Evinrude E-TEC 200 User manual

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250 Sea Horse Drive
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Evinrude
®
Twist Grip™
Johnson
®
Nut Lock™
Evinrude
®
E-TEC
®
Screw Lock™
FasTrak™ Ultra Lock™
S.A.F.E.™ Moly Lube™
SystemCheck™
Triple-Guard
®
Grease
I-Command™ DPL™ Lubricant
Evinrude
®
ICON™ 2+4
®
Fuel Conditioner
Evinrude
®
/ Johnson
®
XD30™ Outboard Oil
Carbon Guard™
Evinrude
®
/ Johnson
®
XD50™ Outboard Oil
HPF XR™ Gearcase Lubricant
Evinrude
®
/ Johnson
®
XD100™ Outboard Oil
HPF PRO™ Gearcase Lubricant
Gel-Seal II™
2
SERVICE MANUAL
CONTENTS
SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE
1 REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
2 ROUTINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 ENGINE COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . 49
4 ENGINE MANAGEMENT MODULE (EMM) . . . . . . . . . . 53
5 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . 87
7 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
8 OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
9 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
10 EVINRUDE ICON REMOTE CONTROL SYSTEM . . . . 193
11 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
12 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
13 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
GEARCASE – STANDARD ROTATION . . . . . . . . . . . . 294
GEARCASE – COUNTER ROTATION . . . . . . . . . . . . . 317
14 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S–1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I–1
TROUBLE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . T–1
DIAGRAMS
IMPORTANT: For complete outboard rigging and control installation information, refer to the Predeliv-
ery and Installation Guide included with the service manual set.
All special tools referenced in this manual can be found in the Special Tools Guide, P/N 5008526.
REFERENCE INFORMATION
3
1
REFERENCE INFORMATION
TABLE OF CONTENTS
SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
EMISSION-RELATED INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
MANUFACTURER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
DEALER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OWNER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
EPA EMISSION REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
SAFETY NOTICE
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This publication is written for qualified, factory-
trained technicians who are already familiar with
the use of Evinrude/Johnson Special Tools. The
included information is not a substitute for work
experience. It is an organized guide for reference,
repair, and/or maintenance.
The following symbols and/or signal words
may be used in this document:
Indicates an instruction which, if
not followed, could severely damage engine
components or other property.
These safety alert signal words mean:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
IMPORTANT: Identifies information that controls
correct assembly and operation of the product.
DO NOT perform any work until you have read
and understood these instructions completely.
Torque wrench tightening specifications must
strictly be adhered to.
Should removal of any locking fastener (lock tabs,
locknuts, or patch screws) be required, always
replace with a new one.
When replacement parts are required, use
Evinrude/Johnson Genuine Parts or parts with
equivalent characteristics, including type, strength
and material. Use of substandard parts could
result in injury or product malfunction.
Always wear EYE PROTECTION AND APPRO-
PRIATE GLOVES when using power tools.
Unless otherwise specified, engine must be OFF
when performing this work.
Always be aware of parts that can move, such as
flywheels, propellers, etc.
Some components may be HOT. Always wait for
engine to cool down before performing work.
If you use procedures or service tools that are not
recommended in this manual, YOU ALONE must
decide if your actions might injure people or dam-
age the outboard.
This document may be translated into other lan-
guages. In the event of any discrepancy, the
English version shall prevail.
DANGER
Indicates a hazardous situation which, if
not avoided, will result in death or serious
injury.
WARNING
Indicates a hazardous situation which, if
not avoided, could result in death or seri-
ous injury
CAUTION
Indicates a hazardous situation which, if
not avoided, could result in minor or mod-
erate personal injury.
NOTICE
1
DANGER
Contact with a rotating propeller is likely to result in serious injury or death. Assure the
engine and prop area is clear of people and objects before starting engine or operating boat.
Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and
the propeller can continue to turn even after the engine is off. Remove propeller before ser-
vicing and when running the outboard on a flushing device.
DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to
accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled,
can cause serious brain damage or death.
WARNING
Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172
kPa).
The motor cover and flywheel cover are machinery guards. Use caution when conducting
tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and
clothing away from rotating parts.
During service, the outboard may drop unexpectedly. Avoid personal injury; always support
the outboard’s weight with a suitable hoist or the tilt support bracket during service.
To prevent accidental starting while servicing, disconnect the battery cables at the battery.
Twist and remove all spark plug leads.
The electrical system presents a serious shock hazard. DO NOT handle primary or secondary
ignition components while outboard is running or flywheel is turning.
Gasoline is extremely flammable and highly explosive under certain conditions. Use caution
when working on any part of the fuel system.
Protect against hazardous fuel spray. Before starting any fuel system service, carefully
relieve fuel system pressure.
Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular
phones in the vicinity of a fuel leak or while fueling.
Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and
causing an explosion.
Always work in a well ventilated area.
Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak.
Definite resistance to tightening must be felt when reusing a locking fastener. If replacement
is indicated, use only authorized replacement or equivalent.
6
REFERENCE INFORMATION
ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL
Units of Measurement List of Abbreviations
A Amperes
amp-hr Ampere hour
fl. oz. fluid ounce
ft. lbs. foot pounds
HP horsepower
in. inch
in. Hg inches of mercury
in. lbs. inch pounds
kPa kilopascals
ml milliliter
mm millimeter
N·m Newton meter
P/N part number
psi pounds per square inch
RPM revolutions per minute
°C degrees Celsius
°F degrees Fahrenheit
ms milliseconds
µs microseconds
Ohms
VVolts
VAC Volts Alternating Current
VDC Volts Direct Current
ABYC American Boat & Yacht Council
ATDC after top dead center
AT air temperature sensor
BPS barometric pressure sensor
BTDC before top dead center
CCA cold cranking amps
CFR Code of Federal Regulations
CPS crankshaft position sensor
EMM Engine Management Module
EPA Environmental Protection Agency
ICOMIA International Council of Marine
Industry Associations
ID Inside dimension
MCA marine cranking amps
MWS modular wiring system
NMEA National Marine Electronics Assoc.
ROM read only memory
S.A.F.E. speed adjusting failsafe electronics
SAC start assist circuit
SAE Society of Automotive Engineers
SYNC synchronization
TDC top dead center
TPS throttle position sensor
USCG United States Coast Guard
WOT wide open throttle
WTS water temperature sensor
7
REFERENCE INFORMATION
EMISSION-RELATED INSTALLATION INSTRUCTIONS
1
EMISSION-RELATED
INSTALLATION
INSTRUCTIONS
Failing to follow these instructions when
installing a certified engine in a vessel violates
federal law (40 CFR 1068.105 (b)), subject to
fines or other penalties as described in the
Clean Air Act.
Maintenance, replacement, or repair of the emis-
sion control devices and systems may be per-
formed by any marine SI (spark ignition) engine
repair establishment or individual.
Manufacturers Responsibility
Beginning with 1999 model year outboards, man-
ufacturers of marine outboards must determine
the exhaust emission levels for each outboard
horsepower family and certify these outboards
with the United States of America Environmental
Protection Agency (EPA). An emissions control
information label, showing emission levels and
outboard specifications, must be placed on each
outboard at the time of manufacture.
Dealers Responsibility
When performing service on all 1999 and more
recent Evinrude/Johnson outboards that carry an
emissions control information label, adjustments
must be kept within published factory specifica-
tions.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the outboard in any
manner that would alter the horsepower or allow
emission levels to exceed their predetermined
factory specifications.
Exceptions include manufacturer’s prescribed
changes, such as altitude adjustments, for exam-
ple.
Owners Responsibility
The owner/operator is required to have outboard
maintenance performed to maintain emission lev-
els within prescribed certification standards.
The owner/operator is not to, and should not allow
anyone to, modify the outboard in any manner
that would alter the horsepower or allow emis-
sions levels to exceed their predetermined factory
specifications.
Tampering with the fuel system to change horse-
power or modify emission levels beyond factory
settings or specifications will void the product war-
ranty.
EPA Emission Regulations
All new 1999 and more recent Evinrude/Johnson
outboards are certified to the EPA as conforming
to the requirements of the regulations for the con-
trol of air pollution from new watercraft marine
spark ignition outboards. This certification is con-
tingent on certain adjustments being set to factory
standards. For this reason, the factory procedure
for servicing the product must be strictly followed
and, whenever practical, returned to the original
intent of the design. The responsibilities listed
above are general and in no way a complete list-
ing of the rules and regulations pertaining to the
EPA requirements on exhaust emissions for
marine products. For more detailed information on
this subject, you may contact the following loca-
tions:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
501 3rd St. NW
Washington, DC 20001
EPA INTERNET WEB SITE:
www.epa.gov
8
REFERENCE INFORMATION
MODEL DESIGNATION
MODEL DESIGNATION
Model and serial numbers are located on the swivel bracket and on the powerhead.
B E 200 DP X II E
STYLE:
J = Johnson
E = Evinrude
HORSEPOWER
LENGTH:
= 15” Std.
L = 20” Long
Y = 22.5” Special
X = 25” X-long
Z = 30” XX-long
MODEL YR:
I= 1
N= 2
T= 3
R= 4
O= 5
D= 6
U= 7
C= 8
E= 9
S= 0
Ex: II = 2011
MODEL RUN
or SUFFIX
DESIGN FEATURES:
B = Blue Paint
C = Counter Rotation
D = Evinrude E-TEC
®
E = Electric Start w/Remote Steering
F = Direct-Injection
G = Graphite Paint
H = High Output
J = Jet Drive
M = Military
P = Power Trim and Tilt
R = Rope Start w/Tiller Steering
S = Saltwater Approved
T = Tiller Steering
TE = Tiller Electric
V = White Paint
W = Commercial Model
PREFIX:
B = Bodensee model
D = ICON model
1. Model and serial number 000449
1
1. Serial number 006828
1
REFERENCE INFORMATION
MODELS COVERED IN THIS MANUAL
9
1
MODELS COVERED IN THIS MANUAL
This manual covers service information on all 200.1 cubic inch (3.3 L) and 210 cubic inch (3.4 L), 90° V
Evinrude E-TEC models.
Mode
l
Dis
p
lacement Gearcase Hei
g
ht Color
Description
E200HSLIIB 3.3 L, 200.1 ci .538 L2 20" White Stainless Steering Arm, H.O./Standard Styling
E200HVLIIA 3.3 L, 200.1 ci .542 M2 20" White Stainless Steering Arm, H.O./Standard Styling
E200DHLIID 3.3 L, 200.1 ci .538 L2 20" Blue Steel Steering Arm, H.O./Standard Styling
E200DHXIIB 3.3 L, 200.1 ci .542 M2 25" White Stainless Steering Arm, H.O./Standard Styling
E200HCXIIB 3.3 L, 200.1 ci .542 M2 CR 25" White Stainless Steering Arm, H.O./Standard Styling
E225DPLIID 3.3 L, 200.1 ci .542 M2 20" Blue Steel Steering Arm, Standard Styling
E225DPXIID 3.3 L, 200.1 ci .542 M2 25" White Stainless Steering Arm, Standard Styling
E225DCXIID 3.3 L, 200.1 ci .542 M2 CR 25" White Stainless Steering Arm, Standard Styling
E225DPZIID 3.3 L, 200.1 ci .542 M2 30" White Stainless Steering Arm, Standard Styling
E225DCZIID 3.3 L, 200.1 ci .542 M2 CR 30" White Stainless Steering Arm, Standard Styling
E225HSLIIA 3.3 L, 200.1 ci .542 M2 20" White Stainless Steering Arm, H.O. Styling
E225DHLIID 3.3 L, 200.1 ci .542 M2 20" Blue Steel Steering Arm, H.O. Styling
E225DHXIIE 3.3 L, 200.1 ci .542 M2 25" Blue Stainless Steering Arm, H.O. Styling
E250DPLIID 3.3 L, 200.1 ci .542 M2 20" Blue Steel Steering Arm, Standard Styling
E250DPXIID 3.3 L, 200.1 ci .542 M2 25" White Stainless Steering Arm, Standard Styling
DE250PXIIC 3.3 L, 200.1 ci .542 M2 25" White
ICON Control
Stainless Steerin
Arm
,
Std St
y
lin
g
E250DCXIID 3.3 L, 200.1 ci .542 M2 CR 25" White Stainless Steering Arm, Standard Styling
DE250CXIIC 3.3 L, 200.1 ci .542 M2 CR 25" White ICON Control, Stainless Steering Arm, Std Styling
E250DPZIID 3.3 L, 200.1 ci .542 M2 30" White Stainless Steering Arm, Standard Styling
DE250PZIIC 3.3 L, 200.1 ci .542 M2 30" White ICON Control, Stainless Steering Arm, Std Styling
E250DCZIID 3.3 L, 200.1 ci .542 M2 CR 30" White Stainless Steering Arm, Standard Styling
DE250CZIIC 3.3 L, 200.1 ci .542 M2 CR 30" White ICON Control, Stainless Steering Arm, Std Styling
E250HSLIIR 3.4 L, 210 ci .542 M2 20" White Stainless Steering Arm, H.O. Styling
E250DHLIIA 3.4 L, 210 ci .542 M2 20" Blue Steel Steering Arm, H.O. Styling
E250DHXIIA 3.4 L, 210 ci .542 M2 25" Blue Stainless Steering Arm, H.O. Styling
E300DSLIIR 3.4 L, 210 ci .542 M2 20" White Stainless Steering Arm, Standard Styling
E300DPXIIA 3.4 L, 210 ci .542 M2 25" White Stainless Steering Arm, Standard Styling
DE300PXIIC 3.4 L, 210 ci .542 M2 25" White ICON Control, Stainless Steering Arm, Std Styling
E300DPZIIA 3.4 L, 210 ci .542 M2 30" White Stainless Steering Arm, Standard Styling
DE300PZIIC 3.4 L, 210 ci .542 M2 30" White ICON Control, Stainless Steering Arm, Std Styling
E300DCXIIA 3.4 L, 210 ci .542 M2 CR 25" White Stainless Steering Arm, Standard Styling
DE300CXIIC 3.4 L, 210 ci .542 M2 CR 25" White ICON Control, Stainless Steering Arm, Std Styling
E300DCZIIA 3.4 L, 210 ci .542 M2 CR 30" White Stainless Steering Arm, Standard Styling
DE300CZIIC 3.4 L, 210 ci .542 M2 CR 30" White ICON Control, Stainless Steering Arm, Std Styling
10
REFERENCE INFORMATION
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
ENGINE
HP 200 225 250
Full Throttle
Operating Range
4500–5800 RPM
Power
200 HP
(149 kw)
@ 5150 RPM
225 HP
(168 kw)
@ 5150 RPM
250 HP (187 kw)
@ 5150 RPM
Idle RPM in Gear 500 ± 50
Test Propeller
Standard Rotation Models: P/N 436080 or P/N 396277
Counter Rotation Models: P/N 436081 or P/N 398674
Weight
(may vary depending
on model)
20 in. (L) Models: 503 lbs. (228 kg)
25 in. (X) Models: 524 lbs. (238 kg)
30 in. (Z) Models: 530 lbs. (240 kg)
Lubrication
Evinrude/Johnson XD100 Oil
Refer to Recommended Lubricants on p. 164
Engine Type 90° V 6-Cylinder Loop-Charged
Displacement
200.1 cu. in. (3279 cm
3
)
Bore 3.854 in (97.89 mm)
Stroke 2.858 in. (72.60 mm)
Standard Bore
3.8535 to 3.8545 in. (97.87 to 97.90 mm)
To bore oversize, add piston oversize dimension to standard bore
Top Crankshaft Journal 1.6199 to 1.6204 in. (41.15 to 41.16 mm)
Center Crankshaft Journals 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Bottom Crankshaft Journal 1.5747 to 1.5752 in. (40.0 to 40.01 mm)
Rod Crankpin 1.4995 to 1.5000 in. (38.09 to 38.106 mm)
Piston Ring End Gap, Both 0.022 to 0.028 in. (0.57 to 0.72 mm)
FUEL
Fuel/Oil Ratio EMM Controlled
Starting Enrichment EMM Controlled
Preferred Fuel Regular unleaded gasoline
Acceptable Fuel See Fuel Requirements on p. 134 for additional information.
Minimum (High) Fuel Pressure
@ IDLE RPM – 500 ± 50
22 to 28 psi (152 to 193 kPa)
Minimum Fuel Lift Pump Pressure
@ IDLE RPM – 500 ± 50
3 psi (21 kPa)
Maximum Fuel Inlet Vacuum 4 in. Hg. (13.5 kPa)
Minimum Octane 87 AKI (R+M)/2 or 90 RON
Additives
2+4
®
Fuel Conditioner, Fuel System Cleaner
Use of other additives may result in engine damage.
See Fuel Requirements on p. 134 for additional information.
REFERENCE INFORMATION
SERVICE SPECIFICATIONS
11
1
ELECTRICAL
HP 200 225 250
Minimum Battery
Requirements
675 CCA (845 MCA); or
750 CCA (940 MCA) below 32°F (0°C)
(Use a 107 amp-hr battery for extreme applications.)
Alternator
Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation. Refer to Predeliv-
ery and Installation Guide for multiple battery applications.
Tachometer Setting 6 pulse (12 pole)
Charging Isolator Integral, Terminal on Engine Harness
Engine Fuse P/N 967545 – 10 A
COOLING
Thermostat 143°F (62°C)
Maximum Temperature 190°F (88°C)
Water pressure 15 to 17 psi @ 5000 RPM
IGNITION
Type Capacitor Discharge
Firing Order 1-2-3-4-5-6
Ignition Features EMM Controlled
RPM Limit 6050
Crankshaft Position Sensor Air Gap Fixed
Spark Plug
Refer to Emission Control Information Label
Champion
QC8WEP @ 0.028 ± 0.003 in. (0.71 mm)
GEARCASE
Gear Ratio
“M2” Type Gearcase: 13:24 (.542) (1.85:1)
“L2” Type Gearcase – 200 HP: 14:26 (.538) (1.86:1)
“L2” Type Gearcase – 225 HP: 14:24 (.583) (1.71:1)
Refer to GEARCASE TYPES on p. 283
Lubricant HPF XR Gearcase Lubricant
Capacity
“M2” Type Gearcase: 38.9 fl. oz. (1150 ml)
“M2” Type – Counter Rotation: 35.8 fl. oz. (1060 ml)
“L2” Type Gearcase: 32.5 fl. oz. (960 ml)
Refer to GEARCASE TYPES on p. 283
Shift Rod Height
20 in. (L) Models: 21 29/32 (556.25 mm) ± one-half turn
25 in. (X) Models: 26 29/32 (683.25 mm) ± one-half turn
30 in. (Z) Models: 31 29/32 (810.25 mm) ± one-half turn
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD
POWER TRIM/TILT
Lubrication
Power Trim/Tilt & Power Steering Fluid or
GM Dexron
II Automatic Transmission Fluid
Fluid Capacity 21 fl. oz. (622 ml)
Trim Range 0° to 21°
Tilt Range 22° to 75°
Tilt UP Stall Pressure 1500 psi (10342 kPa)
Tilt IN Stall Pressure 800 psi (5516 kPa)
12
REFERENCE INFORMATION
SERVICE SPECIFICATIONS
ENGINE
HP 250 H 300
Full Throttle
Operating Range
4500–6000 RPM 5000–6000 RPM
Power
250 HP
(187 kw)
@ 5250 RPM
300 HP
(234 kw)
@ 5500 RPM
Idle RPM in Gear 500 ± 50
Test Propeller
Standard Rotation Models: P/N 436080 or P/N 396277
Counter Rotation Models: P/N 436081 or P/N 398674
Weight
(may vary depending
on model)
20 in. (L) Models: 507 lbs. (230 kg)
25 in. (X) Models: 528 lbs. (239 kg)
30 in. (Z) Models: 534 lbs. (242 kg)
Lubrication
Evinrude/Johnson XD100 Oil
Refer to Recommended Lubricants on p. 164
Engine Type 90° V 6-Cylinder Loop-Charged
Displacement 210.0 cu. in. (3441 cc)
Bore 3.854 in (97.89 mm)
Stroke 3.000 in. (76.20 mm)
Standard Bore
3.8535 to 3.8545 in. (97.87 to 97.90 mm)
To bore oversize, add piston oversize dimension to standard bore
Top Crankshaft Journal 1.6199 to 1.6204 in. (41.15 to 41.16 mm)
Center Crankshaft Journals 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Bottom Crankshaft Journal 1.5747 to 1.5752 in. (40.0 to 40.01 mm)
Rod Crankpin 1.4995 to 1.5000 in. (38.09 to 38.106 mm)
Piston Ring End Gap, Both 0.022 to 0.028 in. (0.57 to 0.72 mm)
FUEL
Fuel/Oil Ratio EMM Controlled
Starting Enrichment EMM Controlled
Preferred Fuel Regular unleaded gasoline
Acceptable Fuel See Fuel Requirements on p. 134 for additional information.
Minimum (High) Fuel Pressure
@ IDLE RPM – 500 ± 50
22 to 28 psi (152 to 193 kPa)
Minimum Fuel Lift Pump Pressure
@ IDLE RPM – 500 ± 50
3 psi (21 kPa)
Maximum Fuel Inlet Vacuum 4 in. Hg. (13.5 kPa)
Minimum Octane 87 AKI (R+M)/2 or 90 RON
Additives
2+4
®
Fuel Conditioner, Fuel System Cleaner
Use of other additives may result in engine damage.
See Fuel Requirements on p. 134 for additional information.
13
REFERENCE INFORMATION
SERVICE SPECIFICATIONS
1
ELECTRICAL
HP 250 H 300
Minimum Battery
Requirements
675 CCA (845 MCA); or
750 CCA (940 MCA) below 32°F (0°C)
(Use a 107 amp-hr battery for extreme applications.)
Alternator
Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation. Refer to Predeliv-
ery and Installation Guide for multiple battery applications.
Tachometer Setting 6 pulse (12 pole)
Charging Isolator Integral, Terminal on Engine Harness
Engine Fuses P/N 967545 – 10 A
COOLING
Thermostat 143°F (62°C)
Maximum Temperature 190°F (88°C)
Water pressure 18 to 25 psi @ 5000 RPM
IGNITION
Type Capacitor Discharge
Firing Order 1-2-3-4-5-6
Ignition Features EMM Controlled
RPM Limit 6050
Crankshaft Position Sensor Air Gap Fixed
Spark Plug
Refer to Emission Control Information Label
Champion
QC8WEP @ 0.028 ± 0.003 in. (0.71 mm)
GEARCASE
Gear Ratio
“M2” Type Gearcase: 13:24 (.542) (1.85:1)
Refer to GEARCASE TYPES on p. 283
Lubricant HPF XR Gearcase Lubricant
Capacity
“M2” Type Gearcase: 38.9 fl. oz. (1150 ml)
“M2” Type – Counter Rotation: 35.8 fl. oz. (1060 ml)
“L2” Type Gearcase: 32.5 fl. oz. (960 ml)
Refer to GEARCASE TYPES on p. 283
Shift Rod Height
20 in. (L) Models: 21 29/32 (556.25 mm) ± one-half turn
25 in. (X) Models: 26 29/32 (683.25 mm) ± one-half turn
30 in. (Z) Models: 31 29/32 (810.25 mm) ± one-half turn
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD
POWER TRIM/TILT
Lubrication
Power Trim/Tilt & Power Steering Fluid or
GM Dexron
II Automatic Transmission Fluid
Fluid Capacity 21 fl. oz. (622 ml)
Trim Range 0° to 21°
Tilt Range 22° to 75°
Tilt UP Stall Pressure 1500 psi (10342 kPa)
Tilt IN Stall Pressure 800 psi (5516 kPa)
14
REFERENCE INFORMATION
STANDARD TORQUE SPECIFICATIONS
STANDARD TORQUE
SPECIFICATIONS
PRODUCT REFERENCE
AND ILLUSTRATIONS
BRP US Inc. reserves the right to make changes
at any time, without notice, in specifications and
models and also to discontinue models. The right
is also reserved to change any specifications or
parts, at any time, without incurring any obligation
to equip same on models manufactured prior to
date of such change. Specifications used are
based on the latest product information available
at the time of publication.
The continuing accuracy of this manual cannot be
guaranteed.
All photographs and illustrations used in this man-
ual may not depict actual models or equipment,
but are intended as representative views for refer-
ence only.
Certain features or systems discussed in this
manual might not be found on all models in all
marketing areas.
All service technicians must be familiar with nauti-
cal orientation. This manual often identifies parts
and procedures using these terms.
Size In. Lbs. Ft. Lbs. N·m
No. 6 7–10 0.58–0.83 0.8–1.1
No. 8 15–22 1.25–1.83 1.7–2.5
No. 10 24–36 2–3 2.7–4.0
No. 12 36–48 3–4 4.0–5.4
1/4 in. 60–84 5–7 7-9.5
5/16 in. 120–144 10–12 13.5–16.5
3/8 in. 216–240 18–20 24.5–27
7/16 in. 336–384 28–32 38–43.5
M3 15–22 1.25–1.83 1.7–2.5
M4 24–35 2–2.9 2.7–4.0
M5 35–60 2.9–5 4.0–6.8
M6 84–106 7–8.8 9.5–12
M8 177–204 14.7–17 20–23
M10 310–336 25.8–28 35–38
IMPORTANT: These values apply only when
a specific torque for a specific fastener is not
listed in the appropriate section. When tighten-
ing two or more screws on the same part, DO
NOT tighten screws completely, one at a time.
WARNING
Torque wrench tightening specifications
must be strictly adhered to. Replace any
locking fastener (locknut or patch screw)
if its locking feature becomes weak. Defi-
nite resistance to turning must be felt
when reusing a locking fastener.
If replacement is specified or required
because the locking fastener has become
weak, use only authorized Evinrude/
Johnson Genuine Parts.
Nautical Orientation 006411
ROUTINE SERVICE
15
2
ROUTINE SERVICE
TABLE OF CONTENTS
INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
LIFTING THE OUTBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
OUTBOARD RIGGING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
CONTROL CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
BATTERY CABLE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
SYSTEMCHECK HARNESS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
I-COMMAND NETWORK CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
ICON NETWORK CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
WATER PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
BATTERY AND BATTERY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
OETIKER CLAMP SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
TILT LIMIT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
TRIM SENDING UNIT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
TRIM TAB ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
DUAL-OUTBOARD ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
ENGINE FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
RUNNING THE OUTBOARD USING A HOSE AND FLUSHING ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . .35
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
SWIVEL BRACKET AND TRAILERING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
THROTTLE AND SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
FUEL AND OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
OIL FILTERS AND OIL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
AIR SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
HOSES AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
EXHAUST PRESSURE FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
PRE-SEASON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
SUBMERGED ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
16
ROUTINE SERVICE
INSPECTION AND MAINTENANCE SCHEDULE
INSPECTION AND MAINTENANCE SCHEDULE
Routine inspection and maintenance is necessary to prolong outboard life. The following chart provides
guidelines for inspection and maintenance to be performed by an authorized Dealer.
IMPORTANT: Outboards used in rental, commercial, or other high hour applications require more fre-
quent inspections and maintenance. Adjust schedule for operating and environmental conditions.
Description
Engine
Care
Product
Routine
Inspection
Every 300 hours
or every three
years
(1)
(1) Average recreational use. Commercial use, heavy use, or use in salt or polluted water requires more frequent inspection and maintenance.
Engine Monitor self-test and warning horn, check
Emergency stop circuit and lanyard, check operation
Controls, steering and tilting; check operation
Engine mounting hardware, re-tighten (40 ft. lbs.)
Fasteners, tighten any loosened components
Water intake screens, check condition
Cooling system; check water pump indicator / water pressure
Anticorrosion anodes, check condition
Gearcase, check condition
Propeller, check condition
Fuel and oil systems, inspect and repair leaks
(2)
(2) Emission-related component
Check battery connections and condition
Access EMM information, resolve any service codes
Electrical and ignition wires, inspect for wear or chafing
Fuel filter, replace
Oil filters, replace
Gearcase lubricant, replace A
Spark plugs, inspect or replace
(2)
Thermostats, inspect and check operation
(2)
Grease fittings, lubricate
(3)
(3) Annually in salt water applications
C
Power trim/tilt and fluid level, inspect B
Propeller shaft splines, inspect and lubricate
(3)
C
Starter pinion shaft, inspect and lubricate
(3)
D
Control cables, inspect and adjust
Steering cable, inspect and lubricate C
Water pump, inspect / replace
(more often if water pressure loss or overheating occurs)
A HPF Pro Gearcase Lubricant
B Power Trim/Tilt Fluid (Three ram hydraulic systems)
C Triple-Guard Grease
D Starter Bendix Lube Only
17
ROUTINE SERVICE
LIFTING THE OUTBOARD
2
LIFTING THE
OUTBOARD
Use correct Lifting Fixture to lift outboard:
Place lifting tool on flywheel and seat the three
screws completely.
Fasten appropriate chain hook to eye of tool.
Carefully hoist outboard with chain and unbolt out-
board mounting brackets from frame.
OUTBOARD RIGGING
CONNECTIONS
IMPORTANT: For complete outboard rigging
and remote control installation information, refer to
the Predelivery and Installation Guide included
with the service manual set.
Common Practices – All Models
Control Cable Identification
IMPORTANT: Identify control cable function
before rigging outboard.
Identify each control cable:
Put the control handle into NEUTRAL position.
The throttle cable casing guide will retract com-
pletely and the shift cable casing guide will go to
the midpoint of its travel.
Extend the control cables and lubricate them with
Triple-Guard grease.
WARNING
To avoid personal injury, make sure the
lifting capacity of the hoist is at least twice
the weight of the outboard.
DO NOT allow the lift hook or chain from
the hoist to come in contact with any part
of the engine during lifting.
Model Lifting Fixture
90° V6 P/N 396748 with
1 3/4 in. screws
1. Lifting fixture
2. 1 3/4 in. screws
002419
2
1
1. Shift cable casing guide extended to midpoint
2. Throttle cable casing guide retracted
DP0811
30501
1
2
18
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
Cable Retainer Clip Installation
When installing retainer clips on control arm link-
age pins, clips should be locked and must not be
bent or deformed.
For proper installation, review the following steps:
Place washer on pin.
Position retainer clip with straight section on the
bottom and angled section on the top.
Use long nose pliers to insert straight section of
clip into linkage pin hole.
Push the clip towards the hole while lifting on
the curved end with the pliers.
Be sure retainer clip fully engages the pin.
Lock the retainer by moving the angled section
behind the straight section.
Cable, Hose, and Wire Routing
Refer to Control Cable Identification on p. 17.
Remove two screws and bracket that fasten the
grommet to lower motor cover.
Route all hoses, control cables, and wiring
through a protective sleeve or conduit into the
boat and through the grommet.
The fuel hose may be routed through the protec-
tive sleeve or through an alternate hole in the
lower motor cover grommet.
To route the fuel hose outside the sleeve, trim the
material covering the alternate fuel hose slot in
the grommet.
1. Straight section
2. Angled section
DP0818
DP0817
Locked Retainer Clip
1. Angled section behind straight section
DP0817A
1
2
1
CAUTION
To prevent accidental starting while servic-
ing, disconnect the battery cables at the
battery. Twist and remove all spark plug
leads.
1. Grommet retaining bracket 003964
1. Alternate fuel hose location 003970
1
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Evinrude E-TEC 200 User manual

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User manual
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