XD30 I Command BRP Logo S A F EM 2447 Fuel Conditioner SystemCheck HPF XR Gearcase Lubricant Triple Guard Grease HPF Pro Gearcase Lubricant Dear Boating Enthusiast Congratulations on your purchase of our industry leading Evinrude E TEC outboard Your purchase comes with the full commitment and backing of the BRP Outboard Engine team We know your Evinrude E TEC outboard will provide you with years of reliable use and we hope you will enjoy using it as much as we enjoyed designing and building this innovative product You can be proud you purchased an Evinrude E TEC outboard with the following benefits EASY TO OWN amp OPERATE With your Evinrude E TEC outboard there is no more time wasted in the shop In fact you only have to bring your Evinrude E TEC outboard in for dealer scheduled main tenance every 300 hours or every three years of normal recreational use That s three trips to the shop in nine years four trips in twelve years five trips in fifteen years you get the picture And if that is not enough with your new outboard you will have zero oil changes absolutely no break in period and a simple winterization process that can be done at t
73. r responsibility for any additional charges due to local practices and conditions such as but not limited to freight insurance taxes license fees import duties and any and all other financial charges including those levied by governments states territories and their respective agencies BRP reserves the right to improve modify or change Products from time to time without assuming any obligation to modify Products previously manufactured 66 PRODUCT WARRANTY INFORMATION 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 BRP or Dealer and gives the name and address of the new owner 9 CONSUMER ASSISTANCE In the event of a controversy or dispute in connection with this BRP limited warranty BRP recommends that you first try to resolve the issue at the dealership level by discussing the issue with Dealer s service manager or owner If further assistance is required please contact BRP US Inc Outboard Engines Division After Sales Support P O Box 597 Sturtevant WI 53177 1 847 689 7090 n IL 60085 1 847 689 7090 BOMBARDIER RECREATIONAL PRODUCTS LIMITED WARRANTY FOR 2009 EVINRUDE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA For a copy of the Limited Warranty see your Bombardier Recreational Products
74. r arcing and causing an explosion If the battery mounting sys tem does not cover the connections install covers Check often to see that connections stay clean and tight 60 IMPORTANT DO NOT use wing nuts on bat tery connections even if they came with the battery Wing nuts can loosen and cause er rant warning signals or electrical system dam age Service Before servicing the battery or the outboard remove both battery cables from the battery battery negative 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 A WARNING Battery electrolyte is acidic handle with care If electrolyte contacts any part of the body immediately flush with water and seek medical attention Do not use a booster battery and jumper cables to start the outboard Gasoline fumes can cause explosion and fire resulting in property damage gt INSTALLATION PROPELLER Propeller Selection A WARNING A Be alert of people in the water Always shift the outboard to NEUTRAL and shut off the engine immediately when your boat is in an area where there might be people in the water Serious injury or death can result from contact ing a rotating propeller or moving boat and outboard personal injury or death To select
75. re that can cause corrosion of metallic parts in the fuel System Alcohol blended fuel may cause engine per formance problems Using alcohol extended fuels is acceptable ONLY if the alcohol content does not exceed 10 ethanol by volume or 5 methanol with 5 cosolvents by volume IMPORTANT Always use fresh gasoline Gasoline will oxidize the result is loss of oc tane volatile compounds and the production of gum and varnish deposits which can de grade the fuel system 18 FUEL SYSTEM OPERATION Connecting the Fuel Hose Connect the fuel hose to the connector If equipped open vent screw on fuel tank s fill er cap Squeeze fuel primer bulb outlet end up until firm 007004 1 Fuel fitting A WARNING A Store fuel tanks in a well ventilated area away from heat and open flame Prevent escape of liquid or vapors which could accidentally ignite Close the filler cap vent screw if equipped Be sure the disconnected fuel hose does not drip OIL AND FUEL IMPORTANT Fuel distribution hoses in the boat must deliver fuel at the rate of flow need ed by the outboard Minimum inside diameter of fuel hoses must be 5 16 in 7 9 mm Fuel systems with built in tanks particularly those that include antisiphon valves and filter primer units may have restrictions not allow ing the engine fuel pump to deliver sufficient fuel under all conditions This c
76. 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 op portunity to repair the defect The expenses of transporting Product to and from Dealer for warranty ser vice are to be borne by the owner If the Product has not previously been registered the owner may also be required to present proof of pur chase 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 BRP 7 WHAT BRP WILL DO BRP 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 BRP Such repair or replacement of parts will be done without charge for parts and labor at any authorized Dealer BRP s responsibility is limited to making the required repairs or replacements of parts with new or BRP 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 bea
77. rength and material A 59 Product Information BATTERY ELECTRIC START MODELS Requirements 12 volt heavy duty designated for marine use Vented refillable or maintenance free and Rated according to the minimum require ments in Specifications on page 64 Deep cycle batteries are suitable IF they meet or exceed the minimum CCA require ments Ask your Dealer about your outboard s re quirements before installing longer battery ca bles or a battery switch Installation Read and understand the safety information supplied with your battery BEFORE you begin installation IMPORTANT Make sure all components are clean and free of corrosion Connect the RED cable to the positive battery post first Connect the BLACK ca ble to the negative battery post last If you have marine battery posts install each main cable on the clamp adapter with a star washer below it Install all wires from acces Sories on the threaded portion of the post 1 Main cable 2 Starwasher 3 Accessory wires If you have automotive battery posts place a starwasher on the clamp adapter first then the main cable and then the wires from the accessories 1 Main cable 2 Starwasher 3 Accessory wires Tighten all connections securely and coat the installation with Triple Guard grease A WARNING Keep the battery connections clean tight and insulated to prevent their shorting o
78. rface Connect the clip to the emergency stop switch Snap the lanyard to a secure place on the operators clothing or life vest not where it might tear away instead of activating the stop switch 007005 1 Clip 2 Emergency stop clip switch 3 Lanyard WARNING A Always use the safety lanyard when Operating your boat to help prevent a runaway boat and reduce the risk of personal injury or death 20 Move the shift lever to NEUTRAL Refer to Shifting and Speed Control Tiller Models on page 26 1 NEUTRAL WARNING Always shift to NEUTRAL before start ing the outboard to prevent sudden boat movement which can cause injury Twist throttle grip to slowest idle position 007007 007008 1 Slowest idle position C DO NOT advance the throttle before start up Advancing the throttle overrides the electron ic idle control system If the outboard is started with the throttle ad vanced the outboard will be in a safety mode It will not respond to throttle until the throttle twist grip is returned to slowest IDLE position gt OPERATION TILLER ROPE MODELS While seated grasp the starter handle and pull slowly until the starter engages then pull hard Repeat if needed until outboard starts To prevent damage to starter assembly allow starter cord to rewind before releasing starter handle 007009 1 Starter handle 2 NEUTRAL If your outboard d
79. rrosion anodes annually or every 100 hours Check for debris on propeller shaft requires propeller removal Clean and wax upper and lower engine covers annually or every 100 hours In salt water applications check lubrication points and corrosion protection Use Evinrude anti corrosion spray or Evinrude 6 in 1 multi purpose lubricant annually or 100 hours 44 MAINTENANCE Maintenance ENGINE EMISSIONS INFORMATION Maintenance replacement or repair of the emission control devices and systems may be performed by any marine SI spark ignition engine repair establishments or individual Manufacturer s Responsibility Beginning with 1999 model year outboards manufacturers of marine engines must deter mine the exhaust emission levels for each en gine horsepower family and certify these outboards with the United States of America Environmental Protection Agency EPA An emissions control information label showing emission levels and engine specifications must be placed on each outboard at the time of manufacture Dealer s Responsibility When performing service on all 1999 and more recent Evinrude outboards that carry an emissions control information label adjust ments must be kept within published factory specifications Replacement or repair of any emission relat ed component must be executed in a manner that maintains emission levels within the pre scribed certification standards Dealers are n
80. rs in the event you run out of oil Refill the oil tank immediately Refer to Filling the Oil Tank on page 17 WATER TEMP or HOT Symptom The engine is overheating Result EMM will activate S A F E mode A continuous light with S A F E mode The EMM has identified an over heating condition Check the water pump indicator for a steady stream of wa ter Shut OFF the engine Clear the water intake screens of any debris If the Action overheat condition still exists the engine will operate in get home mode Re turn to harbor immediately A flashing light The EMM has identified a damaging overheating condi tion The engine will not operate Allow the engine to cool for 20 minutes and return to harbor immediately See your Dealer CHECK ENGINE or CHK ENG Symptom An abnormal operating condition Result EMM will activate check engine light or display warning A continuous light with S A F E mode The EMM has identified a problem with the outboard Seek assistance and or return to harbor See your Dealer Action Acontinuous light without S A F E mode The EMM has identified a prob lem that should be addressed by your Dealer as soon as practical to avoid operational difficulties WARNING If the outboard shuts OFF and the CHECK ENGINE or CHK ENG light is flash ing the outboard cannot be restarted A hazardous fuel condition may exist Seek assistance t
81. t emissions for marine products For more detailed information on this subject you may contact the following locations VIA U S POSTAL SERVICE Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group 6403J 401 M St NW Washington DC 20460 VIA EXPRESS or COURIER MAIL Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group 6403J 501 3rd St NW Washington DC 20001 EPA INTERNET WEB SITE www epa gov 46 gt MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE Routine inspection and maintenance is nec essary to prolong outboard life The following chart provides guidelines for inspection and maintenance to be performed by an autho rized Dealer IMPORTANT Outboards used in rental com mercial or other high hour applications re quire more frequent inspections and maintenance Adjust schedule for operating and environmental conditions Engine Every 300 Care Hours or Description Product Three Years Electrical and ignition wires inspect for wear or chafing Engine to transom mounting hardware re torque 40 ft Ibs v Fasteners inspect any loosened components 4 Fuel and oil system components inspect and repair leaks 2 v Fuel filter replace Y Gearcase lubricant replace A Y Grease fittings lubricate 9 C Y Power trim tilt system and fluid level inspect B Y Propeller shaft splines
82. the correct propeller for your boating application your boat and outboard MUST be water tested See your Dealer for assistance 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 Specifications on page 64 WARNING When servicing the propeller always shift the outboard to NEUTRAL posi tion turn the key switch OFF and twist and remove all spark plug wires so the outboard cannot be started acciden tally IMPORTANT Apply Triple Guard grease to the entire propeller shaft before installing the propeller At least annually remove the pro peller and check for debris Clean the shaft and regrease it before reinstalling a propeller 61 Product Information Installation Slide thrust washer onto shaft with fishline trap groove facing forward 007054 Slide propeller onto shaft engaging the splines and seating it on the thrust bushing Slide spacer onto the shaft and engage the propeller shaft splines 007055 Wedge a block of wood between the propeller blade and the anti ventilation plate Install propeller nut and tighten to a torque of 120 144 in lbs 13 6 16 3 Nm If cotter pin holes in the propeller nut and pro peller shaft are not aligned tighten the nut un til they are in line Do not loosen Install new cotter pin and bend ends
83. tically disengage Slowly lower outboard to its normal operating position 33 Using Your E TEC Outboard POWER TRIM AND TILT MODELS 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 Correct fluid level must be maintained to ensure operation of the impact protection on this unit 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 or otherwise seriously injuring occupants Some boat outboard propeller combinations may encounter boat instability and or high steering torque when operated at high speed at or near the outboard s trim range limits 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 instabil ity and or high steering torque see your Dealer to correct these conditions Some boats plow or are difficult to plane trim limiter rod to limit the travel of the power when operated in the trim s lowest position If trim If your outboard is not equipped with this your boat handles unsuitably when trimmed rod purchase one from your Dealer fully bow down set the angle adjusting rod or WARNI
84. tional Products BRP are pleased to ex plain the emission control system warranty on your 2009 Evinrude E TEC outboard In California new out board engines must be designed built and equipped to meet the State s stringent anti smog standards BRP must warrant the emission control system on your outboard for the periods of time listed below pro vided 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 BRP will repair your outboard at no cost to you including diagnosis parts and labor provided that such work is performed by an authorized BRP dealer Manufacturer s Limited Warranty Coverage This emission limited warranty covers Evinrude outboards certified and produced by BRP for sale in Cal ifornia that are originally sold in California to a California resident or subsequently warranty registered to a California resident The BRP U S and Canada limited warranty conditions for Evinrude outboards are still applicable to these models with the necessary modifications Select emission control parts of your Evinrude E TEC outboard are warranted from the date of purchase by the first retail consumer or the date the product is first put to use whichever
85. ut of the hose using air pressure of 25 psi or less Reconnect speedometer pickup after all the water has been removed 3 Top off oil tank PRE SEASON CHECK Om Extra engine oil is used during the winteriza tion procedure Some excess oil may appear on the skeg below the gearcase area This is normal Avoid potential oil stains by placing a shop towel or suitable container under the propel ler and skeg for the duration of the storage Remove your outboard from storage and pre pare it for a season of reliable service by per forming a general check and a few preventive maintenance procedures Examine all loosened or removed hardware Replace damaged or missing parts with Evinrude Johnson Genuine Parts or equiva lent Check the gearcase for leakage If leak age is evident the gearcase seals should be replaced See your Dealer IMPORTANT Gearcase lubricant is thick and clear Do not confuse this with engine oil which may normally appear on the skeg after performing the long term winterization stor age procedure Anticorrosion anodes Check condition Refer to Anti Corrosion Anodes on page 49 IMPORTANT Do not run your outboard even for a brief start up without supplying water to it Following Engine Starting Tiller Models on page 20 or Remote Control Models on page 24 start the outboard If the outboard was auto winterized it will emit a puff of smoke on the first start of the season Let it id
86. y blockage 6 Lower the outboard 7 Restart the engine and run at idle IF cleaning the screens and indicator does not restore the water pump indicator s steady discharge the engine will operate only in get home mode Return to harbor immediately See your Dealer IF cleaning the screens and indicator does restore the water pump indicators steady discharge you might have to run for two min utes in NEUTRAL to allow the engine to cool IMPORTANT If cooling is not restored the EMM will identify a progressive overheating condition and shut off the engine The engine will not restart until the engine is allowed to cool After any overheat causing engine shutdown see your Dealer for Inspection of the water pump for excessive wear or damage Inspection of the thermostats IMPORTANT Although the S A F E mode can help prevent engine damage it does not guarantee you can run your engine indefinite ly without engine damage 41 Using Your E TEC Outboard SPECIAL OPERATING CONDITIONS SALT WATER Anode protection for the outboard has been provided for use in salt or brackish water Upon removal from salt water leave outboard in a vertical position until its cooling system has drained During long periods of mooring tilt the gearcase out of the water except in freezing temperatures Flush the outboard if desired Refer to Short Term Storage on page 51 Salt Water Lubrication Points A 007032
87. y and convenience features as Start in gear prevention Plug in compatibility with Evinrude Modular Wiring System MWS Side Mount Control Single Lever Binnacle Mount Control 1 Handle shift and throttle 1 Handle shift and throttle 2 Trim tilt switch where equipped 2 Trim tilt switch where equipped 3 Neutral lock lever 3 Fast idle button warm up 4 Fast idle lever warm up 4 Throttle friction adjusting screw under cover 5 Throttle friction adjusting screw 5 Emergency stop clip and lanyard 6 Emergency stop clip and lanyard Concealed Side Mount Control Dual Lever Binnacle Mount Control 1 Handle shift and throttle 1 Handle shift and throttle 2 Trim tilt switch where equipped 2 Trim tilt switch where equipped 3 Neutral lock lever 3 Fast idle button warm up 4 Fast idle button warm up 4 Throttle friction adjusting screw under cover 5 Throttle friction adjusting screw 28 Emergency Stop Key Switch A combination emergency stop switch and key switch is a feature of Evinrude prewired remote controls and all Evinrude control wir ing kits Connect the clip to the emergency stop key switch Snap the lanyard to a secure place on the operators clothing or life vest not where it might tear away instead of activating the stop switch Disconnecting 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 l

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