Evinrude E-TEC 200 User manual

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Printed in the United States.

TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

BRP US Inc.

Technical Publications

250 Sea Horse Drive

Waukegan, Illinois 60085 United States

† AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II

are registered trademarks of Tyco International, Ltd.

† Amphenol is a registered trademark of The Amphenol Corporation.

† BEP is a registered trademark of Actuant Corporation.

† Champion is a registered trademark of Federal-Mogul Corporation.

† Deutsch is a registered trademark of The Deutsch Company.

† Dexron is a registered trademark of The General Motors Corporation.

† Fluke is a registered trademark of The Fluke Corporation

† GE is a registered trademark of The General Electric Company.

† GM is a registered trademark of The General Motors Corporation.

† Locquic and Loctite are registered trademarks of The Henkel Group.

† Lubriplate is a registered trademark of Fiske Brothers Refining Company.

† NMEA is a registered trademark of the National Marine Electronics Association.

† Oetiker is a registered trademark of Hans Oetiker AG Maschinen.

† Packard is a registered trademark of Delphi Automotive Systems.

† Permatex is a registered trademark of Permatex.

† STP is a registered trademark of STP Products Company.

† Snap-on is a registered trademark of Snap-on Technologies, Inc.

The following trademarks are the property of BRP US Inc. or its affiliates:

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

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.

Manufacturer’s 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.

Dealer’s 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.

Owner’s 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 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

g

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

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

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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