2011 Product Service Update, P/N 5008496

2011 Product Service Update, P/N 5008496
Product Service Update
BRP US Inc.
Technical Publications
300 Sea Horse Drive
Waukegan, Illinois 60085 United States
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AMP is a registered trademark of Tyco International, Ltd.
Champion is a registered trademark of Federal-Mogul Corporation.
MicroSoft, MicroSoft Windows XP, Windows Vista and Windows 7 are registered trademarks of MicroSoft Corporation.
Molex is a registered trademark of Molex Inc.
NMEA is a registered trademark of the National Marine Electronics Association.
Oetiker is a registered trademark of Hans Oetiker AG Maschinen
The following trademarks are the property of BRP US Inc. or its affiliates:
Evinrude ® E-TEC ®
S.A.F.E.
Evinrude ® / Johnson ® XD30™ Outboard Oil
Johnson ®
FasTrak™
SystemCheck™
Evinrude ® / Johnson ® XD50™ Outboard Oil
Triple-Guard
I-Command™
DealerPort ®
BossWeb
Evinrude ® / Johnson ® XD100™ Outboard Oil
TBX™
Evinrude
®
ICON™
Viper™
Printed in the United States
© 2011 BRP US Inc. All rights reserved.
TM, ® and the BRP logo are registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WARRANTY INFORMATION – NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WARRANTY INFORMATION – OUTSIDE OF NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FIELD SERVICE AND TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TECHNICAL PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2011 PRODUCT IMPROVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
15 – 90 HP INLINE MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
115 – 300 HP 60°/90° V4/V6 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
15 – 30 HP MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75 – 90 HP (1.3L) MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115 – 300 HP 60°/90° V4/V6 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
200 – 300 HP 90° V6 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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EVINRUDE DIAGNOSTICS SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
IMPROVEMENTS AND CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
EVINRUDE ICON REMOTE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .43
ICON KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ICON RIGGING KIT SELECTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ICON INSTALLATION TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ICON SERVICE TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CONTENTS
I-COMMAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
I-COMMAND INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
PARTS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
P&A INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
NEW SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ELECTRICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
EVINRUDE E-TEC SPARK PLUG SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
EMM SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
EVINRUDE E-TEC GEARCASE LINE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2011 EVINRUDE E-TEC GEARCASE APPLICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
EVINRUDE E-TEC SHIFT ROD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
EXTERNAL WATER SCREENS AND APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2011 RPM QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2011 WATER PRESSURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
BULLETINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
TOPIC REFERENCE INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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GENERAL INFORMATION
5
CONTACT INFORMATION
Dealers outside of North America should contact their regional
office. Refer to Dealers – Outside North America (BRP International Offices) on p. 7.
Dealers – North America
North American dealers should use the following contact information.
Technical Support
After Sales Support
250 Sea Horse Drive
Waukegan, IL 60085
Ph: 1-800-888-4662 (Authorized Dealers only)
Fax: 1-847-689-6902 (Authorized Dealers only)
Warranty Administration Support
After Sales Support
250 Sea Horse Drive
Waukegan, IL 60085
Ph: 1-800-888-4662 (Authorized Dealers only)
Fax: 1-847-689-7235 (Authorized Dealers only)
Consumer Support
BRP US Inc. Customer Support Services
250 Sea Horse Drive
Waukegan, IL 60085
Ph: 1-847-689-7090 (Non-authorized dealers/consumers)
Fax 1-847-689-6902 (Non-authorized dealers/consumers)
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Parts & Accessories Support
North American dealers may call 1-800-888-4662 for technical
assistance with parts and accessories.
• Select option 3 for ordering assistance, pricing, and back order
or returns information.
• Select option 6 for service parts issues, or application and warranty questions.
To speed up the process, have your dealer number, the engine
model number, part number and invoice date available.
Technical Training Support
For questions regarding technical training, contact the Technical
Training Center.
Technical Training Center
250 Sea Horse Drive
Waukegan, IL 60085
Ph: 1-847-689-7500
Fax: 1-847-689-7510
AFTER SALES SUPPORT
Dealers – Outside North America
(BRP International Offices)
AUSTRALIA
Bombardier Recreational Products Australia Pty Limited
56 Canterbury Road
Bankstown 2200
New South Wales, Australia
Phone: +612 9794 6600
BENELUX
BRP Europe
Skaldenstraat 125
B-9042 Gent Belgium
Phone: +32 9 218 26 00
BRAZIL
Bombardier Recreational Products do Brasil
Rodovia Anhanguera Km 104 - Loteamento Tecno Park
Condominio Empresarial AZTech
Avenida James Clerck Maxwell, 280 Modulo 04
Campinas, SP 13069-380 Brasil
Phone +55 19 3716 8600
CARIBBEAN AND LATIN AMERICA
BRP US Inc.
1600 Sawgrass Corporate Parkway, Suite 150
Sunrise FL 33323
954-846-1442
EUROPE, MIDDLE EAST AND AFRICA
BRP International Division
5-7 CH Chemin du Messidor
Lausanne Switzerland
Phone: +41 21 318 78 00
FRANCE
Bombardier Recreational Products France
Les Jardins de la Duranne Bâtiment C
510 rue René Descartes
F - 13857, Aix en Provence France
Phone: +33 4 42 94 25 00
GERMANY
BRP Germany GmbH
Itterpark 11
D-40724 Hilden
Germany
Phone: +49 2103 960 680
JAPAN
BRP Japan Limited
15/F Parale Mitsui Building
8 Higashadi-Cho, Kawasaki-Ku
Kawasaki 210-0005
Phone: +81 44 200 1431
NEW ZEALAND
BRP New Zealand
7-11 Arwen Place
East Tamaki
Auckland 2130
Phone: +64 9 274 5718
SPAIN
BRP Recreational Products Spain S.L.
c/ Bertrán i Musitu 99-101
Edificio Brasil
08840 Viladecans-Barcelona Spain
Phone: +34 93 636 10 97
UK AND IRELAND
BRP Recreational Products UK Ltd
4 Brunel Close
Ebblake Industrial Estate
Verwood Dorset UK BH31 6BA
Phone: +44 1202 812 100
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WARRANTY INFORMATION –
NORTH AMERICA
North American dealers should use the following information.
Warranty Allowance Claims
All warranty allowance claims should be entered online when possible. When a written warranty Allowance Request Form,
P/N 773629, is required it should be mailed to:
BRP US Inc.
After Sales Support
P.O. Box 597
Sturtevant, WI 53177
Warranty parts returned with a Warranty Allowance Request Form,
P/N 773629, should be shipped to:
U.S. dealers ship to:
BRP US Inc.
After Sales Support
300 Sea Horse Drive Dock 5
Waukegan, IL 60085
Canadian dealers ship to:
BRP Warranty Returns – Waukegan
c/o Affiliated Global Logistics
500 Carlingview Drive
Etobicoke, ON M9W 5R3
Prior Authorization Required for Parts and
Accessories Warranty
If a replacement part or a dealer-rebuild fails, contact
Evinrude/Johnson After Sales Support. Dealers are not authorized
to rebuild assemblies without prior authorization.
Have your dealer number, the engine model and serial number,
part number and invoice date available.
Certain parts or assemblies may require additional documentation:
• BRP invoice for the assembly
• installation work order
• previous work order for original repair
• sales receipt (over the counter sales)
Refer to “Parts and Accessories Claims” in the current Warranty
Procedures Manual.
B.E.S.T. Warranty
As outboards enter the service period of a B.E.S.T. contract, there
are several requirements that dealers and customers should be
aware of:
• A 300 hour service (or 3 year inspection) on every outboard
• An inspection report must be provided before any B.E.S.T contract repairs are performed
• Engine must have less than 1000 hours
• There is a $50.00 deductible for each B.E.S.T. contract repair
• Dealers must qualify all engine repairs for outboards with
B.E.S.T. coverage
Refer to Administrative Bulletin 2010-04(A) for complete details
and coverage checklist.
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AFTER SALES SUPPORT
WARRANTY INFORMATION –
OUTSIDE OF NORTH AMERICA
Dealers outside of North America should contact their regional
office for processing of warranty allowance claims, or returning
parts. Refer to Dealers – Outside North America (BRP International Offices) on p. 7.
Predelivery Checklist Included in Shipping
Crate
A Predelivery Checklist is now included in the shipping crate
(owner’s package) of all Evinrude E-TEC outboards. A pack of ten
(10) predelivery checklist forms, P/N 5008381, is available through
Evinrude/Johnson Genuine Parts.
Dealers are REQUIRED to perform a complete predelivery inspection on each outboard. Dealers MUST keep predelivery checklists
on file for a minimum of seven years.
Refer to Predelivery Bulletin 2010-01(D) for complete details.
9
FIELD SERVICE AND TRAINING
Dealers outside of North America should contact their regional
office. Refer to Dealers – Outside North America (BRP International Offices) on p. 7.
Dealers – North America
Technical Service Representatives –
Applications Engineers (TSR-AE’s)
TSR–AE's support both Dealer and OEM Partners. TSR–AE technical support visits are coordinated through the After Sales Support
Call Center. Dealer and OEM Technicians should first contact the
After Sales Support Center Team to resolve technical issues. Contact them at 1-800-888-4662 and follow the prompts.
TSR-AE's provide the following dealer support:
• Service department development assistance (Service Evaluations and goal setting)
• Feedback reports for product and business trends
• Technical support of BRP Outboard Engine products
• Customer Relations
• Serve as instructors at Dallas, Tacoma and Laval Training Centers
TSR's provide the following OEM partner support:
• All aspects of rigging, technical training to ensure safety and
maximum performance for BRP powered boats
• Feedback reports for product and business trends
• Preparation and distribution of Performance Reports
10
Training
Schedule training online (www.DealerPort.com). For questions
contact the Technical Training Center.
Training courses are offered at the following locations:
• Waukegan, Illinois
• Morrow, Georgia
• Tacoma, Washington
• Laval, Quebec
• Dallas, Texas
Technician Certification
Technicians who achieved "Certified" status between June 2005
and June 2006 must attend the Outboard Certification Course by
May 30, 2011. Certified status WILL EXPIRE soon for technicians
who fall into this category.
Technicians who achieved "Certified" status prior to June 2005
were required to return in prior training seasons. Certified status is
EXPIRED for technicians who fall into this category. They should
return as soon as possible to recertify.
AFTER SALES SUPPORT
Master Technician Program
Technicians desiring Master Technician status MUST:
1. Maintain Certified status for at least 4 years (no lapses).
2. Successfully complete all updates by the due date.
3. Complete Outboard Certification Course in 4.5 days or less.
4. Upon successful completion of the Outboard Certification
Course, technicians who meet the qualifications, and who are
approved by their instructor(s) will be given the opportunity to
take the Master Technician exam.
5. Complete the 50 question exam with a minimum score of 90%.
The exam may include questions on ANY outboards sold or marketed by BRP.
To maintain Master Technician status, technicians MUST:
• Complete all distance learning updates by the due date.
• Return for hands-on training when required. See Technician
Certification on p. 10.
• When returning to the Outboard Certification Course, technicians
must complete the course and pass Master Technician exam as
outlined in steps 3 through 5 above.
TECHNICAL PUBLICATIONS
Changes to Service Manual Set
Please note the following changes to the 2011 Service Manuals
and Service Manual Sets:
• The Installation and Predelivery section has been removed from
individual service manuals.
• The Special Tools section has been removed from individual service manuals.
• The 2011 Installation and Predelivery Guide has been added to
the Service Manual Set. Additional Installation and Predelivery
Guides may be ordered using P/N 5008506.
• The 2011 Special Tool Guide has been added to the Service
Manual Set.
IMPORTANT: The 2011 Special Tool Guide, P/N 5008526, contains tools for current Evinrude E-TEC product only. Dealers should
retain a copy of the 2010 Special Tools Guide, P/N 5007858, or a
prior Special Tools Guide as a reference of tools for older outboard
products.
If a technician allows their Certification to lapse, Master Technician
status is lost.
A technician can take a missed exam at any time to have Certified
status reinstated. However, Master Technician status can only be
reinstated by again meeting the qualifications listed in steps 1
through 5 above.
11
NOTES – GENERAL INFORMATION
12
2011 PRODUCT IMPROVEMENTS
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15 – 90 HP INLINE MODELS
Engine Management Software 15 – 30 HP Models
Engine management software has been developed to improve emissions and
reduce fuel consumption on 15 – 30 HP models.
1
Update engine management software on engines with serial numbers 5283875
to 5289986.
Refer to Warranty Bulletin 2010-09(W).
1. Engine management software version and revision
1
Engine Wiring Harness Change 15 – 30 HP Models
Evinrude E-TEC 15 – 30 HP (C, H, R, and S-suffix) model outboards have a new
engine wiring harness to support changes to the Touch Troll and neutral
switches.
The Touch Troll switch connector has been eliminated. Wiring for the Touch Troll
switch has been relocated to a new 6-pin AMP connector of the tiller harness.
The neutral switch has a dedicated 2-pin AMP connector, similar to other
Evinrude E-TEC models.
2
1. 6-pin AMP connector (tiller harness)
2. 2-pin AMP connector (neutral switch)
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2011 PRODUCT IMPROVEMENTS
New Flywheel Torque Specification 15 – 30 HP Models
When servicing flywheels on Evinrude E-TEC 15 – 30 HP outboards, torque the
flywheel nut to 66 to 70 ft. lbs (90 to 95 N·m).
IMPORTANT: Torque the flywheel using the correct flywheel holder. To prevent
damage to the crankcase or the cylinder block, DO NOT allow the flywheel
holder to rest against the mounting boss for the recoil starter.
Also refer to Service Bulletin 2010-08(S), or the 2011 Service Manual.
Lower Mount 15 – 30 HP Models
A bump stop washer, P/N 353674, was added to the lower mount on 15 – 30 HP
models. This change to improves impact protection, and provides common service parts and procedures for all 15 – 30 HP models.
Refer to the correct Service Manual for lower mount service procedures.
1
1.
Bump stop washer
15
Oil Cap Assembly, 15 – 90 HP Models
The oil cap used on 15 – 90 HP models has changed.
1
The oil cap has a redesigned vent valve, to help prevent oil from leaking out of
the vent while the engine is tilted.
Oil cap assembly, P/N 5008406, replaces oil cap assembly, P/N 5007256, and
services 2009 and newer 15 – 30 HP models and 2010 and newer 40 – 90 HP
(F-suffix) models.
1. Vent
1
Electric Starter Motor Change 40 – 65 HP Models
The electric starter motor used on Evinrude E-TEC 40 – 65 HP models has been
changed.
2
The starter features a new nut and spring to retain the drive gear. Previously, the
drive gear was retained with a clip, spring and spacers. This change improves
the durability of the starter and provides common service for all 15 – 65 HP models.
The electric starter motor, P/N 587045, services all 2004 and newer 15 – 65 HP
models.
1. Nut
2. Spring
16
2011 PRODUCT IMPROVEMENTS
Throttle Body Assembly 40 – 65 HP Models
A new throttle body assembly is used on all 40 – 65 HP models.
The throttle body assembly features a nickel-plated throttle valve, which
improves corrosion resistance and durability. The new throttle valve is silver in
color, while the previous throttle valve was gold in color.
The new throttle body assembly, P/N 5008407, services all 2004 and newer 40 –
65 HP models.
1
1. Throttle valve
Exhaust Housings 40 – 65 HP Models
A change was made to the exhaust housing for 40 – 65 HP models.
Retainer tabs have been added to the exhaust housing to better secure the
engine wiring harness. Tie straps are now used to secure the engine wiring harness, rather than the previous “J-clamps.”
This change also makes it easier to reinstall and secure the engine wiring harness when servicing the engine.
Exhaust housing, P/N 5008275, services 2006 and newer 40 – 50 HP models.
1
Exhaust housing, P/N 5008274, services 2006 and newer 60 – 65 HP models.
Exhaust Housing
1. Tie straps
17
115 – 300 HP 60°/90° V4/V6 MODELS
Lower Engine Covers 115 – 200 HP 60° Models
Lower engine covers for 115 – 200 HP 60° models have been changed. The
lower engine covers feature a new fastener insert that reduces the risk of cracking the lower engine covers during removal and installation.
Service parts for older product will supersede to new part numbers. Refer to the
correct Parts Catalog for parts ordering information.
Note: Do not use power/impact tools to tighten lower engine cover screws.
Oil Pressure Sensor 115 – 300 HP Models
Clamp, P/N 982115, is now used to retain the oil pressure sensor to the oil pump
housing on all V4 and V6 models.
1
1. Clamp, oil sensor to housing, P/N 982115
18
This change improves the retention of the oil pressure sensor and provides common service parts for these models.
2011 PRODUCT IMPROVEMENTS
Oil Recirculation System Hoses 200 – 300 HP 90° V6
Models
1
Oil recirculation hoses on all 200 – 300 HP 90° V6 models have been changed
from black rubber to the blue hose used for oil distribution.
This change provides a common service part (P/N 778708) for the oil distribution
and recirculation hose for these models.
1
1
1. Recirculation hoses
Rear Oiling System 250 – 300 HP 90° (3.4 L) Models
A new rear oil pump replaces the rear oil manifold on 250 – 300 HP (3.4 L) models. The oil pump is a positive displacement oil pump which supplies oil to each
piston.
IMPORTANT: Correct oil priming procedure is required when installing a new
engine, or after servicing the oil system on 3.4 L engines that use this oil pump.
Refer to Predelivery Bulletin 2010-02(D) or the 2011 Service Manual for the
correct oil priming procedure.
The rear oil pump requires a new EMM, engine wiring harness and engine management software. For this reason this oil pump CANNOT be fitted to older
engines.
1
1. Rear oil pump
19
Shift Switch 200 – 300 HP 90° V6 Models
Shift switch, P/N 586861, has been relocated from the shift linkage to the cylinder and crankcase. This change improves the operation of the shift switch.
1
1. Shift switch
A new EMM and engine management software allow the shift switch to perform
the following functions:
• Start in gear protection – prevents the starter motor from operating if the shift
lever is not in NEUTRAL.
• Shift interrupt – reduces shift effort when the engine is shifted out of gear.
• Neutral rpm limit – limits engine speed to approximately 1100 rpm when shift
lever is in NEUTRAL position.
Note: DE model engines (ICON Electronic Shift and Throttle) do not have the
shift switch. Also see ICON Conversion Kit Installation 200 – 300 HP 90° V6
Models on p. 49.
Cooling System Change 250 – 300 HP 90° V6 (3.4 L)
Models
The cooling water hose from the vapor separator outlet to the exhaust adapter
has been relocated to the exhaust emission test port of the exhaust adapter.
1
1. Cooling water hose
20
This change improves water pressure to the powerhead and provides additional
water to cool the propeller hub.
2011 PRODUCT IMPROVEMENTS
Powerhead Change 200 – 300 HP 90° V6 Models
The following changes have been made to improve powerhead durability:
• Piston splash port and dome have been redesigned to improve durability of
the piston.
• Piston ring locating pins have been changed to reduce locating pin migration.
• Cylinder sleeve oil grooves redesigned to provide consistent oil flow to piston
skirt.
L2-Type Gearcase ( .58 Ratio) Replaced by M2-Type
Gearcase ( .54 Ratio) on 225 – 300 HP 90° Models
0
0
The L2-Type gearcase (with .58 gear ratio) has been replaced by the M2-Type
gearcase (with .54 gear ratio) on all 225 – 300 HP models.
0
0
The larger gear set used in the M2-Type gearcase improves durability. Front
water inlets provide additional cooling water for the powerhead and can boost
water pressure in excess of 40 psi (275 kPa).
2
Also see Exhaust Housing to Gearcase Alignment Pins on p. 38.
1
Additional benefits of the M2-Type gearcase:
• Improved acceleration due to (.542) (1.85:1) gear ratio.
• Front and side water inlets.
• Wider propeller selection available to optimize performance.
M2-Type Gearcase
1. Front water inlet
2. Side water inlet
21
Exhaust Grommet 115 – 300 HP Models
A new exhaust grommet is used on all V4 and V6 models.
The new exhaust grommet features ribs to strengthen the grommet and reduce
flexing around the insert area. This improves retention of the overboard indicator
hose.
1
1
When installing an exhaust grommet, clean and dry all parts. Make sure the Oetiker clamp that retains the overboard indicator hose is correctly positioned. Refer
to the appropriate Service Manual for installation instructions.
Exhaust grommet, P/N 5008518 services all 2005 and newer 115 – 300 HP
Evinrude E-TEC models.
1. Strengthening ribs
Fuel Hoses – All Models
New and revised U.S. Environmental Protection Agency (U.S. EPA) regulations
have resulted in a number of changes to fuel hoses.
New fuel rails are used on all 40 – 300 HP models. The new fuel rails are constructed with a three layers of material to meet the U.S. EPA requirements for
evaporative emissions.
Service parts for older product will supersede to new part numbers. Refer to the
appropriate Parts Catalog for correct parts ordering information.
Fuel Rail (Typical)
22
SERVICE INFORMATION
23
15 – 30 HP MODELS
.
SystemCheck Warnings
Due to the limited number of circuit inputs and outputs to the EMM, 15 – 30 HP
models have limited warnings when a SystemCheck gauge is installed. These
models only provide tachometer signal and the LOW OIL warning to a SystemCheck gauge.
Refer to the Operator’s Guide for a complete explanation of warning system
functions.
3
2
4
5
1
NO
6
0
7
1
Typical SystemCheck Gauges
1. LOW OIL warning
Engine Overheat Damage
If a customer reports a loss of performance, use Evinrude Diagnostics software
to check for the following:
• Code 31; Engine temperature over range
• Code 40; Engine temperature above range – Low speed
• Code 43; Engine temperature above range
• Recorded maximum engine temperature
If any of these service codes are stored, and the maximum engine temperature
is over 248°F (120°C), remove the gearcase. Inspect the water pump and the
exhaust housing megaphone for engine overheat damage.
Loss of performance will result from a damaged exhaust housing megaphone.
The megaphone can be damaged when a significant loss of water flow occurs.
Exhaust Housing Megaphone
Note: Engine damage due to overheat conditions is NOT covered by the BRP
Limited Warranty. Customers should contact their insurance company to file a
claim for financial assistance in the repair.
24
TEMP
CHECK
ENGINE
LOW
NO HOT CHK LOW
OIL
ENG OIL
OIL
WATER
OIL
SERVICE INFORMATION
Water Pump Impeller Kit, P/N 5008185
Water Pump Impeller Kit, P/N 5008185, is included with Water Pump Repair Kit,
P/N 5008191, for service of 15 – 30 HP models. The water pump impeller kit
contains a new pressure relief valve spring, P/N 355169, and a new thermostat
spring, P/N 355209.
A change to the water pump impeller material improves the performance of the
water pump. This change affects engine water pressure and REQUIRES stronger pressure relief valve and thermostat springs.
IMPORTANT: REPLACE the pressure relief valve and thermostat springs
when installing a water pump repair kit, or a water pump impeller kit in any 2010
or older 15 – 30 HP model.
Water Pump Repair Kit, 15 – 30 HP M0odels
NOTICE Failure to install the impeller assembly and springs as a set can
result in:
•A cold running engine, if the impeller is installed without the pressure
relief valve and thermostat springs.
•An engine overheat, if the pressure relief valve and thermostat springs
are installed without the new impeller.
25
75 – 90 HP (1.3L) MODELS
.
Installation of Oil Pump Assembly
The problem: After installing a replacement oil pump assembly, the LOW OIL
warning light remains on even though the oil tank is full.
The cause: Incorrect installation can result in the low oil switch being held “ON”
by the oil pick up assembly.
2
1
The fix: Be sure to install the oil pump pick up assembly straight into oil tank.
Refer to the correct Service Manual for installation instructions. Make sure the
oil pick up assembly is positioned in front of oil tank baffle. This will prevent interference with the LOW OIL switch.
1. Oil pick up assembly
2. Oil tank baffle
.
26
SERVICE INFORMATION
.
115 – 300 HP 60°/90° V4/V6 MODELS
Exhaust Back Pressure Fitting
A blocked exhaust back pressure fitting can result in difficult starting or other run
quality symptoms.
Use the Data Log feature of Evinrude Diagnostic software to monitor the exhaust
back pressure on an engine that is difficult to start, or runs poorly.
Normally, exhaust back pressure readings are erratic. If the data log shows readings which tend to be linear, check the back pressure sensor.
Remove the fitting and inspect for damage or blockage. Replace if damaged.
Exhaust Back Pressure Fitting
Clean or replace the exhaust back pressure fitting if it is blocked. Clean it by
soaking in Engine Tuner. After soaking use an appropriate size pick, or drill bit to
open blocked holes.
27
200 – 300 HP 90° V6 MODELS
Ordering Replacement Gearcases
The L2-Type gearcase with the0.58 (1.71:1) gear ratio is no longer available.
Use an M2-Type gearcase with the0.54 (1.85:1) gear ratio if replacement is
needed.
Because a gearcase conversion kit is required, existing part numbers do not
supersede. Dealers who enter an order for a0.58 gear ratio L2-Type gearcase
will receive an invoice with a “Note” to call the After Sales Service Department.
This will result in delays receiving the correct replacement gearcase.
Order the following parts:
• Select the correct M2-Type replacement gearcase.
Refer to the Parts Catalog for replacement gearcase part numbers.
• Select the correct gearcase conversion kit –
•order P/N 5008535, for 20 inch models.
•order P/N 5008536, for 25 inch models.
M2-Type Gearcase
Gearcase conversion kits include the correct shift rod, a new exhaust grommet,
new gearcase mounting screws and installation instructions.
Refer to the installation instructions for the following:
• Exhaust grommet and Oetiker clamp installation.
• Shift rod installation and shift rod height adjustment.
• Correct water inlet screen selection.
• Correct trim tab selection and installation.
• Gearcase mounting screw torque.
• The change of gear ratio requires a change of propeller pitch.
Gearcase Conversion Kit (Typical)
28
SERVICE INFORMATION
MAINTENANCE
Maintenance Recommendations – 26 Point Inspection Checklist
Use the 26 Point Inspection Checklist to explain required service for the Evinrude E-TEC 300 hour/3 year service, and to help “sell” a
maintenance plan to your customer.
The parts department can use the checklist to stock service supplies. Service technicians can use the checklist to check off service items
as they are completed.
Description
Engine
Care
Product
Every 300
hours or
3 years(1)
Description
Engine
Care
Product
Every 300
hours or
3 years(1)
Emergency stop circuit and lanyard (check operation)
X
Fuel filter, replace (2)
Controls, steering and tilting; check operation
X
Gearcase lubricant, replace
Engine mounting hardware, re-tighten
X
Spark plugs, inspect or replace (3)
X
Fasteners, tighten any loosened components
X
Thermostats, inspect and check operation (3)
X
Water intake screens, check condition
X
Grease fittings, lubricate
C
X
Cooling system; check water pump indicator
X
Power trim/tilt and fluid level, inspect
B
X
Anticorrosion anodes, check condition
X
Propeller shaft splines, inspect and lubricate (4)
C
X
Gearcase, check condition
X
Starter pinion shaft, inspect and lubricate (4)
D
X
Propeller, check condition
X
Control cables, inspect and adjust
X
Fuel and oil systems, inspect and repair leaks
X
Steering cable, inspect and lubricate
X
Check battery connections and condition
X
Water pump, inspect / replace
X
Access EMM information (resolve any service codes)
X
Exhaust back pressure fitting (if equipped)
X
Electrical and ignition wires (inspect for wear or chafing)
X
Oil filters remote tank / engine (115 – 300 HP models)
X
X
A
X
(1) Average recreational use. Commercial use, heavy use or use in salt or polluted water requires more frequent inspection and maintenance.
(2) Boat mounted fuel water separating filters should be replaced annually
(3) Emission-related component.
(4) Annually in salt water applications
A – HPF Pro Gearcase Lubricant
B – Trim and Tilt Fluid, use Biodegradeable Fluid on single ram hydraulic systems, use Power Trim and Tilt Fluid on three ram hydraulic systems
C – Triple Guard Grease
D – Use Starter Bendix Lube only
29
ELECTRICAL SYSTEM
Starter Drive Gear Engagement, 115 – 300 HP Models
The problem: A limited quantity of starter drive gears may be machined with the
wrong chamfer (beveled edge) on the teeth of the gears. If this condition exists,
the starter drive gear (bendix) may not engage the ring gear of the flywheel and
the starting process can fail. Service replacement starter motor assemblies,
P/N 586957 and P/N 586890, could experience this issue.
1
The Fix: Remove starter motor assembly and identify the chamfer on the teeth
of the starter drive gear. Refer to Warranty Bulletin 2010-08(W), for complete
instructions.
1. Chamfer
FAQ: Spark Plugs – All Models
The Service Teams are frequently asked if it is permissible to substitute spark
plugs. the answer is NO, unless there is an APPROVED substitution.
At this time, the only approved substitution is 2005 – 2006 Evinrude E-TEC 200
– 250 HP 90° V6 (3.3 L) models.
U.S. EPA regulations prohibit modification to any system, that could effect the
engine’s exhaust emissions level. This includes spark plugs. Engine emission
certification REQUIRES only approved spark plugs be used in the engine.
1
Refer to the Evinrude E-TEC Spark Plug Service Chart on p. 68, the appropriate Parts Catalog, or the Emissions Control Information (ECI) Label on the
swivel bracket of the outboard for correct spark plug information.
ECI Label
1. Spark plug information
30
SERVICE INFORMATION
V–
NEG
V
1
1.
2.
3.
4.
Negative battery cable
Positive battery cable
Solenoid
Starter cable
2
A voltage drop test is an effective and easy to perform electrical test. The purpose of this test is to make sure the load in the circuit consumes the maximum
amount of voltage. An excessive voltage drop in a circuit will result in the load
not performing at its maximum potential.
Use a digital voltmeter to measure the voltage drop on each section of the start
circuit. Always connect the voltmeter leads with the positive (+)/red lead closest
to the positive terminal and the negative (–)/black lead closest to the negative
terminal of the battery.
3
+
Voltage Drop Test
4
If any voltage reading is greater than 0.5 VDC check that connections are clean,
tight and free of corrosion. Clean or replace any corroded or damaged cables or
connections.
Note: Disconnect the Crankshaft Position Sensor (CPS) to prevent the engine
from starting.
STEP 1: Connect voltmeter positive (+) lead to the terminal for the negative (–)
battery cable at powerhead. Connect voltmeter negative (–) lead to negative (–)
battery post.
• Activate starter motor and observe voltage reading.
STEP 2: Connect positive (+) lead to battery positive (+) terminal. Connect negative (–) lead to starter solenoid terminal.
• Activate starter motor and observe voltage reading.
STEP 3: First, activate starter motor. Connect positive (+) lead to starter solenoid
terminal. Connect negative (–) lead to opposite starter solenoid terminal.
• Observe voltage reading.
STEP 4: Connect positive (+) lead to starter cable of solenoid terminal. Connect
negative (–) lead to starter motor terminal.
• Activate starter motor and observe voltage reading.
31
Inductive Ignition System
1
2
3
The inductive (IDI) ignition system provides ignition spark with a fast rise time
and a long, continuous duration spark, compared to the multi-strike cd ignition
used on older models. The benefit is a smoother running engine under a variety
of load conditions.
The inductive ignition uses an ignition coil which contains an internal circuit
board to control current flow through the primary winding.
How it works: System voltage (55 volts) is supplied through the white/red wire
to the primary winding. Ground is provided through the black wire to the circuit
board and to the coil primary. The EMM provides a low voltage control signal
through orange wire to the circuit board.
When the circuit board receives the control signal, it momentarily stops current
flow through the coil primary winding. The surrounding magnetic field collapses,
creating high voltage in the coil secondary winding.
IDI Ignition Coil Tests: Because the ignition coil contains an internal circuit
board, there are no simple ignition coil tests available.
CDI Multi - Strike Ignition
1. Fast rise time
2. Short spark duration
3. No spark in gap
1
Before replacing an ignition coil, be sure:
• 55 V is supplied to the white/red wire of the ignition coil connector.
• A control signal is present on the orange wire of the ignition coil connector.
Refer to Ignition Control Circuit Tests in the appropriate service manual.
• The black wire of the ignition coil connector provides continuity to ground.
• The secondary spark plug lead provides continuity.
Refer to Ignition Output Tests in the appropriate service manual for other ignition system test procedures.
Evinrude E-TEC IDI
1. Fast rise time
2. Long spark duration
32
2
SERVICE INFORMATION
FUEL SYSTEM
Injector Coefficient Database
Dealers can now download the coefficient files for new service fuel injectors from
a database available on the internet.
This process eliminates the need for a 3.5 inch floppy drive on the service laptop
computer and the problems created when the disk is packaged with a service
fuel injector is damaged.
1
2
Refer to the serial number label attached to the fuel injector electrical connector.
ACCURATELY record the 14-digit Serial Number (SN) and the 5-digit Checksum
(CS) number from the injector serial number label.
Injector Serial Number Label
1. Serial number
2. Checksum number
Log on to DealerPort or BossWeb to download injector coefficient files from the
internet. Refer to Service Bulletin 2010-07(S) for complete instructions. A copy
of this bulletin is packaged with each service fuel injector.
Internet Browser Blocks Download of Injector
Coefficient File
The problem After entering injector serial number and checksum, nothing happens after pressing the “Download Injector Coefficient File” button.
1
The cause: Internet browser security settings are blocking download of the coefficient file and displays a security message bar above the screen.
The fix: Click on the security message bar that reads “Click here for options.”
Select “Download File” to start the download process.
1. Click here for options
33
Fuel Issues
Reports received by the After Sales Department indicate fuel related problems
persist in areas where alcohol extended fuels are used.
These problems include:
• Excessive alcohol content in fuel
• Water or other contaminants in the fuel tank
• Phase separation
These problems can result in:
Corrosion of fuel system metal parts
Deteriorated fuel hoses
Blockage in the fuel system
Engine damage
•
•
•
•
Deteriorated fuel hose and primer bulb
As part of routine maintenance, inspect fuel hoses from the tank to the outboard.
Make sure fuel supply hoses have not deteriorated. Replace deteriorated fuel
hoses. Routine inspection of fuel hoses can help prevent expensive repairs.
Refer Service Bulletin 2006-06(S) and to the 2008 and 2009 Product Service
Update books for additional information and recommendations.
These problems can occur with all brands and types of outboards and are
related to fuel blending, contaminants, and atmospheric conditions.
Blockage in the fuel system
34
SERVICE INFORMATION
OILING SYSTEM
Code 36; Rear Oil Injection Pump Circuit OPEN
Code 36 is a new service code for Evinrude E-TEC 250 – 300 HP 90° V6 (3.4L)
models with the new rear oil pump. The rear oil pump is powered by the 12 V
electrical circuit. The EMM controls pump operation by rapidly connecting and
disconnecting the pump’s internal coil to ground.
1
Refer to the 2011 Service Manual for code description.
Possible Causes: Damaged wire harness or electrical connector between EMM
and oil pump. Failed internal coil of oil pump. Failed circuit in EMM.
1. Rear oil injection pump
Troubleshooting procedure: Use the correct service manual to check the following:
• Rear oil pump voltage and control signal. Refer to Cylinder Oil Pump Voltage
Tests.
• Oil injection pump circuit resistance. Refer to Cylinder Oil Pump Resistance
Test.
35
COOLING SYSTEM
Gearcase Flushing Adapter
Cover auxiliary water inlet holes on the gearcase when a gearcase flushing
adapter is used to flush the outboard. If auxiliary water inlet holes on the gearcase are not covered, water can drain from them, resulting in engine overheat.
1
To insure enough water travels to the powerhead from the water intakes, temporarily cover auxiliary water inlets as follows:
15 – 30 HP Models – Temporarily cover the two small auxiliary water inlet holes
on each side of the gearcase with waterproof tape.
150 – 300 HP Models (equipped with an M2-Type gearcase) – Temporarily
cover the six auxiliary water inlet holes on the front of the gearcase with waterproof tape.
15 – 30 HP Models
1. Auxiliary water inlets
Be sure to remove waterproof tape from auxiliary water inlets when flushing is
complete.
1
150 – 300 HP Models (M2-Type Gearcase)
1. Auxiliary water inlets
36
SERVICE INFORMATION
TRIM AND TILT
Single Piston Hydraulic Trim and Tilt Assemblies
Identification
Dealers must correctly identify single piston hydraulic trim and tilt assemblies to
order the correct service parts.
1
The single piston hydraulic trim and tilt assembly is used on 75–90 HP (20 inch)
models in 2005 and on 115–130 HP V4 (20 inch) models in 2007.
Hydraulic Trim and Tilt Assembly, P/N 5005756 superseded to P/N 5007776,
starting in 2008.
Some service parts for these hydraulic trim and tilt assemblies are NOT interchangeable. Use the table below and the appropriate Parts Catalog to correctly
identify the hydraulic trim and tilt assembly.
Hydraulic Trim and Tilt Assembly
1. P/N 5007776, Black anodized manifold
1
Model Year
Models
2005–2008
2007–2008
75 – 90
115 – 130
75 – 90
115 – 130
2009 & newer
Hydraulic
Trim and Tilt
Assembly P/N
Manifold
Description
Use Parts
Catalog
5005756
Painted Gloss
Black
5007776
Anodized Flat
Black
2005–2008
2007–2008
2009 or newer
2009 or newer
Manual Release Issue
2
If a hydraulic trim and tilt assembly, P/N 5007776, cannot be lifted manually,
replace the manual release valve, P/N 5007782. The replacement manual
release valve is identified by its red anodized color.
Manual Relief Valves
1. P/N 5006321, use in hydraulic trim and tilt assembly, P/N 5005756
2. P/N 5007782 (red anodized), use in hydraulic trim and tilt assembly,
P/N 5007776
37
GEARCASE
1
Exhaust Housing to Gearcase Alignment Pins
Current production M2-Type gearcases are fitted with exhaust housing to gearcase alignment pins, P/N 350943.
If installing a replacement M2-Type gearcase on a 2008 or older engine, inspect
the exhaust housing. Make sure it is machined to accept the exhaust housing to
gearcase alignment pins.
If the exhaust housing is not machined to accept the alignment pins, remove the
alignment pins from the replacement gearcase.
NOTICE Failure to remove the exhaust housing to gearcase alignment
pins can damage the exhaust housing mounting flange and prevent correct installation of the gearcase.
Use Gearcase Alignment Kit, P/N 5007231 to accurately align gearcase housing
to exhaust housing on engines where the exhaust housing is not machined to
accept the alignment pins.
1. Exhaust housing to gearcase alignment pins
1
Exhaust Housing
1. machined to accept exhaust housing to gearcase alignment pins
38
EVINRUDE DIAGNOSTICS SOFTWARE
39
IMPROVEMENTS AND CHANGES
New Software Version 5.1
Evinrude Diagnostics software is a Windows based diagnostic tool developed for
Evinrude E-TEC outboards. The latest version will communicate with DI engines
back to 1997.
Model year changes require the release of new software versions. Version 5.1 is
required for model year 2012 and older.
New diagnostics software (version 5.1, P/N 5008689) automatically shipped to
all authorized U.S. and Canadian service dealers as part of the North American
Essential Tools and Software Program. Existing dealers are charged a reduced
price for this software as an annual software license renewal and update.
Evinrude Diagnostics software version 5.1 Minimum Hardware Requirements:
Personal Computer: IBM-compatible laptop computer.
Operating System: Microsoft Windows 7, Vista, XP, 2008 or 2003.
CPU Speed: Pentium II 133 MHz or higher.
Memory: 64 megabyte or more.
Hard disk: 40 megabyte or more of free space.
Floppy drive: necessary for injector coefficient file installations, but not required if
user has internet access to DealerPort or BOSSWeb.
Refer to Service Bulletin 2010-07(S).
• Display resolution: 800 x 600 (1024 x 768 preferred), font size 96 dpi.
• Interface Port:
•Computer RS-232 (9-pin) Serial Port.
•USB to RS-232 (9-pin) Serial Adapter: Configured to ComPort 1 through 9.
•CardBus/PCMCIA to RS-232 (9-pin) Serial Adapter: Configured to ComPort 1
through 9.
• Communications Cable: Use Interface Cable, P/N 437955.
•
•
•
•
•
•
IMPORTANT: Version 5.1 software MUST be installed using the program CD,
P/N 5008689. Version 5.1 software is NOT available online.
40
Evinrude Diagnostics software (version 5.1)
EVINRUDE DIAGNOSTICS SOFTWARE
Important Information for Evinrude Diagnostics
Software Version 5.1 Program Installation
Initial Setup
The first time the program is run, an Initial Setup form will appear. Initial setup
items are set to default conditions. Possible changes are as follows:
• Unless directed by BRP do not uncheck "Automatically Save Engine Data File
(EDF) Upon Engine Connection".
• If computer normally has an internet connection then check the "Use Automatic Website Updates".
• Verify assigned website (DealerPort or BossWeb, depending on your subscription service).
Initial Setup
Changes to these selections may be made at any time, by selecting the “Tools”
menu and selecting “Options”.
Software Registration
Software registration is required to run this program.
• After the Initial Setup is complete, the program will check for a prior version of
Evinrude Diagnostics registration. If prior version registration information is
found, Evinrude Diagnostics version 5.1 will automatically use the existing registration information.
• If a prior version is not found, the user MUST complete the registration, Enter
your dealer number, dealership name, address and country. An internet connection is NOT needed to complete this registration.
Note: Registration information is only used for identification purposes on printed
reports.
Software Registration
41
NOTES – EVINRUDE DIAGNOSTICS SOFTWARE
42
EVINRUDE ICON REMOTE CONTROL SYSTEM
43
ICON KITS
ICON Rigging Kits
ICON rigging kits are designed to make rigging kit selection an easy three or four
step process. Refer to the ICON Rigging Kit Selection Chart on p. 45, for rigging kit selection.
Each ICON rigging kit includes all the boat related ICON components needed to
rig a single station or an optional second station, plus the appropriate ICON
remote control for the number of engines installed on the boat.
ICON Rigging Kit
ICON Conversion Kits
ICON Conversion Kits add digital electronic shift and throttle control to 2008 and
newer Evinrude E-TEC 150 – 300 HP models. To add digital electronic shift and
throttle control to an Evinrude E-TEC outboard, order:
• ICON Conversion Kit, P/N 764979, for 200 – 300 HP 90° V6 models.
• ICON Conversion Kit, P/N 765304, for 150 – 200 HP 60° V6 models.
ICON conversion kits must be:
• installed by a dealer using Evinrude Diagnostics software.
• used on a boat equipped with an ICON remote control network.
• used with ICON, I-Command, or other NMEA 2000 compliant CANbus instruments.
Update engine management software on 2008 – 2010 engines to ensure ICON
compatibility. Refer to the Installation Instructions provided with the kit.
ICON Conversion Kit
Note: 2007 and older models are NOT compatible with the ICON remote control
system.
44
EVINRUDE ICON REMOTE CONTROL SYSTEM
ICON RIGGING KIT SELECTION CHART
Step 1: Select number of engines.
1
2
Step 2: Select appropriate remote control.
Concealed
Side Mount
Single Lever
Binnacle Mount
Step 3: Order P/N for main or single station
rigging kit.
Rigging Kit
P/N 764990
Rigging Kit
P/N 764980
3
4
5
Dual Lever Binnacle Mount
Rigging Kit
P/N 764982
Rigging Kit
P/N 764984
Rigging Kit
P/N 764986
Rigging Kit
P/N 764988
Main Station Rigging Kits include:
ICON Remote Control, P/N
765412
765381
765382
765383
765384
765385
Master Power/Key Switch, P/N
765371
765373
765374
765371
765371
765371
Start/Stop Switch Panel, P/N
765378
765375
765376
765377
765388
765389
765390
–
Trim Switch Panel, P/N
–
Network Power Cable, P/N
764921
ICON Gateway Module Kit, P/N
764922
ICON Accessory Power Relay, P/N
765296
ICON Hubs (2), P/N
764943
Buss Cable Extension 15ft (4.57m), P/N
764948
(Kit includes 1 buss cable per engine)
Buss Cable Backbone 20ft (6.1m), P/N
764950
–
Buss Cable Backbone 25ft (7.4m), P/N
–
764951
Engine Identity Plug ID#1, P/N
–
764916
Engine Identity Plug ID#2, P/N
–
Engine Identity Plug ID#3, P/N
–
Engine Identity Plug ID#4, P/N
ICON Remote Control User’s Guide
764917
764918
–
765410
764919
764954
Installation Instructions included:
ICON Remote Controls, P/N
355248
355084
ICON Switch Panels, P/N
355085
355085
ICON Gateway Module & Cable Kit, P/N
355086
355086
ICON Accessory Power Relay Kit, P/N
355087
355087
ICON Quick Connect Guide, P/N
765409
764953
45
Concealed
Side Mount
Rigging Kit
Not Available
Rigging Kit
P/N 764981
Rigging Kit
P/N 764983
Rigging Kit
P/N 764985
Rigging Kit
P/N 764987
Rigging Kit
P/N 764989
ICON Remote Control, P/N
–
765381
765382
765383
765384
765385
Emergency Stop Switch Panel, P/N
–
765379
765380
765372
765372
765372
Step 4 (optional): Order P/N for
second station rigging kit.
Second Station Rigging Kits Include:
Start/Stop Switch Panel, P/N
–
–
765375
765376
765377
Trim Switch Panel, P/N
–
–
765388
765389
765390
Buss Cable Extension 15ft (4.57m), P/N
–
764948
Buss Cable Extension 20ft (6.1m), P/N
–
–
764949
Installation Instructions included:
46
ICON Remote Controls, P/N
–
355084
ICON Switch Panels, P/N
–
355085
ICON Quick Connect Guide, P/N
–
764953
EVINRUDE ICON REMOTE CONTROL SYSTEM
1
ICON INSTALLATION TIPS
Buss Cable Issues
Incorrect alignment and assembly of ICON buss cables can result in a non-functional ICON network. Use the following information to avoid network communication issues.
Assemble connectors dry. Do NOT use Electrical Grease on this style connector.
Visually check the alignment and assembly of connectors. Align tabs and sockets of the female connector to the grooves and pins of the male connector.
Tighten locking rings of connectors finger-tight.
Do not rotate the connectors to align pins to sockets. This can damage the pins
of the connector. A damaged connector can cause an electrical short in the network, resulting in a failed 3 Amp fuse at the master power key switch.
1. Damaged pins
It is possible for the pins of one connector to enter the sockets of the other connector when the tabs and grooves of the connector are misaligned. This damages the connector housing and makes an extra groove in the misaligned
connector.
1
2
Misaligned connectors can cause the 3 Amp fuse at the master power key
switch to blow and disrupt or eliminate communication on the network.
Improper network communication can create non-recoverable fault codes and
activate S.A.F.E.
1. Groove
2. Extra groove in the misaligned connector
47
150 – 200 HP 60° V6 Models,
Code 152; Shift Actuator Motion Fault
The problem: After installing an ICON conversion kit, P/N 765304, on a 150 –
200 HP 60° V6, Code 152; Shift Actuator Motion Fault occurs when the engine is
shifted into forward gear, due to incorrect shift actuator calibration.
The fix: Use Evinrude Diagnostic software (version 4.0 or higher) to verify shift
actuator calibration. Refer to the installation instructions provided with the conversion kit.
If the problem persists, perform the following adjustment:
• Turn the master power key switch to the ON position.
• Position control levers to the NEUTRAL detent.
• Move the control lever to the FORWARD detent.
• Manually turn the propeller shaft to confirm FORWARD gear engagement.
• Move the control lever to the REVERSE detent. Manually turn the propeller
shaft to confirm REVERSE gear engagement.
• Move the control lever to the NEUTRAL detent. Rotate the propeller shaft
back and forth to ensure the face of the clutch dog does not contact FORWARD or REVERSE gear.
If gear engagement is NOT correct, a shift actuator motion fault can occur when
the control lever is moved to FORWARD or REVERSE.
Use Evinrude Diagnostic software “Settings” screen and select the “EST Calibration” tab. Use the “Nudge” buttons to adjust the shift stroke to the forward or
backward direction. Be sure to press the “Save” button after completing the
adjustment.
After using the “Nudge” feature, repeat the gear verification process.
Note: Do NOT preload the shift actuator calibration toward FORWARD gear on
outboards with a counter rotation gearcase.
48
Code 152; Shift Actuator Motion Fault
EVINRUDE ICON REMOTE CONTROL SYSTEM
ICON Conversion Kit Installation
200 – 300 HP 90° V6 Models
When installing an ICON conversion kit on 2011 and newer 200 – 300 HP 90° V6
models the shift switch must be removed. Install protective cover, P/N 586821,
on shift switch connector of the engine harness.
1
Refer to the installation instructions provided with ICON conversion kit,
P/N 764979.
1. Neutral switch
49
ICON SERVICE TIPS
ICON Troubleshooting Guide, P/N 356076
The ICON Troubleshooting Guide, P/N 356076, will automatically ship to all
authorized U.S. and Canadian service dealers.
The ICON Troubleshooting Guide contains installation tips to help avoid common problems. Simple, effective troubleshooting flow charts are also included to
help dealers efficiently troubleshoot and make repairs to an ICON network.
Additional copies may be ordered from Evinrude/Johnson Genuine Parts and
Accessories.
ICON Troubleshooting Guide
Remote Control Neutral Position
1
Before attempting to change ICON network settings, set shift and throttle calibration adjustments, or perform troubleshooting steps:
• Turn master power/key switch to the ON position (engine OFF)
• Place control lever(s) in the NEUTRAL position
15.0°
15.0°
85.5°
40.5°
Failure to follow these steps could result in false warnings or service codes, or
can disrupt network communication.
9.5°
1. Neutral position
50
14.5°
EVINRUDE ICON REMOTE CONTROL SYSTEM
13.25
VDC
Battery Voltage
Battery voltage of 13.25 VDC or higher is required for stable ICON network operation. Inconsistent voltage on the ICON network can effect operation.
Use Evinrude Diagnostics software “Monitor” screen or a NMEA 2000 gauge
(I-Command or ICON) to monitor voltage. Perform the following steps if ICON
network voltage is below 13.25 VDC.
+
Identify which battery is powering the ICON network. Test battery connections
and charge. Run the engine connected to the battery for the ICON network or
use a battery charger to support the battery voltage.
Visually inspect the 3A fuse for the master power key switch and the 10A fuse
for the power supply cable. Check network voltage at the 10A fuse of the ICON
power supply cable.
Look for an Accessory Power Relay Kit, P/N 765296, in the ICON network. This
(optional) power relay kit connects to one of the 6-port hubs and is required to
power any accessory controlled by the master power key switch.
Connect only the positive lead of an accessory to the terminal board provided
with the accessory power relay kit. Do NOT connect accessory wiring to the
master power key switch.
Accessory Power Relay Kit
51
Failed 3 Amp Fuse (Master Power/Key Switch)
A failed 3 amp fuse for the master power/key switch is normally caused by one
of the following:
• Failed or damaged master power/key switch
• Damaged master power/key switch wire harness
• Damaged or faulty buss cable or back bone cable
• Damaged or faulty hub
RUN
OFF
3 Amp Fuse
Follow these steps to troubleshoot a failed 3 amp fuse:
Step 1: Inspect master power/key switch for damage. Test key switch function
with an ohm meter. Refer to MWS Key Switch Diagram in the service
manual.
Step 2: Inspect master power/key switch wire harness for damage or short circuit.
Repair or replace damaged master power/key switch or wire harness. If the master power key switch or wire harness is not damaged or the fuse fails again, continue with Step 3.
Step 3: Turn the master power/key switch OFF. Replace 3 amp fuse.
Step 4: Disconnect ALL hubs, the back bone cable and buss cables (including
buss cables for ESM, gateway module and accessory power relay) from
the ICON network.
Step 5: Reconnect one hub or buss cable to the ICON network.
Step 6: Turn master power/key switch ON.
Step 7: If the fuse does not fail, turn the master power/key switch OFF. Repeat
steps 5 through 7 until the faulty hub or cable is reconnected and the 3
amp fuse fails.
Repair or replace the hub or buss cable that causes the 3 amp fuse to fail.
Step 9: Replace 3 amp fuse.
Verify remaining hubs or buss cables are not faulty. Repeat steps 5 through 9
until all hubs and buss cables are reconnected to the ICON network.
52
FUSE
+
1.
I-COMMAND
53
I-COMMAND INFORMATION
Instancing
I-Command digital gauges with software version 2.1 or higher, support up to five
engines and eight fuel tanks.
A NMEA 2000 network can be configured to support many instances of duplicate
or similar devices on the same network. Additional devices must be added
through careful network configuration. Instance numbers are used to represent
similar devices on a common network.
When adding devices to the NMEA 2000 network:
• Unconfigured devices MUST be added one device at a time.
• Preconfigured device kits can be added to the network all at one time.
• In either case, if a device is associated with an engine the device instance
number MUST match the engine instance number.
Engine / Device Association
Port
Number of
Outboards
1
2
3
4
5
Port
Center
Center
Starboard
Center
Starboard
Instance Numbers
0
0
0
0
0
1
1
1
2
2
3
1
2
3
4
Use Evinrude Diagnostics software to confirm engine instance, or transom position.
54
Engine Instance (Transom Position) Information
I-COMMAND
I-Command Water Pressure Sensor Kit, P/N 5008300
Use this kit to provide water pressure data to I-Command or other instruments
on a NMEA 2000 network. Install this kit on Evinrude E-TEC 115 – 300 HP outboards only.
The water pressure sensor used in this kit is capable of providing water pressure
readings from 0 to 30 psi (0 to 206 kPA).
Refer to the installation instructions provided with the kit for correct installation.
The water pressure sensor MUST be installed in a vertical position. Hose installation MUST provide complete drainage of water from the sensor.
Software for I-Command Devices
Software is available to update I-Command digital gauge and device software.
Log into DealerPort (www.dealerport.com) or BOSSWeb (www.bossweb.brp.com) to download the latest I-Command software and information.
Refer to I-Command Software Update Kit, P/N 765357 on p. 63.
DealerPort
55
I-Command Bulletins
This list of bulletins provides a reference to specific I-Command issues.
Bulletin
Number
Affected Models
Problem
I-Command Classic
Instruments
All I-Command Classic instruments
with date codes prior to and including
date code 089/06 are suspect.
Certain I-Command Classic instruments may
accumulate moisture internally and experience
excessive lens fogging. Instruments with an accumulation of internal moisture should be replaced.
2006-04(S)
Evinrude E-TEC CANBus Software Update
All Evinrude E-TEC 115–250 HP outboards using CANBus network communications.
NMEA 2000 Lowrance † depth-finders and GPS
units can interfere with engine management module (EMM) functions on certain Evinrude
E-TEC outboards during certain CANBus communication modes.
2007-01(P)
I-Command Network
Connector(s)
2005 & newer 200 - 250 HP 90° V6
2007 & newer 115 - 200 HP 60° V4/V6
2008 & newer 40 - 90 HP
This bulletin provides information related to a
change in I-Command network connectors. (Blue
to Red connectors)
2008-01(P)
I-Command and NMEA
2000 Network Connectors
ALL
This bulletin provides information related to the differences in I-Command compatible DeviceNetstyle connectors.
2008-03(P)
I-Command Water
Pressure Sensor Kits
ALL
This bulletin provides information related to the
selection and installation of I-Command water
pressure sensors kits.
2008-04(P)
I-Command Fuel Level
Converter Kits
ALL
This bulletin provides information related to the
configuration of I-Command fuel level converters.
2010-01(P)
I-Command Digital
Gauges
ALL
This bulletin provides recommended service procedures and information to update software and to
submit warranty allowance requests.
2006-04(P)
56
Subject
PARTS AND ACCESSORIES
57
P&A INFORMATION
Tiller Handle Kits Evinrude E-TEC 15 – 30 HP Models
Tiller Handle Kits for 15 – 30 HP models are available as follows:
Color
Model Year
2009–2010
2011 & newer
Blue
White
Note
5007834
5008256
not available
5008237
5-pin electrical connector
6-pin electrical connector
Uses a 5-pin electrical connector. The neutral switch is attached. Refer to the
2009 or 2010 Accessory Parts Catalog for parts information.
Uses a 6-pin electrical connector. Refer to the 2011 Parts Catalog for order
information. Refer to the 2011 Accessory Parts Catalog for service parts information.
Tiller handle kits for 2009/10 models are not interchangeable with 2011 model.
Frequently Requested Part Numbers
The following items are frequently requested part numbers and should be
ordered as needed:
• Predelivery Checklist, P/N 5008381, 10/pack
• Warranty Allowance Requests (warranty claim forms), P/N 773629, 25/pack
• RCM Form (form for return of unused, saleable parts), P/N 11111, 10/pack
• Model Year Reference Guide, P/N 5006145
• 2011 Predelivery and Installation Guide, P/N 5008506 *
• ICON Installation Guide, P/N 764952 *
• I-Command Users Guide, P/N 355917 (3.5 inch) *
• I-Command Users Guide, P/N 355918 (2 inch) *
• I-Command Product Selection Guide, P/N 764677 *
* Available for download from DealerPort or BossWeb.
58
PARTS AND ACCESSORIES
Propeller Shaft Failures
Propeller shaft failures can occur when incorrect propeller hardware is installed.
1
2
1. BRP thrust bushing
2. Competitor’s thrust bushing
The thrust bushing provided with some competitor’s propeller and removable
hub kits may be significantly thinner than the thrust bushing provided with BRP
propeller kits.
The surface area of the thrust bushing which contacts the propeller shaft does
not provide sufficient clamp load after the propeller hardware and propeller are
installed.
Insufficient clamp load causes the propeller to loosen and can result in scoring of
the propeller shaft by the thrust bushing. The area that is scored by the thrust
bushing will weaken. Because the loose propeller puts an abnormal amount of
stress on the propeller shaft, the failure occurs at the weak point created by the
insufficient clamp load on the thrust bushing. This type of failure also results in
the loss of the propeller and propeller hardware.
Note: Incorrect installation of any manufacturer’s propeller and propeller hardware that results in the failure of the propeller shaft is not a condition which will
be covered under the BRP Limited Warranty.
Propeller Shaft Failure
59
NOTES – PARTS AND ACCESSORIES
60
SERVICE TOOLS
61
NEW SERVICE TOOLS
New service tools have been developed for 2011 Model Year outboards. New
tools were announced in Service Bulletin 2010-09(S).
Fuel Flow Test Kit, P/N 5008371
The Fuel Flow Test Kit, P/N 5008371, is used to check a boat’s fuel system for
fuel flow restrictions and air leaks without having to start the outboard or run the
vessel through the water. Developed for Evinrude E-TEC 115 – 300 HP outboards.
This tool was shipped automatically as part of the essential tool program.
Refer to Service Bulletin 2010-09(S) and the instructions for additional information.
62
Fuel Flow Test Kit, P/N 5008371
SERVICE TOOLS
I-Command Software Update Kit, P/N 765357
Use I-Command Software Update Kit, P/N 765357, to update I-Command digital
gauge software.
Software to run the update kit is available for use with Windows XP or Windows
Vista/Windows 7.
Log into DealerPort (www.dealerport.com) or BOSSWeb (www.bossweb.brp.com) to download the latest I-Command software and information.
This tool was shipped automatically as part of the essential tool program.
Refer to Parts and Accessories Bulletin 2010-01(P) or the instruction sheet
provided with the kit.
I-Command Software Update Kit, P/N 765357
63
NOTES – TOOLS
64
REFERENCE
65
PAINT
Paint codes have been added to the paper parts catalogs and to the Electronic Parts Catalogs (EPC) for the 2011 model year.
Color
Spray Can
PRIMER
PRIMER (Gray)
PRIMER (Black)
BLACK (Gloss)
BLACK (Military)
WHITE
CLEARCOAT
BLUE (Evinrude E-TEC)
777172
–
–
777179
351066
777171
772414
351907
PPG Paint Code
Paint / Catalyst
–
W42650 / W29741
SEP61993 / W29585
W28610 / W28792
W43653 / W26790
W28502 / W45315
W29461 / W26790
SAC61243 / W45315
Application
Midsection & Gearcase
Use for white engines
Use for blue engines
Engine cylinder/crankcase
Covers, Midsection, & Gearcase
Base coat
Use with base coat on upper & lower engine covers
Base coat
ELECTRICAL INFORMATION
Battery Cable Length Guide
Battery Recommendations
Battery cable must be of the correct gauge to carry the electrical
current required to start the outboard. Use the chart below to select
the correct gauge battery cable.
Each outboard requires its own starting battery. Use the chart
below to select a battery that meets or exceeds the minimum
requirements.
Outboard Model
Battery Cable Length
66
15–30 HP
Outboard Model
115–300 HP
675 CCA (845 MCA), or 800 CCA
(1000 MCA) below 32°F (0°C)
107 amp-hr in extreme applications
15–90 HP
640 CCA (800 MCA), or 800 CCA
(1000 MCA) below 32° F (0° C)
107 amp-hr in extreme applications
40–300 HP
1 to 10 Ft. (.3 to 3 m)
6 Gauge
4 Gauge
11 to 15 Ft. (3.4 to 4.6 m)
4 Gauge
2 Gauge
16 to 20 Ft. (4.9 to 6.1 m)
2 Gauge
1 Gauge
Battery Rating
REFERENCE
1
FUSES
2
The chart below list all fuses available from Evinrude/Johnson Genuine Parts
and Accessories.
4
3
5
6
Fuse Types
1. AGA
2. AGC/SFE
3. AGU
4. ATC/ATO
5. ATM/Mini
6. JT
ATC/ATO Fuse
ATM/Mini Fuse
0.430”
10.82 mm
0.760”
19.3 mm
0.207”
5.25 mm
0.15”
3.81 mm
0.460”
11.7 mm
0.492”
12.5 mm
0.263”
6.67 mm
0.347”
8.81 mm
0.752”
19.1 mm
0.642”
16.31 mm
0.295”
7.50 mm
Fuse
P/N
Fuse
Type
Amp
Rating
Fuse
Color
114509
512129
510884
5031911
511386
123852
5030348
512672
3850985
982019
763640
764538
763641
967545
5032215
514021
5032230
514764
514766
514767
514768
5032630
5033633
304980
AGA
AGA
AGA
AGA
AGA
AGC
AGC
AGU
AGU
AGU
ATC/ATO
ATC/ATO
ATC/ATO
ATC/ATO
ATC/ATO
ATC/ATO
ATC/ATO
ATM/Mini
ATM/Mini
ATM/Mini
ATM/Mini
ATM/Mini
JT
SFE
3
5
20
25
30
1
20
40
50
50
1
3
5
10
15
20
30
5
10
15
20
30
60
20
Glass
Glass
Glass
Glass
Glass
Glass
Glass
Glass
Glass
Glass
Black
Violet
Tan
Red
Blue
Yellow
Green
Tan
Red
Blue
Yellow
Green
Yellow
Glass
Fuse
Dimensions
(Length x Diameter)
0.625 x 0.25
0.625 x 0.25
0.625 x 0.25
0.625 x 0.25
0.625 x 0.25
1.25 x 0.25
1.25 x 0.25
1.5 x 0.411
1.5 x 0.411
1.5 x 0.411
See Fuse
Dimension
Diagram
1.25 x 0.25
Package
Qty
1
5
10
1
1
1
1
1
1
10
1
1
10
1
1
5
1
5
5
1
1
1
1
1
Fuse Dimension Diagram
67
EVINRUDE E-TEC SPARK PLUG SERVICE CHART
Model
15 H.O. – 30 HP
40 – 50 HP
60 – 65 HP
75 – 90 HP
115 – 130 HP
60° V4
150 – 200 HP
60° V6
200 – 250 HP
90°V6 (3.3L)
250 HO – 300 HP
90°V6 (3.4L)
2004
2005
2006
2007
68
2010
2011
QC10WEP
QC10WEP
QC12PEP†
QC12PEPB†
QC12PEPB†
QC10WEP
QC10WEP
QC10WEP
QC10WEP
QC12PEP†
QC12PEP†
QC12PEPB†
QC12PEPB†
QC10WEP
QC10WEP
QC10WEP
QC10WEP
QC12PEP†
QC12PEP†
QC12PEPB†
QC12PEPB†
QC10WEP
QC10WEP
QC10WEP
QC10WEP
QC10PEPB†
QC10WEP
QC10WEP
QC10WEP
QC10WEP
QC10PEPB†
QC10WEP
QC10WEP
QC10WEP
QC10WEP
QC10WEP
QC10WEP**
QC8WEP
QC8WEP
QC8WEP
QC8WEP
QC8WEP
QC8WEP
QC8WEP
QC10WEP*
QC10WEP*
Spark Plug Part Numbers
QC12PEP
QC12PEPB
QC10WEP
QC8WEP
QC10PEPB
2009
QC10WEP
QC12PEP†
† DO NOT substitute spark plugs on these models.
* QC10WEP may be substituted for QC10PEPB on 2005/2006 200 - 250 HP 90° V6 models.
** H suffix models use QC8WEP
Spark Plug
2008
(4-pack)
P/N
(6-pack)
(24-pack)
5001866
775983
5006525
763689
5007419
764643
5007597
5006308
778874
REFERENCE
EMM SERVICE CHART
EMMs cannot be ordered as a regular parts order, since they must be programmed before shipping.
BEFORE ordering a replacement EMM:
• Review Administrative Bulletin 2009-02(A) for the policies and procedures for the Warranty Replacement of Evinrude E-TEC EMMs.
• Review Parts and Accessories Bulletin 2008-02(P) for the policies and procedures for Service Replacement of Evinrude E-TEC EMMs.
Model
2004
2005
2006 - 2007
2008
15 – 30 HP
40 – 50 HP
586759
60 – 65 HP
75 – 90 HP
586759
2011
587062
587062
587062
586759
586968
586968
586968
586968
586759
586862
586970
586970
586970
586970
586759
586759
586970
586970
586970
586970
586867
586982
5869821
5870482
587048
587067
115 – 130 HP 60° V4
150 – 200 HP 60° V6
250 – 300 HP 90° V6 (3.4 L)
2010
586759
115 HP 60° V4
200 – 250 HP 90° V6 (3.3 L)
2009
586707
586707
586982
587048
587048
587067
586707
586982
587048
587048
587067
586982
587048
587048
587115
Notes:
1. 2009 115 HP F suffix ONLY
2. 2009 115 H.O. and 130 HP
IMPORTANT: Do NOT install an EMM from a newer engine on an older engine. Changes in the newer models will result in damage to
the EMM if installed on an older engine.
69
EVINRUDE E-TEC GEARCASE LINE DRAWINGS
S-Type: 75 – 90 HP (20 inch), I3 and
S2 Type: 115 – 130 HP (20 inch), V4
H-Type: 15 H.O. – 30 HP, I2
14.24”
361.65mm
19.079
3.22”
81.81mm
O-Type: 90 – 130 HP (25 inch), I3 & V4 and
150 – 200 HP (20 inch), 60° V6
F-Type: 40 – 65 HP, I2
19.20
17.46
4.06
70
4.124
4.918
REFERENCE
L-Type: No longer produced
M-Type: No longer produced
19.20
19.20
4.918
L2-Type: 150 H.O. 60° V6 (20 inch) and
200 H.O. 90° V6 (3.3L) (20 inch)
5.078
M2-Type: 150 –200 HP 60° V6 (25 inch) and
200 – 300 HP 90° V6 (20 & 25 inch)
19.20
4.918
19.20
5.082
71
2011 EVINRUDE E-TEC GEARCASE APPLICATION CHART
Gear Ratio
Gear Set
Reverse
Gear
Oil
Capacity
13:28 (.465) 2.15:1
392475 (F), 351147 (P)
327655
11 oz (325 ml)
13:28 (.465) 2.15:1
392475 (F), 351147 (P)
327655
11 oz (325 ml)
20”
12:32 (.375) 2.67:1
398522 (F,P)
318353
21 oz (620 ml)
40 – 60HP
20”
12:32 (.375) 2.67:1
398522 (F,P)
318353
21 oz (620 ml)
Blue
65 Comm
22.5”
12:32 (.375) 2.67:1
398522 (F,P)
318353
21 oz (620 ml)
5006555
Blue
75 – 90 HP
20”
13:26 (.500) 2:1
436746 (F,P)
345992
31.6 oz (935 ml)
5006426
White
75 – 90 HP
20”
13:26 (.500) 2:1
436746 (F,P)
345992
31.6 oz (935 ml)
5006326
Blue
60° V4
20”
13:26 (.500) 2:1
5006311 (F,P)
352319
31.6 oz (935 ml)
5006520
White
60° V4
20”
13:26 (.500) 2:1
5006311 (F,P)
352319
31.6 oz (935 ml)
5007023
White
75 – 90 HP
25”
12:27 (.444) 2.25:1
435123 (F,P)
336574
32.8 oz (970 ml)
5007334
Blue
60° V4
25”
12:27 (.444) 2.25:1
435123 (F,P)
336574
32.8 oz (1250 ml)
5007023
White
60° V4
25”
12:27 (.444) 2.25:1
435123 (F,P)
336574
32.8 oz (970 ml)
5006554
Blue
60° V6
20”
14:26 (.538) 1.86:1
5004218 (F,P,R)
336561
33.1 oz (980 ml)
5007134
White
60° V6
20”
14:26 (.538) 1.86:1
5004218 (F,P,R)
336561
33.1 oz (980 ml)
5007594
White
60° V4
25”
12:27 (.444) 2.25:1
435932 (F,P)
431702
Type
Assembly
Part No.
Color
Model
Family
H-Type
5008162
Blue
15 H.O. –
30 HP
5008214
White
15 H.O. –
30 HP
5006558
Blue
40 – 60HP
5007628
White
5006126
F-Type
S-Type
S2-Type
O-Type
CORO
72
Shaft
Length
15”
20”
25”
15”
20”
25”
REFERENCE
Type
Assembly
Part No.
Color
Model Family
Shaft
Length
Gear Ratio
Gear Set
Reverse
Gear
Oil
Capacity
M2-Type
5007705
Blue
60° V6
25”
13:24 (.542) 1.85:1
5007389 (F,P,R)
347373
38.9 oz (1150 ml)
5007669
White
60° V6
25”
13:24 (.542) 1.85:1
5007389 (F,P,R)
347373
38.9 oz (1150 ml)
5007705
Blue
90° V6 (3.3L)
20”
13:24 (.542) 1.85:1
5007389 (F,P,R)
347373
38.9 oz (1150 ml)
5007705
Blue
20”/25”
13:24 (.542) 1.85:1
5007389 (F,P,R)
347373
38.9 oz (1150 ml)
5007669
White
20”
13:24 (.542) 1.85:1
5007389 (F,P,R)
347373
38.9 oz (1150 ml)
5007705
Blue
20”/25”
13:24 (.542) 1.85:1
5007389 (F,P,R)
347373
38.9 oz (1150 ml)
5007669
White
90° V6 (3.3L)
20”/25”/
30”
13:24 (.542) 1.85:1
5007389 (F,P,R)
347373
38.9 oz (1150 ml)
5007669
White
90° V6 (3.4L)
25”/30”
13:24 (.542) 1.85:1
5007389 (F,P,R)
347373
38.9 oz (1150 ml)
5007670
White
60° V6
25”
13:24 (.542) 1.85:1
5007388 (F,P,R)
5008224
35.8 oz (1060 ml)
5007670
White
90° V6 (3.3L)
25”/30”
13:24 (.542) 1.85:1
5007388 (F,P,R)
5008224
35.8 oz (1060 ml)
5007670
White
90° V6 (3.4L)
25”/30”
13:24 (.542) 1.85:1
5007388 (F,P,R)
5008224
35.8 oz (1060 ml)
5007668
Blue
60° V6
20”
14:26 (.538) 1.86:1
5007663 (F,P)
353544
32.5 oz (960 ml)
5007706
White
60° V6
20”
14:26 (.538) 1.86:1
5007663 (F,P)
353544
32.5 oz (960 ml)
5007668
Blue
20”/25”
14:26 (.538) 1.86:1
5007663 (F,P)
353544
32.5 oz (960 ml)
5007706
White
20”
14:26 (.538) 1.86:1
5007663 (F,P)
353544
32.5 oz (960 ml)
CORO
L2-Type
225 HP 90° V6
(3.3L)
225 HP 90° V6
(3.3L)
250 H.O. 90° V6
(3.4L)
200 H.O. 90° V6
(3.3L)
200 H.O. 90° V6
(3.3L)
73
EVINRUDE E-TEC SHIFT ROD CHART
Shaft
Length
Gearcase
Type
Gear
Ratio
Shift
Rod P/N
Height Adjustment
(±1/2 turn)
Shift Rod
Dimension (A)
Model
Year
2004-2011
20
S
.50
351179
21 1/4 in
(53.975 cm)
31.0 in
(78.74 cm)
75 – 90 HP
2004-2005
25
O
.44
351180
26 1/4 in
(66.675 cm)
36.0 in
(91.44 cm)
2006-2011
25
O
.44
352886
26 1/4 in
(66.675 cm)
35.85 in
(91.05 cm)
A
115 – 130 HP
150 – 200 HP
60° V6
2007-2011
20
S2
.50
350464
20 15/16 in
(53.20 cm)
30.57 in
(77.65 cm)
2007-2011
2007-2011
25
O
.44
352957
25 15/16 in
(65.90 cm)
35.55 in
(90.29 cm)
20
L / L2
.54
350464
20 15/16 in
(53.20 cm)
30.57 in
(77.65 cm)
2007-2011
20
O
.54
350464
20 15/16 in
(53.20 cm)
30.57 in
(77.65 cm)
2007-2011
25
M / M2
.54
352808
25 15/16 in
(65.90 cm)
35.32 in
(89.71 cm)
A
200 – 300 HP
90° V6
2005-2011
20
L / L2
.54 / .58
329864
21 29/32 in
(55.60 cm)
31.49 in
(79.98 cm)
2005-2010
25
L / L2
.54 / .58
329865
26 29/32 in
(68.30 cm)
36.49 in
(92.68 cm)
2005-2011
20
M / M2
.54
347300
21 29/32 in
(55.60 cm)
31.25 in
(79.37 cm)
2005-2011
25
M / M2
.54
347301
26 29/32 in
(68.30 cm)
36.25 in
(92.07 cm)
2005-2011
30
M / M2
.54
347391
31 29/32 in
(81.00 cm)
41.25 in
(104.77 cm)
A
74
REFERENCE
EXTERNAL WATER SCREENS AND APPLICATIONS
This chart lists standard and available optional water screens. For applications which may require additional cooling water, select optional
water screens based on the type of application.
M-Type, M2-Type and L2-Type Gearcases
Water Screen Kit †
Port
High Performance, P/N 5005124 (L2 Standard)
348479
High Flow, P/N 5005063
350264
Ultra High Flow, P/N 5006337 (M2 Standard)
350946
Ultra High Flow +1/4, P/N 5007081
350790
Screws, P/N 337061
† Note: Kits include both screens, screws and instruction sheet.
O-Type Gearcase
Individual Water Screens ††
Port
Standard
337778
Optional
339247
Screws, P/N 337061
†† Note: Screens are symmetrical, use two per outboard.
S-Type and S2-Type Gearcases
Individual Water Screens ††
Standard (through 2006)
Standard (2007 and newer)
Optional
Screws, P/N 340665
Port
340495
337778
339247
Starboard
348480
350265
350945
350791
Height
Flush
0.060
0.160
0.410
Application
High Speed (over 60 MPH)
General
Aerated
Severely aerated
Starboard
337778
339247
Height
0.023
0.055
Application
General
Aerated
Starboard
340495
337778
339247
Height
Flush
0.058
0.200
Application
General
Aerated / Weedy
Severely aerated
†† Note: Screens are symmetrical, use two per outboard.
75
2011 RPM QUICK REFERENCE CHART
Recommended
Operating Range
Optimum
RPM Range
RPM @
Rated HP
15 H.O.
5500 – 6100
5400 – 5800
5800
25 HP
5500 – 6100
5400 – 5800
5800
30 HP
5500 – 6100
5400 – 5800
5800
40 HP
5000 – 6000
5400 – 5600
5500
50 HP
5500 – 6000
5600 – 5750
5750
60 HP
5500 – 6000
5600 – 5750
5750
65 HP Commercial
5500 – 6000
5600 – 5750
5750
75 HP
4500 – 5500
5000 – 5200
5000
90 HP
4500 – 5500
5000 – 5200
5000
115 – 130 HP 60° V4
5500 – 6000
5500 – 5750
5750
150 HP/150 H.O. 60° V6
4850 – 5850
5500 – 5600
5350
175 HP 60° V6
4850 – 5850
5500 – 5600
5350
200 HP 60° V6
4850 – 5850
5600 – 5850
5350
200 H.O. 90° V6 (3.3L)
4500 – 5800
5500 – 5700
5150
225 HP/225 H.O. 90° V6 (3.3L)
4500 – 5800
5500 – 5700
5150
250 HP 90° V6 (3.3L)
4500 – 5800
5500 – 5700
5150
250 H.O. 90° V6 (3.4L)
4500 – 6000
5500 – 5850
5250
300 HP 90° V6 (3.4L)
5000 – 6000
5500 – 5850
5500
Model
76
How to Use the RPM Quick
Reference Chart
When selecting a propeller for an outboard and boat
application, refer to the recommended wide open
throttle operating range for the outboard model.
When determining propeller selection, choose a propeller that will best suit the customer’s needs. For
example:
• choose a higher pitch propeller for low-to-mid rpm
for light load cruising.
• choose a lower pitch propeller to attain top rpm for
water skiing or other high load applications.
For best overall performance choose a propeller that
allows the outboard to run in the optimum rpm range,
which is usually the point of peak horsepower.
Remember, only a thorough water test will determine
which propeller works best for a particular application.
REFERENCE
2011 WATER PRESSURE CHART
This chart lists typical water pressure readings for 2011 model outboards for boat speeds up to 50 mph (80 kph/43 knots) and is provided
as a general guide for use when troubleshooting over-heating or over-cooling issues.
Water pressure readings can vary depending on water inlet screen type, hull design, set up, and operating conditions.
RPM
Idle
1000
1500
2000
40 – 65 HP
4-5
(27-34)
5-6
(34-41)
7-9
(48-62)
10-11
(68-75)
75 – 90 HP
5-6
(34-41)
10-11
(68-75)
12-14
15-17
16-18
16-18
13-15
15-17
16-18
19-21
20-22
(82-96) (103-117) (110-124) (110-124) (89-103) (103-117) (110-124) (131-144) (137-151)
115 – 130 HP
60° V4
5-6
(34-41)
9-10
(62-68)
12-14
15-17
18-20
20-21
20-22
21-23
21-23
21-23
21-23
(82-96) (103-117) (124-137) (137-144) (137-151) (144-158) (144-158) (144-158) (144-158)
150 – 200 HP
60° V6
4-5
(27-34)
24-26
9-11
14-16
17-19
19-21
20-22
20-22
21-23
22-24
23-25
(62-75) (96-110) (117-131 (131-144) (137-151) (137-151) (144-158) (151-165) 158-172) (165-179)
Model
200 – 250 HP
3-5
(27-34)
90° V6 (3.3L)1
250 HO – 300 HP
4-6
(27-41)
90° V6 (3.4L)1
2500
3000
3500
Water Pressure (psi/kpa)
4000
4500
14-15
15-17
16-18
16-18
14-16
(96-103) (103-117) (110-124) (110-124) (96-110)
12-14
(82-96)
13-15
(89-103)
5000
5500
12-14
(82-96)
10-12
(68-82)
7-9
(48-62)
8-10
(55-68)
9-11
(62-75)
10-12
(68-82)
11-13
(75-89)
14-16
15-17
16-18
(96-110) (103-117) (110-124)
7-11
(48-75)
9-12
(62-82)
10-14
(68-96)
12-15
(82-103)
14-16
15-18
16-19
18-20
18-25
20-30
(96-110) (103-124) (110-131) (124-137) (124-172) (137-207)
Notes:
1. Water pressure readings in excess of 40 psi (275 kpa) are possible for these models at boat speeds above 50 MPH (80 KPH/43 knots).
77
SERVICE LITERATURE
2011
Description
English
Operator’s
Guide
15 - 30 HP
40 - 60 HP
65 HP Commercial
55 HP MFE
75 - 90 HP
115 - 130 HP 60° V4
150 - 200 HP 60° V6
200 - 300 HP 90° V6
215992
215994
216018
215996
215998
216000
216000
216002
French
Operator’s
Guide
Evinrude Models
215993
215995
216019
215997
215999
216001
216001
216003
Literature Sets
2011 Illustrated Parts & Accessory Catalog
2011 Parts Catalog Set – Paper
2011 Service Manual Set – English
2011 Service Manual Set – French
2011 Service Manual CD – English
2011 Service Manual CD – French
78
Parts
Catalog
English
Service
Manual
French
Service
Manual
5008317
5008318
5008318
5008319
5008320
5008321
5008322
5008323
5008326
5008328
5008328
5008330
5008328
5008332
5008332
5008334
5008327
5008329
5008329
5008331
5008329
5008333
5008333
5008335
Reference
5008324
5008325
5008340
5008341
5008336
5008337
2011 Flat Rate Guide – English
2011 Flat Rate Guide – French
2011 Warranty Procedures – English
2011 Warranty Procedures – French
2011 Product Service Update – English
2011 Product Service Update – French
2011 Update CD – English
2011 Update CD – French
Special Tools Catalog
Predelivery & Installation – All Models – English
Predelivery & Installation – All Models – French
Predelivery & Installation – All Models – Spanish
5008492
5008493
5008494
5008495
5008496
5009497
355838
355839
5008526
5008506
5008507
5008508
REFERENCE
2010
Description
25 - 30 HP
40 - 60 HP
65 HP Commercial
75/90 HP
115 - 130 HP 60° V4
150 - 200 HP 60° V6
200 - 300 HP 90° V6
English
French
Operator’s
Operator’s
Guide
Guide
Evinrude Models
215932
215920
215922
215926
215928
215928
215930
Literature Sets
2010 Illustrated Parts & Accessory Catalog
2010 Parts Catalog Set – Paper
2010 Service Manual Set – English
2010 Service Manual Set – French
2010 Service Manual CD – English
2010 Service Manual CD – French
215933
215921
215923
215927
215929
215929
215931
Parts
Catalog
English
Service
Manual
French
Service
Manual
5007997
5007998
5007998
5008000
5008001
5008002
5008003
5008146
5008148
5008148
5008148
5008152
5008152
5008154
5008147
5008149
5008149
5008149
5008153
5008153
5008155
Reference
5008005
5008004
5008158
5008159
5008156
5008157
2010 Special Tools Catalog
2010 Flat Rate Guide – English
2010 Flat Rate Guide – French
2010 Warranty Procedures – English
2010 Warranty Procedures – French
2010 Product Service Update – English
2010 Product Service Update – English
2010 Update CD – English
2010 Update CD – French
Predelivery & Installation – All Models – English
Predelivery & Installation – All Models – French
5007858
5007856
5007860
5008129
5008130
5008168
5008169
355139
355140
5007857
5007861
79
BULLETINS
2010 Bulletin Index
Bulletin
Number
Models
Subject / Description
Administrative (A)
2010-01(A)
2010 Model Year Outboard Engines
Inbox Components
2010-02(A)
Evinrude ICON
Flat Rate Table
2010-03(A)
ALL
EPA Campaign Label
2010-04(A)
ALL
BEST Warranty
Predelivery (D)
2010-01(D)
ALL
Predelivery Checklist
2010-02(D)
2011 Evinrude E-TEC 250 – 300 HP (3.4 L) Outboards
New Installation and Predelivery Procedure
Parts and Accessories (P)
2010-01(P)
I-Command Digital Gauges
Updating Software
2010-01(S)
2009 Evinrude E-TEC 75 – 90 HP Outboards
Incorrect Wiring Diagram in Service Manual, P/N 5007811
2010-02(S)
Evinrude E-TEC 15 – 300 HP Outboards
Damaged Wiring Resulting from Improper Rigging or Faulty Connections
2010-03(S)
Evinrude E-TEC 75-90 HP Outboards
Gearcase Alignment Gauge Kit, P/N 5006349
Replaces Service Bulletin 2004-09(S)
2010-04(S)
Evinrude E-TEC 15 – 300 HP Outboards
Warranty Powerhead Identification
2010-05(S)
Evinrude E-TEC 150 – 200 HP 60° V6 Outboards
Oil Distribution Hose Routing
2010-06(S)
ALL
Operation in Oil Contaminated Water
2010-07(S)
Evinrude E-TEC 15 – 300 HP outboards,
1999 – 2001 Evinrude Ficht 75 – 250 HP outboards, and
2002–2006 Evinrude DI 75 – 250 HP outboards
Injector Coefficient Database
2010-08(S)
Evinrude E-TEC 15 – 30 HP Outboards
Torque Change for Flywheel Nut
2010-09(S)
ALL
New Service Tools – 2011 Model Year
2010-10(S)
Evinrude E-TEC 40 – 90 HP Outboards
Installing Replacement Lower Engine Covers
Service (S)
80
REFERENCE
Bulletin
Number
Models
Subject / Description
2010-01(W)
2010 Evinrude E-TEC 75 HP – 130HP Outboards
Trim and Tilt Hydraulic Assembly Replacement
2010-02(W)
2010 Evinrude E-TEC 115 – 300 HP Outboards
Oil Pump Assembly Replacement and Oil Hose Routing
2010-03(W)
2009 and 2010 Evinrude E-TEC 15 – 65 HP, and
2009 Evinrude MFE 55 HP Outboards
EPA CAMPAIGN: Fuel Hose and Primer Bulb Assembly Replacement
2010-04(W)
2010 and 2011 Evinrude E-TEC 40 - 90 HP Outboards
SAFETY CAMPAIGN: Incorrectly Installed Clamps on Fuel Hoses
2010-05(W)
2011 Evinrude E-TEC 200 HP – 250 HP 90° V6 (3.3 L)
Outboards
Shift Lever Cam
2010-06(W)
2011 Evinrude E-TEC 15 – 30 HP Outboards
Shift Lever Screws
2010-07(W)
This bulletin was not issued.
2010-08(W)
2010 and 2011 Evinrude E-TEC 115 – 300 HP
Outboards
Starter Drive Gear Engagement
2010-09(W)
2011 Evinrude E-TEC 15 – 30 HP Outboards
EPA CAMPAIGN: Engine Management Software Update
Warranty (W)
81
NOTES – REFERENCE
82
APPENDIX
83
TOPIC REFERENCE INDEX
Model
25 – 30 HP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
40 HP and larger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
60 – 65 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
75 – 90 HP and larger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
115 HP and larger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
115 H.O. – 130 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
150 – 200 HP 60° V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
150 – 300 HP 60° V6 and 90° V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
200 H.O. – 250 HP 90° V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
250 H.O. – 300 HP 90° V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
300 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4-Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
ICON Remote Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
I-Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Stern Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
84
APPENDIX
The table provides a reference to information presented in previous Product Service Updates.
Model
15 – 30
15 – 30
Flywheel servicing
Water pump servicing
Where to Find (Book Year /Section)
2010 - Service Tips
2010 - Service Tips
25 – 30
New model rigging information
2009 - Rigging
25
25
25
25
25
2009 2009 2009 2009 2009 -
25 – 30
25 – 30
40
New model warning system information
Step required to install battery charge module
EMM Light Emitting Diodes (LEDs)
Code 120; Oil level switch open circuit detected
Fuel injector seal kits
Fuel injector and vapor separator servicing, new
procedure
Oil recirculation diagram (new model)
New accessory kits for Evinrude E-TEC 25/30 HP
Tilt assist kit for manual tilt models
40
Rope start models - revised oil pump wire harness routing 2009 - Ignition & Electrical
–
–
–
–
–
30
30
30
30
30
25 – 30
40
40
40
40
40
–
–
–
–
–
60
60
60
60
60
Topic
Predelivery Bulletin
2008-02(D)
Rigging
Diagnostic Software
Engine Management Module
Service Codes
Fuel System
2009 - Fuel System
Service Bulletin
2008-07(S)
2009 - Oiling Systems
2009 - Parts & Accessories
2008 - Parts & Accessories
Water pump o-ring eliminated
Vented water pump housing
Melted propeller hardware or Hydrus exhaust ring
Cover design change
Oil recirculation changes 2004/2005 to 2006 & newer
New trim and tilt assembly, P/N 5007774 - manual relief
valve improved
2008 - Cooling System
2008 - Cooling System
2008 - Cooling System
2008 - Engine Covers
2008 - Oiling System
40 – 90
Engine idle temperature
2008 - Cooling System
40 – 90
40 – 90
Engine cover material
Spark plug replacement - inductive ignition models
2008 - Engine Covers
2008 - Ignition & Electrical
40 – 90
Spark plug life
2008 - Ignition & Electrical
40 – 60
Other References
2009 - Midsection
Service Bulletin
2006-07(S)
Service Bulletin
2006-07(S)
85
2008 2008 2008 2008 2008 2008 2008 2009 2008 2008 2008 2008 2008 2009 2010 2010 2010 2008 2008 2008 2008 2008 2010 -
40 – 300
Longer engine mounting screws
2009 - Rigging
40 – 300
Cylinder head temperature sensor installation change
2009 - Ignition & Electrical
40 – 300
40 – 300
40 – 300
TNT models - Melted wiring and bonding wires
Fuel injector seal kits
Vapor separator filter, P/N 354190, now available
2009 - Ignition & Electrical
2009 - Fuel System
2009 - Fuel System
86
Model
– 90
– 90
– 90
– 90
– 90
– 90
– 90
– 90
– 90
– 90
– 90
– 90
– 90
– 90
– 90
– 90
– 90
– 115
– 115
– 115
– 115
– 115
– 200
Where to Find (Book Year /Section)
Topic
Starter mounting screw installation
Exhaust relief muffler filter service
Oil to fuel hose eliminated
Service oil pump assemblies 2007 & older
Service oil pump assemblies 2008 & newer
Rigging grommet installation tip
Code 117; Critical low oil level - 2008 & newer models
Air bubbles in oil line
Lower motor cover installation
Repairing scratches to motor covers
Inductive ignition information
Inductive ignition testing
Code 38; Oil pressure feedback not detected
Change to flywheel service procedures
New oil tank and oil pump assemblies
Neutral switch
Installing a second battery
Single ram trim and tilt assemblies
Tiller kits
SystemCheck gauge recommendation
Steering friction kit
Missing on acceleration - propeller
Inline and 60° V Models - Cylinder Head Changes
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
Other References
Ignition & Electrical
Midsection
Oiling System
Oiling System
Oiling System
Rigging
Service Codes
Oiling Systems
Engine Covers
Engine Covers
Ignition & Electrical
Ignition & Electrical
Service Codes
Ignition & Electrical
Product Improvements
Product Improvements
Service Tips
Midsection
Parts & Accessories
Parts & Accessories
Parts & Accessories
Rigging
Service Tips
Parts & Accessories
Bulletin 2008-05(P)
Service Bulletin
2008-01(S)
APPENDIX
60
60
65
75
75
75
75
Model
– 65
– 65
–
–
–
–
90
90
90
90
75 – 130
75 – 250
75 – 250
75 – 300
75 – 300
75 – 300
75 – 300
90
90 – 250
115
115
115
115
115
115 – 130
115 – 130
115 – 130
115 – 130
115 – 130
115 – 200
115 – 200
115 – 200
Topic
Water valve operation
Water valve tests
Tilt assist kit for manual tilt models
Oil recirculation changes 2004/2005 to 2006 & newer
Upper mount screw change and service tip
2008 and newer - Changes to temperature monitoring
New starter motor
New trim and tilt assembly, P/N 5007776 - manual relief
valve improved
External water screen chart
Code 40; Engine overheat, low speed (port or single)
Driveshaft bearing housing change to o-ring
Code 70; Engine overheat, low speed (starboard)
O-ring, P/N 314728, supersedes to P/N 354731
Manual tilt midsection not compatible with trim and tilt
Water pump grommet and seal application
S2-Type Gearcase - information
Exhaust valve operation
Exhaust valve testing
Exhaust valve relay module testing
Over-oiling issue
How to identify S2-type gearcase
Oil recirculation changes 2008 & older/2009 & newer
S2-Type gearcase - Pinion screw torque
S2-Type gearcase - Stuck driveshaft
Air Intake and Air Silencer
60° models only - Melted propeller hub, modification to
help prevent
60° models only - Steering arm to cover bumper
60° models only - Rear oil manifold; multi-point oiling
Where to Find (Book Year /Section)
Other References
2008 - Midsection
2008 - Midsection
2008 - Parts & Accessories
2008 - Oiling System
2008 - Powerhead
2009 - Engine Management Software
2010 - Product Improvements
2009 - Midsection
2008 2009 2009 2009 2009 2010 2008 2008 2008 2008 2008 2008 2009 2009 2009 2009 2009 2010 -
Cooling System
Cooling System
Service Codes
Gearcase
Service Codes
Product Improvements
Midsection
Cooling System
Gearcase
Midsection
Midsection
Midsection
Oiling Systems
Gearcase
Oiling Systems
Gearcase
Gearcase
Product Improvements
2008 - Cooling System
2008 - Engine Covers
2008 - Oiling System
87
Model
115 – 200
115 – 200
115 – 200
115 – 200
Topic
115 – 200
115 – 200
Oil to fuel hose eliminated
60° models - Water separating fuel filter kit
60° models - revised oil hose routing
60° models - Upper mount screw change and service tip
60° models - Powerhead replacement kits have revised oil
hose routing
60° models - New flywheel cover
60° models - Ignition coil mounting bracket, mounting
location changed
60° models - Starter cable service kit, improves starting
60° models - water separating fuel filter added to 2009
models
60° models - vapor separator, P/N 5006084, pressure test
port changed
60° models - Rear oil manifold bracket
60° models - Improved shift lever, eliminates lost motion
115 – 200
60° models only - Oil filter installation
115 – 200
115 – 250
60° models only - Flywheel Stud
60° V4 and 60° V6/90° V6 starter motors are different
60° V4 and 60° V6/90° V6 starter motors differences and
changes
Exhaust relief muffler not serviceable
Oil switch improvement
Auxiliary battery charge kit
Trim switch extension kit
Exhaust back pressure sensor damage
Code 38 issue
2008 and newer - Service fuel injector electrical
connectors
Code 77; Start assist circuit over current detected - false
setting
115 – 200
115 – 200
115 – 200
115 – 200
115 – 200
115 – 200
115 – 250
115 – 250
115 – 250
115 – 250
115 – 250
115 – 250
115 – 250
115 – 300
115 – 300
88
Where to Find (Book Year /Section)
2008 2008 2008 2008 -
Oiling System
Parts & Accessories
Powerhead
Powerhead
2009 - Powerhead
2009 - Rigging
2009 - Ignition & Electrical
2009 - Ignition & Electrical
2009 - Fuel System
2009 - Fuel System
2009 - Oiling Systems
2009 - Gearcase
2008 - Rigging
2009 - Rigging
2010 - Product Improvements
2008 - Ignition & Electrical
2009 - Ignition & Electrical
2008 2008 2008 2008 2008 2008 -
Midsection
Oiling System
Parts & Accessories
Parts & Accessories
Powerhead
Rigging
2009 - Fuel System
2009 - Service Codes
Other References
APPENDIX
Model
115 – 300
115 H.O. – 130
115 H.O. – 130
115 H.O. – 130
115 H.O. – 300
115 H.O. – 300
Where to Find (Book Year /Section)
Topic
New engine wiring harnesses
New water pump kit, P/N 5007556
New impeller housing, P/N 5007554
V4 Exhaust adapter improvements
EMM changes
Inductive ignition new on these models
60° models only - Air silencer change can improve
performance
60° models - Powerhead alignment
60° models - New inner exhaust housing, P/N 354148,
improved water flow
M2-Type Gearcase - information
L2-Type Gearcase - information
Forward gear and bearing changes
Propeller shaft bearing housing retainer tabs
White "Stars and Stripes" decal kits
"Stars and Stripes" decal kits
How to identify L2-type gearcase
2008 - Gearcase
2008 - Gearcase
2008 - Gearcase
2008 - Gearcase
2008 - Parts & Accessories
2009 - Parts & Accessories
2009 - Gearcase
150 – 300
Powerhead installation, apply Permatex #2 to gasket area
2009 - Powerhead
200 – 250
200 – 250
90° models - New trim and tilt assembly
Engine idle temperature
2008 - Midsection
2008 - Cooling System
200 – 250
Thermostat venting
2008 - Cooling System
200 – 250
Melted propeller hub, modifications to help prevent
2008 - Cooling System
200 – 250
Fuel inlet hose clip
2008 - Engine Covers
200 – 250
DI models only - Alternate spark plug for extended low
speed operation
2008 - Ignition & Electrical
150 – 200
150 – 200
150 – 200
150
150
150
150
150
150
150
– 250
– 250
– 250
– 250
– 250
– 250
– 300
2009 2009 2009 2009 2009 2009 -
Other References
Ignition & Electrical
Cooling Systems
Cooling Systems
Midsection
Engine Management Module
Ignition & Electrical
2008 - Fuel System
2009 - Powerhead
2009 - Midsection
Service Bulletin
2005-03(S)
Service Bulletin
2005-04(S)
Warranty Bulletin
2005-01(W)
89
Model
Topic
Where to Find (Book Year /Section)
200 – 250
Spark plug life
2008 - Ignition & Electrical
200 – 250
200 – 250
200 – 250
200 – 250
200 – 250
Oil to fuel hose eliminated
2008 - Oiling System
90° models - Oil recirculation changes 2004-2006 to 2007
2008 - Oiling System
& newer
90° models - Flushing adapter
2008 - Parts & Accessories
2008 - Powerhead
90° models - Powerhead replacement kits
2009 - Powerhead
200 – 250
2005 models - Oil priming issue
2008 - Rigging
200
200
200
200
200
90° models - Adapter kit, P/N 5007589
90° (3.3 L) models - Adapter, P/N 5001496
Issue with flushing adapter, P/N 775385
Knock sensors added to these models
3.3 L Models - Water plate, P/N 347251
2009
2009
2009
2010
2010
200 – 300
90° models - Ignition coil mounting location, coil damage
2009 - Ignition & Electrical
200
200
200
200
200
90°
90°
90°
90°
90°
2009 2009 2009 2009 2010 -
–
–
–
–
–
–
–
–
–
–
250
250
250
250
250
300
300
300
300
300
models models models models models -
Pinched oil lines
Powerhead to adapter gaskets different
Trim and tilt assembly improvements
New pinion bearing, P/N 5007751
Trim Limit Rod, P/N 354185
-
Service Bulletin
2004-02(D)
Midsection
Midsection
Cooling System
Product Improvements
Service Tips
Oiling Systems
Midsection
Midsection
Gearcase
Product Improvements
250 H.O.
Important engine management software update
2009 - Engine Management Software
250 H.O.
Water pump installation
2009 - Cooling Systems
250 H.O. – 300 Important engine management software update
2009 - Engine Management Software
250 H.O. – 300 Codes 1 through 6: Excessive knock detected
2009 - Service Codes
90
Other References
Service Bulletin
2005-05(S)
Service Bulletin
2006-02(S)
Warranty Bulletin
2008-04 (W)
Warranty Bulletin
2008-04(W)
Warranty Bulletin
2008-06 (W)
APPENDIX
250
250
250
250
Model
H.O. – 300
H.O. – 300
H.O. – 300
H.O. – 300
Topic
Codes 7 and 8; Knock sensor open circuit detected
Knock sensors added to these models
New water pump kit, P/N 5007972
New impeller housing, P/N 5007968
Where to Find (Book Year /Section)
2009 2009 2009 2009 -
250 H.O. – 300 Temperature sensor and clamp servicing
2009 - Cooling Systems
250 H.O. – 300 New water pump kit, P/N 5007972
250 H.O. – 300 New impeller housing, P/N 5007968
2009 - Cooling Systems
2009 - Cooling Systems
250 H.O. – 300 Temperature sensor and clamp servicing
2009 - Cooling Systems
Melted propeller hub with gearcase seals pushed out, tip
to check for blocked cooling water passage
250 H.O. – 300 90° (3.4 L) models F suffix - Adapter, P/N 5007973
250 H.O. – 300 90° (3.4 L) models C or S suffix - Adapter, P/N 5007971
2009 - Midsection
2009 - Midsection
300
Important engine management software update
2009 - Engine Management Software
300
4-stroke
M2-Type gearcase, alignment pins
4-Stroke accessories and service kits
All
Overboard indicator requirements
All
All
All
2008 Water pressure chart
2009 Water pressure chart
Pressure relief valve improvement
All
Melted propeller hub, modifications to help prevent
All
All
All
EMM LEDs
2008 EMM not compatible with older engines
Fuel injectors - Ball In Plunger (BIP)
All
Unleaded gasoline
All
Alcohol extended fuels
2009 2009 2008 2009 2008 2009 2008 2008 2009 2008 2008 2008 2008 2009 2009 -
250 H.O. – 300
Other References
Service Codes
Ignition & Electrical
Cooling Systems
Cooling Systems
Warranty Bulletin
2008-02(W)
Warranty Bulletin
2008-02(W)
2009 - Cooling Systems
Gearcase
Parts & Accessories
Cooling System
Cooling System
Cooling System
Cooling System
Cooling System
Cooling System
Cooling System
Engine Management Module
Engine Management Module
Fuel System
Fuel System
Fuel System
Fuel System
Warranty Bulletin
2008-03 (W)
Service Bulletin
2006-06(S)
91
Model
Where to Find (Book Year /Section)
All
All
All
Topic
Fuel related problem prevention
Fuel contamination
Fuel additives
All
Fuel system maintenance
All
All
All
All
All
All
All
All
All
All
All
All
Fuel flow compensation
Do NOT mix and match fuel injectors - Nozzle and seat
angles
Injector service kit - Fuel injector crush ring
Fuel pressure test fittings changed
Relieving fuel system pressure
Fuel pressure gauge kits
Fuel lift pump
Fuel pressure and vacuum tests
Fuel control adjustment not available
2008 Gearcase application chart
2009 Gearcase application chart
Gearcase identification chart
How to identify gear ratios
All
Spark plug chart
All
Spark plug life
2008 - Ignition & Electrical
All
All
No lubricant on TPS linkage
TPS installation tip
All
TPS calibration
All
Starter motor service parts
All
All
Neutral switch and shift interrupt switch functions
Circuit testing with inductive pick-up timing light
2008 2008 2008 2009 2008 2009 2008 2008 -
All
92
2009 2008 2008 2008 2009 2008 -
Other References
Fuel System
Fuel System
Fuel System
Fuel System
Fuel System
Fuel System
2008 - Fuel System
2008 2008 2008 2008 2008 2008 2008 2008 2009 2009 2009 2008 2009 -
Fuel System
Fuel System
Fuel System
Fuel System
Fuel System
Fuel System
Fuel System
Gearcase
Gearcase
Gearcase
Gearcase
Ignition & Electrical
Ignition & Electrical
Ignition & Electrical
Ignition & Electrical
Ignition & Electrical
Ignition & Electrical
Ignition & Electrical
Ignition & Electrical
Ignition & Electrical
Ignition & Electrical
Service Bulletin
2006-01(S)
APPENDIX
Model
Topic
All
Oil requirements
All
Oil type setting
All
Powerhead identification tag
All
Powerhead rebuilding
Engine model number on serial number tag different than
model number stored in EMM
Connecting rod screw installation
Improper Gel-Seal II application
Checklist to return outboard to service after powerhead
replacement/rebuild
All
All
All
All
All
Break-in oil cycle
All
All
Different WOT rpm on multiple engine applications propeller
Poor acceleration - propeller
Stern bracket alternate mounting holes eliminated
All
Key switch accessory circuit (Amperage limit)
All
Key switch orientation (water drain)
All
All
All
All
All
All
Flywheel cover isolator installation
Lower motor cover installation
Cable retainer clips - proper installation
Oil priming tip
Tie bar adjustment
RPM Quick reference chart
All
Throttle cable adjustment
All
Code 11; TPS out of idle range
All
Where to Find (Book Year /Section)
2008 2009 2008 2008 2009 2008 2008 2009 2008 2008 2008 2009 2008 2009 -
Other References
Oiling System
Oiling System
Oiling System
Powerhead
Powerhead
Powerhead
Powerhead
Powerhead
Powerhead
Powerhead
Powerhead
Powerhead
Powerhead
Powerhead
2008 - Rigging
2008 2008 2008 2009 -
Rigging
Rigging
Rigging
Rigging
2008 2009 2008 2008 2008 2008 2008 2008 2008 2009 2008 -
Rigging
Rigging
Rigging
Rigging
Rigging
Rigging
Rigging
Rigging
Rigging
Rigging
Service Codes
OMC Service Bulletin
2092
93
Model
Where to Find (Book Year /Section)
All
All
Topic
Code 17; 55 volt circuit below range
Code 37; Water in fuel
Code 97; Intermittent switched B+ detected
RPM Quick reference chart
How to use RPM quick reference chart
Oetiker clamp selection
Oetiker clamp selection chart
Freeze frame data feature
Changes to profile screens
Two-minute history report, new feature on v 3.0
Changes to fuel control feature
Stop break-in feature removed
Ignition voltage display - inductive ignition models
Error message - Windows NT v 5.0
Error message - Invalid Chipset
Diagnostic power supply, P/N 587005
EMM service chart
Codes 81 through 86; Ignition timing circuit open detected
Code 97; Intermittent switched B+ detected
Codes 101 through 106; Ignition timing circuit short
detected
New crankshaft position sensor, P/N 587014
Troubleshooting 5 volt sensor circuit
All
Change to starter solenoid servicing
2009 - Ignition & Electrical
All
All
All
All
All
All
Corrosion
Galvanic corrosion
Stray current corrosion
Corrosion protection testing
Fuel control adjustment not available
Check fuel injectors when water found in fuel
2009 2009 2009 2009 2009 2009 -
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
94
2008 2008 2008 2009 2009 2009 2009 2009 2009 2009 2009 2009 2009 2009 2009 2009 2009 2009 2009 -
Other References
Service Codes
Service Codes
Service Codes
Rigging
Rigging
Rigging
Rigging
Diagnostic Software
Diagnostic Software
Diagnostic Software
Diagnostic Software
Diagnostic Software
Diagnostic Software
Diagnostic Software
Diagnostic Software
Diagnostic Software
Engine Management Module
Service Codes
Service Codes
2009 - Service Codes
2009 - Ignition & Electrical
2009 - Ignition & Electrical
Ignition & Electrical
Ignition & Electrical
Ignition & Electrical
Ignition & Electrical
Fuel System
Fuel System
Service Bulletin
2008-04(S)
APPENDIX
Model
Where to Find (Book Year /Section)
All
All
All
Topic
Evinrude / Johnson XD-100 outboard oil
Evinrude / Johnson XD-50 outboard oil
Evinrude / Johnson XD-30 outboard oil
All
Oil type setting, H.O. models XD-100 setting not available 2009 - Oiling Systems
All
All
All
All
All
All
All
All
All
All
ICON
ICON
ICON
ICON
ICON
ICON
ICON
ICON
ICON
ICON
ICON
Control
Control
Control
Control
Control
Control
Control
Control
Control
Control
Control
ICON Control
ICON Control
ICON Control
Oil type setting, use TCW-3 setting with XD-100 oil
(extreme applications)
Multi-point oiling
Tip to check for aerated cooling water
Mounting screw torque
Gear oil smell
Propeller shaft bearing housings
Use of electrical grease
Electrical test adaptors
Water vapor from exhaust relief
Engine cover care
Features
ICON rigging kits
ICON conversion kits
ICON rigging kit selection chart
ICON remote control system installation
Master power/key switch
Dual lever binnacle mount remote controls
ICON buss cables
Engine identity
Setting up multiple engine applications
Station Protect
ICON Remote control system and engine management
software
ICON remote control trim plates
ICON accessory power relay
Other References
2009 - Oiling Systems
2009 - Oiling Systems
2009 - Oiling Systems
2009 - Oiling Systems
2009 2009 2009 2009 2010 2010 2010 2010 2010 2010 2010 2010 2010 2010 2010 2010 2010 2010 2010 2010 -
Oiling Systems
Cooling Systems
Gearcase
Gearcase
Product Improvements
Service Tips
Service Tips
Service Tips
Service Tips
Evinrude ICON Remote
Evinrude ICON Remote
Evinrude ICON Remote
Evinrude ICON Remote
Evinrude ICON Remote
Evinrude ICON Remote
Evinrude ICON Remote
Evinrude ICON Remote
Evinrude ICON Remote
Evinrude ICON Remote
Evinrude ICON Remote
Control
Control
Control
Control
Control
Control
Control
Control
Control
Control
Control
2010 - Evinrude ICON Remote Control
2010 - Evinrude ICON Remote Control
2010 - Evinrude ICON Remote Control
95
Where to Find (Book Year /Section)
Model
ICON Control
ICON Control
ICON Control
ICON Control
ICON Control
ICON Control
ICON Control
ICON Control
ICON Control
ICON Control
ICON Control
ICON Control
ICON Control
I-Command
I-Command
I-Command
I-Command
I-Command
I-Command
I-Command
Topic
ICON gateway module
ICON hubs (6-port)
Shift and throttle actuator calibration
ICON switch panels
Code 107; Control communication error
Code 108; ICON failsafe mode
Code 109; Control hardware fault
Code 110; Trim switch module communication fault
Code 111; Electronic servo-module communication fault
Code 149; Throttle actuator sensor fault
Code 150; Throttle actuator motion fault
Code 151; Shift actuator sensor fault
Code 152; Shift actuator motion fault
Fuel Level Does Not Display
Alternator voltage incorrect display
Trim level does not display or is inaccurate
I-Command digital product selection guide
I-Command network design and gauge simulator tool
Network tester kit, P/N 765023
GPS Head Unit Kit, P/N 764592
2010 2010 2010 2010 2010 2010 2010 2010 2010 2010 2010 2010 2010 2008 2008 2008 2009 2009 2009 2009 -
I-Command
Device-net style connectors
2009 - I-Command
I-Command
I-Command
Water pressure sensor kit, P/N 5006214
Water pressure sensor kit, P/N 764195
2009 - I-Command
2009 - I-Command
I-Command
Pre-programmed water pressure sensor kits
2009 - I-Command
I-Command
Pre-programmed fuel level converter kits
2009 - I-Command
I-Command
I-Command
I-Command
Fluid level converter kit, P/N 764166
How to set up fuel management options
I-Command gauge installation (dashboard hole size)
2009 - I-Command
2009 - I-Command
2009 - I-Command
96
Evinrude ICON
Evinrude ICON
Evinrude ICON
Evinrude ICON
Evinrude ICON
Evinrude ICON
Evinrude ICON
Evinrude ICON
Evinrude ICON
Evinrude ICON
Evinrude ICON
Evinrude ICON
Evinrude ICON
Rigging
Rigging
Rigging
I-Command
I-Command
I-Command
I-Command
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Other References
Control
Control
Control
Control
Control
Control
Control
Control
Control
Control
Control
Control
Control
Parts & Accessories
Bulletin 2008-01(P)
Parts & Accessories
Bulletin 2008-03(P)
Parts & Accessories
Bulletin 2008-04(P)
APPENDIX
Model
Topic
Where to Find (Book Year /Section)
I-Command
How to reset I-Command gauge to factory default settings 2009 - I-Command
I-Command
I-Command
I-Command
I-Command
I-Command
I-Command
I-Command
I-Command
P&A
P&A
P&A
P&A
Avoid radar antenna when installing GPS module
Fuel level sender resistance different in North America and
Europe
Installing oil level converter kit
Low battery voltage when configuring fuel level converter
Instancing
I-Command and 15 – 90 HP models
Power supply kits, P/N 764157 or P/N 764159
Warranty procedures for I-Command digital gauges
I-Command bulletins
OMS rebuild kits available
Water separating fuel filter gasket issue
OMS replacement checklist
TBX Torsion bushing damage
2009 2009 2010 2010 2010 2010 2010 2009 2009 2009 2009 -
P&A
Rectifier/regulator, no purple wire
2009 - Parts & Accessories
P&A
P&A
Frequently requested part numbers
Reverse gear availability
2010 - Parts & Accessories
2010 - Parts & Accessories
Propeller
Hydrus propeller exhaust ring
2009 - Rigging
I-Command
Propeller
Propeller
Propeller
Propeller
Propeller
Gear ratio and propeller selection (.54 vs. .58 ratio
gearcases)
Demo-prop program
Propellers for 15 – 30 HP models
New aluminum propellers
Installation tip: Interchangeable hub propeller
Identifying correct propeller part numbers
Software
PC Specifications for diagnostic software
Software
USB to serial adapters for diagnostic software
Propeller
Other References
2009 - I-Command
2009 - I-Command
I-Command
I-Command
I-Command
I-Command
I-Command
I-Command
I-Command
Parts & Accessories
Parts & Accessories
Parts & Accessories
Parts & Accessories
Parts & Accessories
Bulletin 2001-01(P)
Parts & Accessories
Bulletin 2005-01(P)
2009 - Rigging
2009 2010 2010 2010 2010 2008 2009 2008 -
Parts & Accessories
Parts & Accessories
Parts & Accessories
Parts & Accessories
Parts & Accessories
Diagnostic Software
Diagnostic Software
Diagnostic Software
97
Where to Find (Book Year /Section)
Model
Software
Software
Topic
New USB to serial adapters for diagnostic software
USB to serial adapter set up
2009 - Diagnostic Software
2008 - Diagnostic Software
Software
Evinrude Diagnostic software program update, v 2.0
2008 - Diagnostic Software
Software
Evinrude Diagnostic software program update, v 3.0
2009 - Diagnostic Software
Software
Evinrude Diagnostic software program update, v 4.0
2010 - Evinrude Diagnostic Software
Software
Software versions and revisions
Software
Software revision updates
Software
Software revision number changes
Software
Software version updates
Software
Inline update - adds TPS calibration
2008 - Engine Management Software
Software
Inline update 2 - adds TPS calibration and improved
calibrations
2009 - Engine Management Software
Software
I-Command and engine management software updates
2009 - Engine Management Software
Software
Mismatch error received during software upload
2008 - Engine Management Software
Software
90° V6 software update - dual temperature monitoring
2008 - Engine Management Software
Software
Fuel adjustment feature not available
2008 - Engine Management Software
Software
Data Logging
2010 - Evinrude Diagnostic Software
Software
Understanding Knock Profiles
2010 - Evinrude Diagnostic Software
Stern Drive
Stern drive parts inquiries
2009 - Parts & Accessories
98
2008
2009
2008
2009
2008
2009
2008
2009
-
Engine
Engine
Engine
Engine
Engine
Engine
Engine
Engine
Other References
Service Bulletin
2008-05(S)
Management Software
Management Software
Management Software
Management Software
Management Software
Management Software
Management Software
Management Software
Warranty Bulletin
2007-01(W)
APPENDIX
Model
Topic
Where to Find (Book Year /Section)
Other References
Service Bulletin
2006-03(S)
Service Bulletin
2005-06(S)
Service Bulletin
2006-03(S)
Service Bulletin
2008-03(S)
Service Bulletin
2008-02(S)
Service Bulletin
2004-011(S)
Predelivery Bulletin
2008-02(D)
Tools
Gearcase alignment pin kit
2008 - Gearcase
Tools
S-2 driveshaft tools
2008 - Gearcase
Tools
60° models - Powerhead alignment tool
2008 - Powerhead
Tools
New tools for M2-Type and L2-Type gearcases
2009 - Gearcase
Tools
Propeller shaft seal tools, allow replacement of seals
without gearcase disassembly
2009 - Gearcase
Tools
Gearcase alignment gauge
2008 - Gearcase
Tools
Enigne lift kit, P/N 354717
2010 - Service Tools
Tools
Stator test adaptor, P/N 354719
2010 - Service Tools
Service Manual
Tools
Diagnostic power supply, P/N 587005
2010 - Service Tools
Service Manual
Tools
Accessory power cable kit, P/N 5008092
2010 - Service Tools
Tools
Bearing Installers, P/N 321428 and P/N 335820
2010 - Service Tools
Tools
Alignment gauge puller, P/N 354718
2010 - Service Tools
Service Manual
Tools
Wrist pin retainer tool, P/N 354720
2010 - Service Tools
Service Manual
99
NOTES – APPENDIX
100
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