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.
INSTALLATION & PREDELIVERY INSTALLATION & PREDELIVERY TABLE OF CONTENTS BOAT RIGGING REMOTE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CONTROL SYSTEM SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CONTROL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION & PREDELIVERY OUTBOARD INSTALLATION HULL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 TRANSOM MEASURING AND DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 LIFTING THE OUTBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 STEERING SYSTEMS . . . . . . . . . . . . . . . . . .
INSTALLATION & PREDELIVERY SAFETY INFORMATION This publication is written for qualified, factorytrained 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: DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
INSTALLATION & PREDELIVERY 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 servicing and when running the outboard on a flushing device.
INSTALLATION & PREDELIVERY ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Units of Measurement List of Abbreviations A Amperes ABYC American Boat & Yacht Council amp-hr Ampere hour ATDC after top dead center fl. oz. fluid ounce AT air temperature sensor ft. lbs. foot pounds BPS barometric pressure sensor HP horsepower BTDC before top dead center in. inch CCA cold cranking amps in. Hg inches of mercury CFR Code of Federal Regulations in. lbs.
INSTALLATION & PREDELIVERY EMISSION-RELATED INSTALLATION INSTRUCTIONS 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 emission control devices and systems may be performed by any marine SI (spark ignition) engine repair establishment or individual.
BOAT RIGGING REMOTE CONTROLS BOAT RIGGING REMOTE CONTROLS Control System Selection Outboard remote control systems provide the operator with tools for: • Starting and stopping the engine • Shifting into Forward, Neutral, or Reverse • Changing engine speed • Changing the tilt/trim angle of the outboard. The remote control system must include the following features: • Shift stroke must be 1.125 to 1.330 in. (28.6 to 33.
BOAT RIGGING REMOTE CONTROLS Control Installation 1 FWD NEUTRAL 15.0° 15.0° REV Plan the installation of remote controls carefully, following all instructions provided with the control. 85.5° Select an appropriate location based on the boat configuration. 1 2 40.5° 2.5 in (64 mm) Typical control clearances 007920 Use an appropriate drill template to cut mounting holes. Templates are included with the control instructions. 1. Side console 2.
BOAT RIGGING REMOTE CONTROLS Control Cable Routing Evinrude ICON Networks Control cables and harnesses should be routed along a protected path to the rear of the boat and secured to prevent movement or damage. All control information is transferred between the outboard and an Evinrude ICON system through a single network cable. For complete installation instructions, refer to the Evinrude ICON Remote Control System Installation Guide, P/N 764952.
BOAT RIGGING INFORMATION DISPLAY SYSTEMS INFORMATION DISPLAY SYSTEMS Engine Monitor System All remote controlled outboards must be equipped with an engine monitoring system to warn the operator of conditions that could damage the outboard. The engine monitor system includes sensors on the outboard and oil tank, a warning horn, a dashmounted display, and related wiring. The outboard’s EMM sends information about monitored functions to: • SystemCheck gauges, or • An I-Command or ICON display.
BOAT RIGGING INFORMATION DISPLAY SYSTEMS SystemCheck (MWS) Harness Connections G I S 3 5 1 2 G I S 6 4 3 PUL REV PUL 4 +12V GND 2 NO OIL WATER TEMP CHECK ENGINE LOW OIL 5 3 6 2 4 5 1 6 0 Typical MWS wiring with a side-mount mechanical remote control 7 007989 1. 6-Pin Connector – Connect to a pre-wired remote control or to a dash-mounted key switch. 2. 3-Pin Connector – Connect to remote control trim switch or to a dash-mounted trim switch. 3.
BOAT RIGGING INFORMATION DISPLAY SYSTEMS I-Command Harness Connections With Mechanical Remote Control 1 30 40 20 10 10 50 x 100 35 0 Water 70 25 30 5 60 0 15 20 RPM 3550 40 1 IT EX MENU S GE PA TE R EN BUSS BUSS BUSS DEVICE BUSS WN 3A 5 6 EP- 85 Memory Module DEVICE DEVICE BUSS BUSS DEVICE DEVICE BUSS 2 BUSS DO DEVICE 3 DEVICE 4 DEVICE MENU DEVICE WN P P DO S GE PA TE R EN U U EX IT MPH 15.
BOAT RIGGING INFORMATION DISPLAY SYSTEMS Evinrude ICON / I-Command Harness Connections EX IT MENU Information Display 60 70 DOW N ES PAG ER ENT MENU DEVICE DEVICE DEVICE DEVICE BUSS MENU 3550 ES PAG ER ENT BUSS EX EX ES PAG ER ENT N 50 x 100 RPM DOW N UP DOW ES PAG ER ENT MENU 30 40 20 10 0 70 RPM 3550 UP IT 3550 DOW N x 100 UP 3550 60 0 70 RPM EX x 100 50 10 60 0 70 30 40 20 50 10 60 RPM IT 30 40 20 50 x 100 IT 30 40 20 10 0 UP Second Statio
BOAT RIGGING BATTERY INSTALLATION BATTERY INSTALLATION Each outboard requires its own starting battery. Select a battery that meets or exceeds the minimum requirements.
BOAT RIGGING BATTERY INSTALLATION Battery Cable Requirements Evinrude outboards are shipped with stranded copper battery cables for typical installations in which the starting battery is close to the transom. Specialized outboard installations with extended length battery cables require an increased wire size. Refer to the following table. 15–30 HP 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.
BOAT RIGGING BATTERY INSTALLATION Battery Switch Operation • Select the primary battery for normal operation. • Secondary batteries should only be selected for emergency starting. • ALL or BOTH switch position is for emergency starting only. 1 1 Provide operator with the documentation supplied by the battery switch manufacturer. Make sure that the operator is informed of proper battery switch operation.
BOAT RIGGING BATTERY INSTALLATION Battery and Switch Wiring Diagrams Single outboard 1 2 4 S S S BOTH 1 ON 2 BOTH OFF 2 1 OFF 3 OFF VSR + #1 PRIMARY 1. 2. 3. 4.
BOAT RIGGING BATTERY INSTALLATION Two outboards: One primary battery each; one isolated accessory battery #1 1 #2 S S Positive (+) Battery Cable Negative (–) Battery Cable Accessory charge wire (V models) 50 amp fuse BOTH BOTH 2 1 2 1 OFF OFF + #1 + #2 + PRIMARY PRIMARY ACCESSORY 008053 Two outboards: One primary battery each; two isolated accessory batteries #1 #2 S S Positive (+) Battery Cable Negative (–) Battery Cable Accessory charge wire (V models) 50 amp fuse BOTH BOTH OFF
BOAT RIGGING FUEL SYSTEM REQUIREMENTS FUEL SYSTEM REQUIREMENTS Regulations and Guidelines Vessel manufacturer, and/or installer of an EPA certified outboard, must meet minimum specifications for boat fuel systems established by: • U.S. Environmental Protection Agency (EPA) – 40 CFR 1045.112 – 40 CFR 1060 • U.S. Coast Guard (USCG) – 33 CFR 183 • American Boat & Yacht Council (ABYC) – Standard H-24 – Standard H-25. NOTICE Do not use portable fuel tanks for outboards larger than 115 HP.
BOAT RIGGING FUEL SYSTEM REQUIREMENTS Fuel System Primer Outboards require a priming system to refill the fuel system after periods of non-use. The most common priming system is a primer bulb in the fuel supply hose. The filter must be mounted to a rigid surface above the full level of the fuel tank and accessible for servicing. Fuel Filter Assembly, P/N 174176, meets all requirements for a water-separating fuel filter.
BOAT RIGGING FUEL SYSTEM REQUIREMENTS Fuel Flow Requirements 15 – 30 HP 40 – 90 HP 115 – 300 HP Fuel tank pickup tube 1/4 in. (6.4 mm) min. ID 5/16 in. (7.9 mm) min. ID 3/8 in. (9.5 mm) min. ID Fuel fittings 5/32 in. (4.1 mm) min. ID 1/4 in. (6.4 mm) min. ID 9/32 in. (7.1 mm) min. ID Fuel supply hoses 1/4 in. (6.4 mm) min. ID 3/8 in. (9.5 mm) min. ID 3/8 in. (9.5 mm) min. ID ALL MODELS Fuel tank pickup screen 100 mesh, 304 grade stainless steel wire, 0.0045 in. wire diameter, 1 in.
BOAT RIGGING REMOTE OIL TANK INSTALLATION (V4 – V6) REMOTE OIL TANK INSTALLATION (V4 – V6) NOTICE Be sure box includes drain holes so it does not fill with water and contaminate oil. Location NOTICE Consider the installation location of the oil tank carefully. The oil tank is vented to the atmosphere. To avoid serious powerhead damage, be sure the oil tank is installed in a location that does not allow constant exposure to sunlight, rain, bilge water or spray.
BOAT RIGGING REMOTE OIL TANK INSTALLATION (V4 – V6) Place floor bracket on center line between end lines. Use the inner bracket holes as guides to drill two 5/32 in. (4 mm) pilot holes. 1.8 GALLON TANK Place rods into floor bracket and secure floor bracket with lag bolts. 1 1 2 2 COB5381 1. Rods 2. Lag bolts 3 GALLON (11.4 L) TANK Place rods into floor bracket and secure floor bracket with lag bolts. 1 1 2 2 1. Rods 2. Lag bolts 22149A Place oil tank onto floor bracket.
BOAT RIGGING REMOTE OIL TANK INSTALLATION (V4 – V6) Oil Tank Profiles 1.8 Gallon Tank P/N 176995 1 3 Gallon Tank P/N 176996 Remote Oil Fill Kit (Optional) The remote oil fill kit (P/N 176461) provides a deck-mounted fill tube, cap, a tank-mounted tube, and nut that replace the original oil tank cap assembly. Installation Recommendations • Select a location on the deck of the boat that is above the oil tank fill cap. • Select a deck location which allows the required length of 1½ in. I.D.
BOAT RIGGING CABLE AND HOSE INSTALLATION CABLE AND HOSE INSTALLATION Boat Cable and Harness Routing WARNING Before installation, identify all required wiring, cables, and hoses: • Throttle and shift cables • Instrument harnesses • Battery cables and switches • Oil tank sender harness • Fuel supply hose • Primer bulb or primer pump • Oil supply hose.
BOAT RIGGING CABLE AND HOSE INSTALLATION Fuel Hose The fuel hose may be routed outside of the protective sleeve or conduit. Electric primers or manual primers may not require this consideration. Route fuel hoses with enough slack to allow the primer bulb arrow to point “up” during use. Install the primer bulb with the arrow pointing in the direction of fuel flow to the outboard. Connect the fuel supply hose from the fuel tank to the fuel supply line at the outboard.
BOAT RIGGING CABLE AND HOSE INSTALLATION Oetiker Clamp Servicing 1 Clamp Identification Use Oetiker clamps for making hose connections. These clamps provide corrosion resistance, minimize the potential for abrasion of rigging components, and provide solid, permanent connections. The selection and installation of an Oetiker clamp is essential in the proper sealing of hose connections. The clamp identification numbers appear on the side of the clamp, near the top of the ear.
BOAT RIGGING CABLE AND HOSE INSTALLATION Clamp Installation Clamp Removal A constant stress should be applied to close the ear clamps. This method ensures a positive stress on the hose and does not result in excessive compression or expansion of the band material. Method 1: Position Oetiker pincers across clamp ear and cut clamp. IMPORTANT: Use only Oetiker recommended tools to close Oetiker stepless clamps. Oetiker pincers are available in the Evinrude/ Johnson Genuine Parts and Accessories Catalog.
BOAT RIGGING NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other 30
OUTBOARD INSTALLATION HULL PREPARATION OUTBOARD INSTALLATION HULL PREPARATION The stern brackets must contact the flat surface of the transom. Modify trim that prevents the stern brackets from resting against the transom surface. Do not modify stern brackets. Maximum Capacity WARNING WARNING Do not overpower the boat by installing an outboard that exceeds the horsepower indicated on the boat’s capacity plate. Overpowering could result in loss of control.
OUTBOARD INSTALLATION HULL PREPARATION Transom Brackets and Jack Plates When mounting an outboard on a jack plate: • Refer to the manufacturer's recommendations for maximum weight and horsepower. • The jack plate must provide a rigid, one-piece mounting assembly—either a solid surface, or surfaces adequately connected to prevent flexing or twisting.
OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING TRANSOM MEASURING AND DRILLING If the standard spacing does not allow full steering travel in a particular installation, it may be necessary to increase the spacing. Hull Centerline IMPORTANT: Some steering systems may Use the chines of the boat as reference points to locate the centerline of the boat transom. Use a straightedge to draw a line connecting the port and starboard chines.
OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING Transom Height Transom Drilling Locations Make sure the transom height matches the length of the outboard to be installed. • A 19 to 21 in. (48.3 to 53.3 mm) transom height uses a 20 in. (50.8 mm) shaft outboard. • The shaft length of the outboard being installed should come close to matching the transom height of the boat. • Refer to SPECIFICATIONS in outboard Operator’s Guide for transom height.
OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING Before drilling any mounting holes: • Make sure the hole locations provide enough clearance for mounting bolts and washers. • Check the inside area of the transom for obstructions. • Check transom height(s) at centerlines. Drill four ½ in. (13 mm) mounting holes in the appropriate locations. 2 1 1 IMPORTANT: Be sure to drill the required holes perpendicular to transom surface.
OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING Drilling and Hardware Diagrams 75–300 HP, ALL MODELS; 40–60 HP, POWER TRIM MODELS; 25–30 HP, POWER TRIM MODELS IMPORTANT: This is not a template. 2 2 in. (50.8mm) 2 1 2 in. (50.8mm) 6 7/16 in. (163.5mm) 6 7/16 in. (163.5mm) 3 3 8 in. (203.2mm) 8 in. (203.2mm) 3 3 1 4 15/16 in. (125.4mm) 4 15/16 in. (125.4mm) Quantity 1. Center of Transom 5. Bolt * 4 * Choose from the following bolt sizes: 2. Top of Transom 6.
OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING IMPORTANT: This is not a template.
OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING 40–65 HP, MANUAL TILT MODELS IMPORTANT: This is not a template. 5.16 in. 131.01 mm) 5.16 in. 131.01 mm) 2 2 2.09 in. (53.08 mm) 2.09 in. (53.08 mm) 3 3 1 8.99 in. 228.34 mm) 3 3 4.031 in. (4 1/32) 4.031 in. (4 1/32) (102.4 mm) (102.4 mm) 1. Center of Transom 2. Top of Transom 3.
OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING IMPORTANT: This is not a template. 2 2.09 in. (53.08 mm) 8.99 in. (228.
OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING 25–30 HP, MANUAL TILT MODELS IMPORTANT: This is not a template. 5 in. (126.2 mm) 5 in. (126.2 mm) 2 4 3/4 in. (121.2 mm) 3 3/4 in. (19 mm) 1. Center of Transom 2. Top of Transom 3. 5/16” Bolt Hole Locations 40 1 4 3/4 in. (121.
OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING IMPORTANT: This is not a template. 2 2 3 3/4 in. (95.25 mm) 3 1/2 in. (91 mm) 2 in. (50.2 mm) 3 3/4 in.
OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING 15 HP, POWER TILT MODELS IMPORTANT: This is not a template. 2.1 in. (53.1 mm) 2 2 3 3 7.39 in. (187.6 mm) 1 3 3 10.25 in. (260.4 mm) 1. Center of Transom 2. Top of Transom 3.
OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING IMPORTANT: This is not a template. 2 2.1 in. (53.1 mm) 9.38 in. (238.
OUTBOARD INSTALLATION LIFTING THE OUTBOARD LIFTING THE OUTBOARD 60° V4 AND V6 MODELS Position lifting tool on crankshaft and tighten the center retaining screw securely using a 1/4 in. Allen wrench. Lifting Fixtures WARNING 1 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. Remove shipping carton. 1.
OUTBOARD INSTALLATION LIFTING THE OUTBOARD 15–30 HP MODELS Lift the engine out of the carton. Install Lifting Tool, P/N 354717, on both sides of the tilt tube. 1 2 1 1. Lifting tool, P/N 354717 007123 Remove upper motor cover. 1. Lifting tool, P/N 354717 007122 Place clean pad or cardboard on the floor. WARNING To avoid personal injury or outboard damage, be sure the lifting tool is fully threaded on both sides of the tilt tube.
OUTBOARD INSTALLATION STEERING SYSTEMS Attach chain to lift eye on back of engine block. WARNING STEERING SYSTEMS Mechanical Cables If the chain snap hooks are too large, the cast in lift eye could break causing the outboard to drop suddenly causing personal injury and damaging the outboard. All Evinrude outboards equipped with tilt tubes are compatible with mechanical steering systems that meet ABYC Standard P-17.
OUTBOARD INSTALLATION STEERING SYSTEMS Manual Hydraulic Steering Drag Links Manual hydraulic steering systems use hydraulic fluid to transfer motion and load from the helm to the outboard. Use the correct drag link to allow full steering travel: Use only a hydraulic steering system designed for the specific application. Refer to the steering system manufacturer’s specifications for recommended applications.
OUTBOARD INSTALLATION OUTBOARD MOUNTING OUTBOARD MOUNTING IMPORTANT: Some rigging components, such as steering cables, must be fitted to the outboard before the outboard is mounted to the transom. Determine what equipment will be installed before mounting. 75–300 HP, ALL MODELS 40–60 HP, POWER TRIM MODELS 25–30 HP, POWER TRIM MODELS Assemble transom mounting plates on mounting bolts. Install the mounting bolts through the transom from the inside of the boat.
OUTBOARD INSTALLATION OUTBOARD MOUNTING 40–65 HP, MANUAL TILT MODELS Manual tilt models require Transom Mounting Kit, P/N 394219. The kit includes a transom mounting plate and hardware for fastening outboard to transom. Install the mounting bolts through the stern brackets and transom. Install round backing plates and locknuts onto bolts and tighten securely. 2 1 2 3 1 1. Transom mounting plate 2. Round backing plates 3. Locknuts 1.
OUTBOARD INSTALLATION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other 50
OUTBOARD RIGGING COMMON PRACTICES – ALL MODELS OUTBOARD RIGGING 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 completely and the shift cable casing guide will go to the midpoint of its travel.
OUTBOARD RIGGING EVINRUDE E-TEC 90° V MODELS 200–300 HP EVINRUDE E-TEC 90° V MODELS 200–300 HP Refer to the following diagram to ensure proper positioning of rigging components in grommet. Cable, Hose, and Wire Routing CAUTION To prevent accidental starting while servicing, disconnect the battery cables at the battery. Twist and remove all spark plug leads. Refer to Control Cable Identification on p. 51. Remove two screws and bracket that fasten the grommet to lower motor cover. 1 1. 2. 3. 4. 5. 6. 7.
OUTBOARD RIGGING EVINRUDE E-TEC 90° V MODELS 200–300 HP same path to the starboard side of the powerhead. Secure all cables with clamps. Hold the shift linkage in NEUTRAL. Push and pull on the shift cable and observe the cable slack. Hold the casing guide in the center of the slack. Adjust shift cable trunnion to align with center of the trunnion block. Place cable trunnion in trunnion block. Install trunnion cover and screw. Tighten screw to a torque of 60 to 80 in. lbs. (7 to 9 N·m).
OUTBOARD RIGGING EVINRUDE E-TEC 90° V MODELS 200–300 HP Make sure that idle stop of the throttle lever is against the crankcase. Battery Cable Connections Install battery cables on starter solenoid and main ground stud. 2 1 1 1. Throttle lever stop 003968 Adjust the throttle cable trunnion to align with the trunnion block. Place the cable trunnion in the trunnion block. IMPORTANT: Move control handle to FORWARD and pull back slowly to NEUTRAL. Make sure the engine throttle lever is against the stop.
OUTBOARD RIGGING EVINRUDE E-TEC 90° V MODELS 200–300 HP Connect outboard main wire harness to boat wire harness. Secure connectors in bracket. Refer to the diagram inside of the electrical cover. If using a mechanical control system, connect the I-Command Engine Interface Cable to the EMM CANbus connector. 1 1 3 1. Harness connections 003973 NOTICE BE SURE all harnesses and wires are not pinched, cannot contact flywheel, and do not interfere with moving throttle or shift linkages.
OUTBOARD RIGGING EVINRUDE E-TEC 90° V MODELS 200–300 HP For an I-Command oil level display, an accessory CANbus oil level sender must be installed in the oil tank. Connect the sender to the I-Command network. Refer to the I-Command Digital Network Guide, P/N 355008. Use Evinrude Diagnostics software to adjust network settings in the EMM. From the Settings screen, select Engine Options. IMPORTANT: Do not force connectors or locking rings. Properly aligned connectors assemble easily.
OUTBOARD RIGGING EVINRUDE E-TEC 90° V MODELS 200–300 HP current, resulting in erratic operation of the remote control system. For more information, refer to the Evinrude ICON Remote Control System Installation Guide, P/N 764952. To send water pressure data to the EMM, along with an I-Command display, install Water Pressure Transducer Kit, P/N 5008300. 1 Water Pressure Gauge To display engine water pressure, install a water pressure hose fitting in the cylinder block as shown.
OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP EVINRUDE E-TEC 60° V MODELS 115–200 HP Refer to the following diagram to ensure proper positioning of rigging components in grommet. Cable, Hose, and Wire Routing 12 9 To prevent accidental starting while servicing, disconnect the battery cables at the battery. Twist and remove all spark plug leads. Refer to Control Cable Identification on p. 51. Remove two screws and bracket that fasten the grommet to lower motor cover.
OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP same path to the starboard side of the powerhead. Secure all cables with clamps. Make sure the remote control, gearcase, shift linkage, and shift cable are in NEUTRAL. Hold the shift linkage in NEUTRAL. 1 Push and pull on the shift cable and observe the cable slack. Hold the casing guide in the center of the slack. Adjust shift cable trunnion to align with center of the trunnion block. Place cable trunnion in trunnion block.
OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP Make sure that idle stop of the throttle lever is against the crankcase. Battery Cable Connections Install battery cables on starter solenoid and main ground stud. 1 2 1 1. Throttle lever stop 004947 Adjust the throttle cable trunnion to align with the trunnion block. Place the cable trunnion in the trunnion block. IMPORTANT: Move control handle to FORWARD and pull back slowly to NEUTRAL. Make sure the engine throttle lever is against the stop.
OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP Connect outboard main wire harness to boat wire harness. Secure connectors in brackets. NOTICE BE SURE all harnesses and wires are not pinched, cannot contact flywheel, and do not interfere with moving throttle or shift linkages. Replace flywheel/harness connector cover. I-Command Network Connections 1 1. Harness connections 004951 Route oil tank sending unit harness around the front to the port side. Secure all cables with tie straps.
OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP Route the harness under the front of the EMM and around the port side of the powerhead. Secure with tie straps. switch is on. Newer, quick connect-style networks do not use this connection. 1 1 1 2 1. Network power supply connector 1. Harness routing 2. Tie straps 005269 005268 Use an I-Command Ignition and Trim Harness to connect the outboard to the key switch and trim/tilt control.
OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP Use Evinrude Diagnostics software to adjust network settings in the EMM. From the Settings screen, select Engine Options. To assemble the connectors: • Use the large tabs and small tabs to carefully align buss cable connectors. • Carefully align pins and sockets of connectors. Do NOT force connectors together. • Tighten locking rings of buss connectors finger tight. Do NOT use locking rings to force connectors together. 1 Engine Options Screen 1.
OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP Water Pressure Gauge To display engine water pressure, install a water pressure hose fitting in the cylinder block as shown. Use Pipe Sealant with Teflon on the threads of the hose fitting. Refer to installation instructions supplied with gauge. To send water pressure data to the EMM, along with an I-Command display, install Water Pressure Transducer Kit, P/N 5008300.
OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP EVINRUDE E-TEC MODELS 40–90 HP When grommet is in place and all cables have been installed, tighten a tie strap around the outside of the grommet to form a watertight seal around the cables. Cable, Hose, and Wire Routing CAUTION To prevent accidental starting while servicing, disconnect the battery cables at the battery. Twist and remove all spark plug leads. Refer to Control Cable Identification on p. 51.
OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP nion into the lower anchor pocket. Adjust the trunnion nut so the casing fits onto the shift lever pin. 1 1 2 1. Throttle lever stop – 3 Cylinder models 1. Shift lever pin 2. Trunnion nut 005111 002100 1 If there are not enough threads on the shift cable for the adjustment, or if the gearcase does not shift fully into FORWARD or REVERSE, refer to the Service Manual for shift rod height adjustment.
OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP SystemCheck Harness Connections Arrange connectors in flywheel cover. Place the wiring harness through notch in lower motor cover and route to the recess in the flywheel cover. Secure the cable with a tie strap as shown: 3 2 1 001999 Install electrical cover and secure with screws. 1. Recess 2. Tie strap 002011 Before installing electrical connectors, check that the seal is in place. Clean off any dirt from connectors.
OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP I-Command Network Connections If the outboard will be used with I-Command, or other NMEA 2000 compliant CANbus instruments, use the following connections to supply information to the network: Connect the I-Command Engine Interface Cable to the EMM CANbus connector. 1 2 Remove lower motor covers. Remove air silencer.
OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP 3 CYLINDER MODELS EMM CANbus connector cap is clipped to EMM cooling water hose. Remove clip from cap and install on I-Command harness connector. 1 2 If connecting to an existing Deutsch-style I-Command network, connect the purple wires between the I-Command Ignition and Trim Harness and the I-Command Engine Interface Cable. This connection supplies power to the network when the key switch is on. Newer, quick connect-style networks do not use this connection.
OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP Use Evinrude Diagnostics software to adjust network settings in the EMM. From the Settings screen, select Engine Options. Water Pressure Gauge To display engine water pressure, install a water pressure hose fitting in the cylinder block as shown. Use Pipe Sealant with Teflon on the threads of the hose fitting. Refer to installation instructions supplied with gauge. 1 Engine Options Screen 008093 1.
OUTBOARD RIGGING EVINRUDE E-TEC MODELS 15–30 HP EVINRUDE E-TEC MODELS 15–30 HP When grommet is in place and all cables have been installed, tighten a tie strap around the outside of the grommet to form a watertight seal around the cables. Cable, Hose, and Wire Routing Place blank sealing decal on lip of lower motor cover at each harness connector tie strap to prevent water intrusion. CAUTION To prevent accidental starting while servicing, disconnect the battery cables at the battery.
OUTBOARD RIGGING EVINRUDE E-TEC MODELS 15–30 HP Adjust the shift cable trunnion to align with the center of the trunnion block. adjust the trunnion nut so the casing fits onto the throttle lever pin. 1 2 1 1. Shift linkage 2. Shift cable 007215 1. Throttle lever pin 2. Trunnion nut 2 007217 1 Install cable retainer and screw. Tighten screw to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). 2 1. Throttle lever stop 007216 IMPORTANT: Move control handle to FOR1.
OUTBOARD RIGGING EVINRUDE E-TEC MODELS 15–30 HP SystemCheck Harness Connections Route trim and tilt connector under air silencer. Use tie strap to secure connector as shown. Before installing electrical connectors, check that the seal is in place. Clean off any dirt from connectors. Apply a light coat of Electrical Grease to the seal only. DO NOT fill connectors with Electrical Grease. 1 3 1. Trim and tilt connector 007264 1 1.
OUTBOARD RIGGING NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other 74
FUEL AND OIL PRIMING FUEL REQUIREMENTS FUEL AND OIL PRIMING FUEL REQUIREMENTS WARNING Gasoline is extremely flammable and highly explosive under certain conditions. Improper handling of fuel could result in property damage, serious injury or death. Always turn off the outboard before fueling. Never permit anyone other than an adult to refill the fuel tank. Do not fill the fuel tank all the way to the top or fuel may overflow when it expands due to heating by the sun.
FUEL AND OIL PRIMING FUEL SYSTEM PRIMING FUEL SYSTEM PRIMING Priming the Fuel System WARNING Vent Line Clamp Federal Regulations require that all outboards with a fuel vapor separator must be shipped with a vent line clamp installed. This clamp must be removed before priming the fuel system or starting the outboard for the first time. Fuel vapors are highly flammable. Perform the following procedure in a well ventilated area.
FUEL AND OIL PRIMING OIL REQUIREMENTS OIL REQUIREMENTS Recommended Lubricants Evinrude/Johnson XD100, XD50, or XD30 outboard oils are recommended for use in Evinrude E-TEC outboards. If these oils are not available, you must use a TC-W3 certified oil. Evinrude/Johnson XD100 outboard oil is highly recommended for all conditions and applications. Engine Lubricant Below 32°F (0°C) If the outboard will be operated in temperatures below freezing (32°F, 0°C), use Evinrude/Johnson XD100.
FUEL AND OIL PRIMING OIL REQUIREMENTS Powerhead oil programming labels are provided to identify EMM oil programming. Install the correct label to alert user to specific oil requirements. 2 1 Install decals in a highly visible location, such as one of the following: • Dashboard/deck of boat, next to key switch • Deck of boat, next to the remote oil fill • Deck of boat, next to oil tank assembly • Oil tank cover • Cover of oil tank compartment • Attach to oil tank or oil fill cap.
FUEL AND OIL PRIMING OIL SUPPLY PRIMING OIL SUPPLY PRIMING WARNING Prime the rear oil pump FIRST (cylinder oil pump). Use the Prime Cylinder Oiler button of the Dynamic Test screen to prime the rear oil pump. Always use caution while working around machinery with moving parts. The following set-up procedures require running tests that are performed with the outboard’s motor cover removed. 250 – 300 HP 90° V6 (3.
FUEL AND OIL PRIMING OIL SUPPLY PRIMING Prime the front oil pump assembly LAST. Use the Prime Oil System button of the Dynamic Test screen to prime the front oil pump. 115 – 200 HP 60° V4/V6 and 200 – 250 HP 90° V6 Models Oil Hose Priming Insert the oil supply hose from the oil tank into a suitable container. Squeeze the oil primer bulb until oil flows from the oil tank into the container.
FUEL AND OIL PRIMING OIL SUPPLY PRIMING Observe oil flow through all oil distribution hoses. Air must be purged during the priming procedure. Make sure that oil flows through the rear oil distribution manifold to the cylinder block fittings. 1 1 1. Rear oil distribution manifold 90° V6 Models 1. Oil distribution hoses 008016 004224 Small bubbles are acceptable. Large bubbles must be eliminated through continued priming. 1 1 3 2 1. Oil distribution hose 2. Small bubbles 3.
FUEL AND OIL PRIMING OIL SUPPLY PRIMING 15 – 90 HP Models Use Evinrude Diagnostics software to make sure the EMM is programmed for the type of oil being used. 1 1 Start the outboard. Use the oil priming function in the software to make sure the system is completely primed. Use the Prime Oil System button of the Dynamic Test screen to prime the oil pump. 15 – 30 HP Models 1. Oil distribution hoses 1 007130 Small bubbles are acceptable. Large bubbles must be eliminated through continued priming.
PREDELIVERY BEFORE START-UP PREDELIVERY BEFORE START-UP Trim and Tilt Fluid CAUTION Gearcase Lubricant With outboard vertical, check the gearcase lubricant level: • Remove the lubricant level plug. Lubricant must be even with the bottom of the threaded hole. • A clean tie strap can be used as a “dip stick” if the lubricant level is not obvious. • Add HPF PRO gearcase lubricant as needed. 1 Correct fluid level must be maintained to ensure operation of the impact protection built into the unit.
PREDELIVERY RUNNING CHECKS • Single Ram System–Add Evinrude/Johnson Biodegradable TNT Fluid, as needed, to bring level to the bottom of the fill plug threads. RUNNING CHECKS DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death. 1 WARNING Single Ram System, 75 - 130 HP 1.
PREDELIVERY RUNNING CHECKS Emergency Stop / Key Switch I-Command Set up Check emergency stop function. With outboard running at IDLE, pull safety lanyard from emergency stop switch. Outboard must stop immediately. Complete basic set up of I-Command gauges. Configure engine and fuel tank, set fuel tank capacity etc. Refer to I-Command User’s Guide. Remote Control Operation A steady stream of water should flow from the overboard indicator.
PREDELIVERY PROPELLERS PROPELLERS Propeller Selection CAUTION Selection of the wrong propeller could reduce engine service life, affect boat performance, or cause serious damage to the powerhead. Water testing with various propeller designs and sizes is the best method of propeller selection. The correct propeller, under normal load conditions, will allow the engine to run near the midpoint of the RPM operating range at full throttle. Refer to SERVICE SPECIFICATIONS in the Service Manual for RPM range.
PREDELIVERY PROPELLERS Propeller Hardware Installation WARNING If cotter pin holes in the nut (without keeper) and shaft do not align, tighten further. Do not loosen. Install keeper (if applicable). Install new cotter pin. To prevent accidental starting while servicing, twist and remove all spark plug leads. 1 Aluminum or stainless steel Small diameter hub Without keeper 120 to 144 in.
PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS WATER TEST AND FINAL ADJUSTMENTS An in the water test is required to make sure the outboard(s) and boat are rigged correctly, propeller selection is correct, and that all accessories function properly.
PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS 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). Water pressure readRPM Idle 1000 1500 2000 Model 2500 ings can vary depending on water screen type, hull design, set up, and operating conditions.
PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS Tilt Limit Switch Adjustment (75 – 300 HP) Place the outboard in normal operating position. Rotate the LOWER adjustment tab UP to reduce the maximum tilt. Rotate the UPPER adjustment tab DOWN to increase the maximum tilt position. WARNING If the outboard does not clear all boat parts when tilted fully or turned side to side, safety related parts could be damaged in the course of such outboard movement. Injuries could result from loss of boat control.
PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS Trim Sending Unit Adjustment (75 – 300 HP) Observe the trim gauge. If the needle does not show center position, tilt the outboard up and adjust the sending unit by pivoting it up or down. Tilt the outboard and engage the tilt support. Temporarily install a thrust rod, P/N 436541, in the number 3 hole. 1 1. Needle at center position 29072 Loosen the sending unit screws, to allow the sending unit to pivot.
PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS Trim Sending Unit Adjustment (25 – 60 HP) WARNING To avoid personal injury, do not adjust the sending unit eccentric cam while the engine is being tilted. The sending unit eccentric cam must be adjusted so that the gauge needle is aligned with the lowest gauge mark with the outboard trimmed all the way DOWN. When the outboard is trimmed all the way DOWN, the sending unit lever touches the eccentric cam just forward of the top of the cam at the contact point.
PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS Trim Tab Adjustment 1 WARNING Improper trim tab adjustment can cause difficult steering and loss of control. A propeller will generate steering torque when the propeller shaft is not running parallel to the water’s surface. The trim tab is adjustable to compensate for this steering torque. IMPORTANT: A single trim tab adjustment will relieve steering effort under only one set of speed, outboard angle and load conditions.
PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS Dual-Outboard Alignment Alignment Adjustment Dual outboards must be connected with a tie bar and adjusted to align the outboards for correct water flow to the gearcases and propellers. Various boat/motor combinations respond differently to dual-outboard alignments. Each application must be thoroughly tested until the ideal combination of performance, steering, and cooling is found.
INDEX INDEX A nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn Abbreviations 6 Accessories Accessory Charge Kit, P/N 5006253 17 Fuel Filter Assembly, P/N 174176
INDEX I nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn I-Command System settings 56, 63, 70 Water Pressure Gauge 57, 64, 70 I-Command Network Outboar
SAMPLE PREDELIVERY CHECKLIST PREDELIVERY CHECKLIST OB 1 2 3 4 5 MODEL NUMBER SERIAL NUMBER KEY NUMBER IMPORTANT: Use this Checklist together with the Evinrude E-TEC Installation and Predelivery Guide, or the correct Service Manual. Dealer must keep this document on file for a minimum of seven years. Every Evinrude/Johnson Dealer is responsible to perform a complete predelivery inspection on all Evinrude E-TEC outboards.
