Product Service Update 2011

Product Service Update
BRP US Inc.
Technical Publications
300 Sea Horse Drive
Waukegan, Illinois 60085 United States
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The following trademarks are the property of BRP US Inc. or its affiliates:
Evinrude ® E-TEC ® S.A.F.E. Evinrude ® / Johnson ® XD30™ Outboard Oil
Johnson ® SystemCheck™ Evinrude ® / Johnson ® XD50™ Outboard Oil
FasTrak™ Triple-Guard Evinrude ® / Johnson ® XD100™ Outboard Oil
I-Command™ DealerPort ® TBX™
® BossWeb Viper™
Evinrude ICON™
Printed in the United States

© 2011 BRP US Inc. All rights reserved.
TM, ® and the BRP logo are registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WARRANTY INFORMATION – NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WARRANTY INFORMATION – OUTSIDE OF NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FIELD SERVICE AND TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TECHNICAL PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2011 PRODUCT IMPROVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

15 – 90 HP INLINE MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
115 – 300 HP 60°/90° V4/V6 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

15 – 30 HP MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
75 – 90 HP (1.3L) MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
115 – 300 HP 60°/90° V4/V6 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
200 – 300 HP 90° V6 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
EVINRUDE DIAGNOSTICS SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

IMPROVEMENTS AND CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
EVINRUDE ICON REMOTE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .43

ICON KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ICON RIGGING KIT SELECTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ICON INSTALLATION TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
ICON SERVICE TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2
CONTENTS
I-COMMAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
I-COMMAND INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
PARTS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

P&A INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
NEW SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ELECTRICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
EVINRUDE E-TEC SPARK PLUG SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
EMM SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
EVINRUDE E-TEC GEARCASE LINE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2011 EVINRUDE E-TEC GEARCASE APPLICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
EVINRUDE E-TEC SHIFT ROD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
EXTERNAL WATER SCREENS AND APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2011 RPM QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2011 WATER PRESSURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
BULLETINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
TOPIC REFERENCE INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3
4
GENERAL INFORMATION
5
Parts & Accessories Support
CONTACT INFORMATION North American dealers may call 1-800-888-4662 for technical
Dealers outside of North America should contact their regional assistance with parts and accessories.
office. Refer to Dealers – Outside North America (BRP Interna- • Select option 3 for ordering assistance, pricing, and back order
tional Offices) on p. 7. or returns information.
• Select option 6 for service parts issues, or application and war-
Dealers – North America ranty questions.
North American dealers should use the following contact informa-
tion. To speed up the process, have your dealer number, the engine
model number, part number and invoice date available.
Technical Support
Technical Training Support
After Sales Support
250 Sea Horse Drive For questions regarding technical training, contact the Technical
Waukegan, IL 60085 Training Center.
Ph: 1-800-888-4662 (Authorized Dealers only) Technical Training Center
Fax: 1-847-689-6902 (Authorized Dealers only) 250 Sea Horse Drive
Waukegan, IL 60085
Warranty Administration Support Ph: 1-847-689-7500
After Sales Support Fax: 1-847-689-7510
250 Sea Horse Drive
Waukegan, IL 60085
Ph: 1-800-888-4662 (Authorized Dealers only)
Fax: 1-847-689-7235 (Authorized Dealers only)
Consumer Support
BRP US Inc. Customer Support Services
250 Sea Horse Drive
Waukegan, IL 60085
Ph: 1-847-689-7090 (Non-authorized dealers/consumers)
Fax 1-847-689-6902 (Non-authorized dealers/consumers)
6
AFTER SALES SUPPORT
Dealers – Outside North America FRANCE
Bombardier Recreational Products France
(BRP International Offices) Les Jardins de la Duranne Bâtiment C
AUSTRALIA 510 rue René Descartes
Bombardier Recreational Products Australia Pty Limited F - 13857, Aix en Provence France
56 Canterbury Road Phone: +33 4 42 94 25 00
Bankstown 2200 GERMANY
New South Wales, Australia BRP Germany GmbH
Phone: +612 9794 6600 Itterpark 11
D-40724 Hilden
BENELUX
BRP Europe Germany
Skaldenstraat 125 Phone: +49 2103 960 680
B-9042 Gent Belgium JAPAN
Phone: +32 9 218 26 00 BRP Japan Limited
15/F Parale Mitsui Building
BRAZIL
8 Higashadi-Cho, Kawasaki-Ku
Bombardier Recreational Products do Brasil
Kawasaki 210-0005
Rodovia Anhanguera Km 104 - Loteamento Tecno Park
Phone: +81 44 200 1431
Condominio Empresarial AZTech
Avenida James Clerck Maxwell, 280 Modulo 04 NEW ZEALAND
Campinas, SP 13069-380 Brasil BRP New Zealand
Phone +55 19 3716 8600 7-11 Arwen Place
East Tamaki
CARIBBEAN AND LATIN AMERICA
Auckland 2130
BRP US Inc.
Phone: +64 9 274 5718
1600 Sawgrass Corporate Parkway, Suite 150
Sunrise FL 33323 SPAIN
954-846-1442 BRP Recreational Products Spain S.L.
c/ Bertrán i Musitu 99-101
EUROPE, MIDDLE EAST AND AFRICA Edificio Brasil
BRP International Division 08840 Viladecans-Barcelona Spain
5-7 CH Chemin du Messidor Phone: +34 93 636 10 97
Lausanne Switzerland
Phone: +41 21 318 78 00 UK AND IRELAND
BRP Recreational Products UK Ltd
4 Brunel Close
Ebblake Industrial Estate
Verwood Dorset UK BH31 6BA
Phone: +44 1202 812 100
7
WARRANTY INFORMATION – Prior Authorization Required for Parts and
Accessories Warranty
NORTH AMERICA If a replacement part or a dealer-rebuild fails, contact
North American dealers should use the following information. Evinrude/Johnson After Sales Support. Dealers are not authorized
to rebuild assemblies without prior authorization.
Warranty Allowance Claims
Have your dealer number, the engine model and serial number,
All warranty allowance claims should be entered online when pos- part number and invoice date available.
sible. When a written warranty Allowance Request Form,
P/N 773629, is required it should be mailed to: Certain parts or assemblies may require additional documentation:
• BRP invoice for the assembly
BRP US Inc.
• installation work order
After Sales Support
• previous work order for original repair
P.O. Box 597
Sturtevant, WI 53177 • sales receipt (over the counter sales)
Warranty parts returned with a Warranty Allowance Request Form, Refer to “Parts and Accessories Claims” in the current Warranty
P/N 773629, should be shipped to: Procedures Manual.
U.S. dealers ship to: B.E.S.T. Warranty
BRP US Inc. As outboards enter the service period of a B.E.S.T. contract, there
After Sales Support are several requirements that dealers and customers should be
300 Sea Horse Drive Dock 5 aware of:
Waukegan, IL 60085
• A 300 hour service (or 3 year inspection) on every outboard
Canadian dealers ship to: • An inspection report must be provided before any B.E.S.T con-
BRP Warranty Returns – Waukegan tract repairs are performed
c/o Affiliated Global Logistics • Engine must have less than 1000 hours
500 Carlingview Drive • There is a $50.00 deductible for each B.E.S.T. contract repair
Etobicoke, ON M9W 5R3 • Dealers must qualify all engine repairs for outboards with
B.E.S.T. coverage
Refer to Administrative Bulletin 2010-04(A) for complete details

and coverage checklist.
8
AFTER SALES SUPPORT
WARRANTY INFORMATION – Predelivery Checklist Included in Shipping

Crate
OUTSIDE OF NORTH AMERICA A Predelivery Checklist is now included in the shipping crate
Dealers outside of North America should contact their regional (owner’s package) of all Evinrude E-TEC outboards. A pack of ten
office for processing of warranty allowance claims, or returning (10) predelivery checklist forms, P/N 5008381, is available through
parts. Refer to Dealers – Outside North America (BRP Interna- Evinrude/Johnson Genuine Parts.
tional Offices) on p. 7.
Dealers are REQUIRED to perform a complete predelivery inspec-
tion on each outboard. Dealers MUST keep predelivery checklists
on file for a minimum of seven years.
Refer to Predelivery Bulletin 2010-01(D) for complete details.
9
Training
FIELD SERVICE AND TRAINING Schedule training online (www.DealerPort.com). For questions
Dealers outside of North America should contact their regional contact the Technical Training Center.
office. Refer to Dealers – Outside North America (BRP Interna-
tional Offices) on p. 7. Training courses are offered at the following locations:
• Waukegan, Illinois
Dealers – North America • Morrow, Georgia
• Tacoma, Washington
Technical Service Representatives – • Laval, Quebec
Applications Engineers (TSR-AE’s) • Dallas, Texas
TSR–AE's support both Dealer and OEM Partners. TSR–AE tech-
nical support visits are coordinated through the After Sales Support Technician Certification
Call Center. Dealer and OEM Technicians should first contact the Technicians who achieved "Certified" status between June 2005
After Sales Support Center Team to resolve technical issues. Con- and June 2006 must attend the Outboard Certification Course by
tact them at 1-800-888-4662 and follow the prompts. May 30, 2011. Certified status WILL EXPIRE soon for technicians
TSR-AE's provide the following dealer support: who fall into this category.
• Service department development assistance (Service Evalua-
Technicians who achieved "Certified" status prior to June 2005
tions and goal setting)
were required to return in prior training seasons. Certified status is
• Feedback reports for product and business trends
EXPIRED for technicians who fall into this category. They should
• Technical support of BRP Outboard Engine products return as soon as possible to recertify.
• Customer Relations
• Serve as instructors at Dallas, Tacoma and Laval Training Cen-
ters
TSR's provide the following OEM partner support:
• All aspects of rigging, technical training to ensure safety and
maximum performance for BRP powered boats
• Feedback reports for product and business trends
• Preparation and distribution of Performance Reports
10
AFTER SALES SUPPORT
Master Technician Program
TECHNICAL PUBLICATIONS
Technicians desiring Master Technician status MUST:
1. Maintain Certified status for at least 4 years (no lapses). Changes to Service Manual Set
2. Successfully complete all updates by the due date. Please note the following changes to the 2011 Service Manuals
3. Complete Outboard Certification Course in 4.5 days or less. and Service Manual Sets:
4. Upon successful completion of the Outboard Certification
• The Installation and Predelivery section has been removed from
Course, technicians who meet the qualifications, and who are
individual service manuals.
approved by their instructor(s) will be given the opportunity to
• The Special Tools section has been removed from individual ser-
take the Master Technician exam.
vice manuals.
5. Complete the 50 question exam with a minimum score of 90%.
The exam may include questions on ANY outboards sold or mar- • The 2011 Installation and Predelivery Guide has been added to
keted by BRP. the Service Manual Set. Additional Installation and Predelivery
Guides may be ordered using P/N 5008506.
To maintain Master Technician status, technicians MUST: • The 2011 Special Tool Guide has been added to the Service
• Complete all distance learning updates by the due date. Manual Set.
• Return for hands-on training when required. See Technician
Certification on p. 10. IMPORTANT: The 2011 Special Tool Guide, P/N 5008526, con-
tains tools for current Evinrude E-TEC product only. Dealers should
• When returning to the Outboard Certification Course, technicians
retain a copy of the 2010 Special Tools Guide, P/N 5007858, or a
must complete the course and pass Master Technician exam as
prior Special Tools Guide as a reference of tools for older outboard
outlined in steps 3 through 5 above.
products.
If a technician allows their Certification to lapse, Master Technician
status is lost.
A technician can take a missed exam at any time to have Certified

status reinstated. However, Master Technician status can only be
reinstated by again meeting the qualifications listed in steps 1
through 5 above.
11
NOTES – GENERAL INFORMATION
12
2011 PRODUCT IMPROVEMENTS
13
15 – 90 HP INLINE MODELS
Engine Management Software 15 – 30 HP Models
Engine management software has been developed to improve emissions and
reduce fuel consumption on 15 – 30 HP models.
Update engine management software on engines with serial numbers 5283875

to 5289986.
1
Refer to Warranty Bulletin 2010-09(W).
1. Engine management software version and revision
Engine Wiring Harness Change 15 – 30 HP Models

1
Evinrude E-TEC 15 – 30 HP (C, H, R, and S-suffix) model outboards have a new
engine wiring harness to support changes to the Touch Troll and neutral
switches.
The Touch Troll switch connector has been eliminated. Wiring for the Touch Troll
switch has been relocated to a new 6-pin AMP connector of the tiller harness.
The neutral switch has a dedicated 2-pin AMP connector, similar to other
Evinrude E-TEC models.
2
1. 6-pin AMP connector (tiller harness)

2. 2-pin AMP connector (neutral switch)
14
New Flywheel Torque Specification 15 – 30 HP Models
When servicing flywheels on Evinrude E-TEC 15 – 30 HP outboards, torque the
flywheel nut to 66 to 70 ft. lbs (90 to 95 N·m).
IMPORTANT: Torque the flywheel using the correct flywheel holder. To prevent
damage to the crankcase or the cylinder block, DO NOT allow the flywheel
holder to rest against the mounting boss for the recoil starter.
Also refer to Service Bulletin 2010-08(S), or the 2011 Service Manual.
Lower Mount 15 – 30 HP Models

A bump stop washer, P/N 353674, was added to the lower mount on 15 – 30 HP
models. This change to improves impact protection, and provides common ser-
vice parts and procedures for all 15 – 30 HP models.
Refer to the correct Service Manual for lower mount service procedures.
1. Bump stop washer
15
Oil Cap Assembly, 15 – 90 HP Models
The oil cap used on 15 – 90 HP models has changed.
1 The oil cap has a redesigned vent valve, to help prevent oil from leaking out of
the vent while the engine is tilted.
Oil cap assembly, P/N 5008406, replaces oil cap assembly, P/N 5007256, and
services 2009 and newer 15 – 30 HP models and 2010 and newer 40 – 90 HP
(F-suffix) models.
1. Vent
1
Electric Starter Motor Change 40 – 65 HP Models
The electric starter motor used on Evinrude E-TEC 40 – 65 HP models has been
changed.
2 The starter features a new nut and spring to retain the drive gear. Previously, the
drive gear was retained with a clip, spring and spacers. This change improves
the durability of the starter and provides common service for all 15 – 65 HP mod-
els.
The electric starter motor, P/N 587045, services all 2004 and newer 15 – 65 HP
models.
1. Nut
2. Spring
16
Throttle Body Assembly 40 – 65 HP Models
A new throttle body assembly is used on all 40 – 65 HP models.
The throttle body assembly features a nickel-plated throttle valve, which

improves corrosion resistance and durability. The new throttle valve is silver in
color, while the previous throttle valve was gold in color.
The new throttle body assembly, P/N 5008407, services all 2004 and newer 40 –
65 HP models. 1
1. Throttle valve
Exhaust Housings 40 – 65 HP Models

A change was made to the exhaust housing for 40 – 65 HP models.
Retainer tabs have been added to the exhaust housing to better secure the
engine wiring harness. Tie straps are now used to secure the engine wiring har-
ness, rather than the previous “J-clamps.”
This change also makes it easier to reinstall and secure the engine wiring har-
ness when servicing the engine.
Exhaust housing, P/N 5008275, services 2006 and newer 40 – 50 HP models.

1
Exhaust housing, P/N 5008274, services 2006 and newer 60 – 65 HP models.
Exhaust Housing
1. Tie straps
17
115 – 300 HP 60°/90° V4/V6 MODELS
Lower Engine Covers 115 – 200 HP 60° Models
Lower engine covers for 115 – 200 HP 60° models have been changed. The
lower engine covers feature a new fastener insert that reduces the risk of crack-
ing the lower engine covers during removal and installation.
Service parts for older product will supersede to new part numbers. Refer to the
correct Parts Catalog for parts ordering information.
Note: Do not use power/impact tools to tighten lower engine cover screws.
Oil Pressure Sensor 115 – 300 HP Models

Clamp, P/N 982115, is now used to retain the oil pressure sensor to the oil pump
housing on all V4 and V6 models.
This change improves the retention of the oil pressure sensor and provides com-
1 mon service parts for these models.
1. Clamp, oil sensor to housing, P/N 982115
18
Oil Recirculation System Hoses 200 – 300 HP 90° V6 1
Models
Oil recirculation hoses on all 200 – 300 HP 90° V6 models have been changed
from black rubber to the blue hose used for oil distribution.
This change provides a common service part (P/N 778708) for the oil distribution
and recirculation hose for these models.
1
1
1. Recirculation hoses
Rear Oiling System 250 – 300 HP 90° (3.4 L) Models

A new rear oil pump replaces the rear oil manifold on 250 – 300 HP (3.4 L) mod-
els. The oil pump is a positive displacement oil pump which supplies oil to each
piston.
IMPORTANT: Correct oil priming procedure is required when installing a new

engine, or after servicing the oil system on 3.4 L engines that use this oil pump.
Refer to Predelivery Bulletin 2010-02(D) or the 2011 Service Manual for the
correct oil priming procedure.
The rear oil pump requires a new EMM, engine wiring harness and engine man-
agement software. For this reason this oil pump CANNOT be fitted to older
1
engines.
1. Rear oil pump
19
Shift Switch 200 – 300 HP 90° V6 Models
Shift switch, P/N 586861, has been relocated from the shift linkage to the cylin-
der and crankcase. This change improves the operation of the shift switch.
A new EMM and engine management software allow the shift switch to perform
the following functions:
• Start in gear protection – prevents the starter motor from operating if the shift
1 lever is not in NEUTRAL.
• Shift interrupt – reduces shift effort when the engine is shifted out of gear.
• Neutral rpm limit – limits engine speed to approximately 1100 rpm when shift
lever is in NEUTRAL position.
Note: DE model engines (ICON Electronic Shift and Throttle) do not have the
shift switch. Also see ICON Conversion Kit Installation 200 – 300 HP 90° V6
1. Shift switch Models on p. 49.
Cooling System Change 250 – 300 HP 90° V6 (3.4 L)

Models
The cooling water hose from the vapor separator outlet to the exhaust adapter
has been relocated to the exhaust emission test port of the exhaust adapter.
This change improves water pressure to the powerhead and provides additional
water to cool the propeller hub.
1
1. Cooling water hose
20
Powerhead Change 200 – 300 HP 90° V6 Models
The following changes have been made to improve powerhead durability:
• Piston splash port and dome have been redesigned to improve durability of
the piston.
• Piston ring locating pins have been changed to reduce locating pin migration.
• Cylinder sleeve oil grooves redesigned to provide consistent oil flow to piston
skirt.
L2-Type Gearcase ( .58 Ratio) Replaced by M2-Type

0
Gearcase ( .54 Ratio) on 225 – 300 HP 90° Models

0
The L2-Type gearcase (with .58 gear ratio) has been replaced by the M2-Type
0
gearcase (with .54 gear ratio) on all 225 – 300 HP models.

0
The larger gear set used in the M2-Type gearcase improves durability. Front
water inlets provide additional cooling water for the powerhead and can boost 2
water pressure in excess of 40 psi (275 kPa).
Also see Exhaust Housing to Gearcase Alignment Pins on p. 38. 1

Additional benefits of the M2-Type gearcase:
• Improved acceleration due to (.542) (1.85:1) gear ratio.
• Front and side water inlets.
• Wider propeller selection available to optimize performance. M2-Type Gearcase
1. Front water inlet
2. Side water inlet
21
Exhaust Grommet 115 – 300 HP Models
A new exhaust grommet is used on all V4 and V6 models.
The new exhaust grommet features ribs to strengthen the grommet and reduce
flexing around the insert area. This improves retention of the overboard indicator
hose.
When installing an exhaust grommet, clean and dry all parts. Make sure the Oet-
1 1 iker clamp that retains the overboard indicator hose is correctly positioned. Refer
to the appropriate Service Manual for installation instructions.
Exhaust grommet, P/N 5008518 services all 2005 and newer 115 – 300 HP
Evinrude E-TEC models.
1. Strengthening ribs
Fuel Hoses – All Models

New and revised U.S. Environmental Protection Agency (U.S. EPA) regulations
have resulted in a number of changes to fuel hoses.
New fuel rails are used on all 40 – 300 HP models. The new fuel rails are con-
structed with a three layers of material to meet the U.S. EPA requirements for
evaporative emissions.
Service parts for older product will supersede to new part numbers. Refer to the
appropriate Parts Catalog for correct parts ordering information.
Fuel Rail (Typical)
22
SERVICE INFORMATION
23
15 – 30 HP MODELS
.
SystemCheck Warnings
3 4
Due to the limited number of circuit inputs and outputs to the EMM, 15 – 30 HP
models have limited warnings when a SystemCheck gauge is installed. These 2 5 NO OIL
WATER TEMP
models only provide tachometer signal and the LOW OIL warning to a System-
Check gauge. 1 6 CHECK ENGINE
LOW OIL
Refer to the Operator’s Guide for a complete explanation of warning system 0 7

NO HOT CHK LOW
functions. OIL ENG OIL
1
Typical SystemCheck Gauges
1. LOW OIL warning
Engine Overheat Damage

If a customer reports a loss of performance, use Evinrude Diagnostics software
to check for the following:
• Code 31; Engine temperature over range
• Code 40; Engine temperature above range – Low speed
• Code 43; Engine temperature above range
• Recorded maximum engine temperature
If any of these service codes are stored, and the maximum engine temperature
is over 248°F (120°C), remove the gearcase. Inspect the water pump and the
exhaust housing megaphone for engine overheat damage.
Loss of performance will result from a damaged exhaust housing megaphone.

The megaphone can be damaged when a significant loss of water flow occurs.
Exhaust Housing Megaphone
Note: Engine damage due to overheat conditions is NOT covered by the BRP
Limited Warranty. Customers should contact their insurance company to file a
claim for financial assistance in the repair.
24
SERVICE INFORMATION
Water Pump Impeller Kit, P/N 5008185
Water Pump Impeller Kit, P/N 5008185, is included with Water Pump Repair Kit,
P/N 5008191, for service of 15 – 30 HP models. The water pump impeller kit
contains a new pressure relief valve spring, P/N 355169, and a new thermostat
spring, P/N 355209.
A change to the water pump impeller material improves the performance of the
water pump. This change affects engine water pressure and REQUIRES stron-
ger pressure relief valve and thermostat springs.
IMPORTANT: REPLACE the pressure relief valve and thermostat springs

when installing a water pump repair kit, or a water pump impeller kit in any 2010
or older 15 – 30 HP model.
Water Pump Repair Kit, 15 – 30 HP M0odels NOTICE Failure to install the impeller assembly and springs as a set can
result in:
•A cold running engine, if the impeller is installed without the pressure
relief valve and thermostat springs.
•An engine overheat, if the pressure relief valve and thermostat springs
are installed without the new impeller.
25
75 – 90 HP (1.3L) MODELS
.
Installation of Oil Pump Assembly

The problem: After installing a replacement oil pump assembly, the LOW OIL
warning light remains on even though the oil tank is full.
The cause: Incorrect installation can result in the low oil switch being held “ON”
by the oil pick up assembly. 2
1
The fix: Be sure to install the oil pump pick up assembly straight into oil tank.
Refer to the correct Service Manual for installation instructions. Make sure the
oil pick up assembly is positioned in front of oil tank baffle. This will prevent inter-
ference with the LOW OIL switch.
1. Oil pick up assembly

2. Oil tank baffle
26
SERVICE INFORMATION
115 – 300 HP 60°/90° V4/V6 MODELS

.
Exhaust Back Pressure Fitting

A blocked exhaust back pressure fitting can result in difficult starting or other run
quality symptoms.
Use the Data Log feature of Evinrude Diagnostic software to monitor the exhaust
back pressure on an engine that is difficult to start, or runs poorly.
Normally, exhaust back pressure readings are erratic. If the data log shows read-
ings which tend to be linear, check the back pressure sensor.
Remove the fitting and inspect for damage or blockage. Replace if damaged.
Clean or replace the exhaust back pressure fitting if it is blocked. Clean it by

Exhaust Back Pressure Fitting
soaking in Engine Tuner. After soaking use an appropriate size pick, or drill bit to
open blocked holes.
27
200 – 300 HP 90° V6 MODELS
Ordering Replacement Gearcases
The L2-Type gearcase with the0.58 (1.71:1) gear ratio is no longer available.
Use an M2-Type gearcase with the0.54 (1.85:1) gear ratio if replacement is
needed.
Because a gearcase conversion kit is required, existing part numbers do not

supersede. Dealers who enter an order for a0.58 gear ratio L2-Type gearcase
will receive an invoice with a “Note” to call the After Sales Service Department.
This will result in delays receiving the correct replacement gearcase.
Order the following parts:

• Select the correct M2-Type replacement gearcase.
Refer to the Parts Catalog for replacement gearcase part numbers. M2-Type Gearcase
• Select the correct gearcase conversion kit –
•order P/N 5008535, for 20 inch models.
•order P/N 5008536, for 25 inch models.
Gearcase conversion kits include the correct shift rod, a new exhaust grommet,
new gearcase mounting screws and installation instructions.
Refer to the installation instructions for the following:

• Exhaust grommet and Oetiker clamp installation.
• Shift rod installation and shift rod height adjustment.
• Correct water inlet screen selection.
• Correct trim tab selection and installation.
• Gearcase mounting screw torque.
• The change of gear ratio requires a change of propeller pitch.
Gearcase Conversion Kit (Typical)
28
SERVICE INFORMATION
MAINTENANCE
Maintenance Recommendations – 26 Point Inspection Checklist
Use the 26 Point Inspection Checklist to explain required service for the Evinrude E-TEC 300 hour/3 year service, and to help “sell” a
maintenance plan to your customer.
The parts department can use the checklist to stock service supplies. Service technicians can use the checklist to check off service items
as they are completed.
Description Engine Every 300 Description Engine Every 300
Care hours or Care hours or
Product 3 years(1) Product 3 years(1)
Emergency stop circuit and lanyard (check operation) X Fuel filter, replace (2) X
Controls, steering and tilting; check operation X Gearcase lubricant, replace A X
Engine mounting hardware, re-tighten X Spark plugs, inspect or replace (3) X
Fasteners, tighten any loosened components X Thermostats, inspect and check operation (3) X
Water intake screens, check condition X Grease fittings, lubricate C X
Cooling system; check water pump indicator X Power trim/tilt and fluid level, inspect B X
Anticorrosion anodes, check condition X Propeller shaft splines, inspect and lubricate (4) C X
Gearcase, check condition X Starter pinion shaft, inspect and lubricate (4) D X
Propeller, check condition X Control cables, inspect and adjust X
Fuel and oil systems, inspect and repair leaks X Steering cable, inspect and lubricate X
Check battery connections and condition X Water pump, inspect / replace X
Access EMM information (resolve any service codes) X Exhaust back pressure fitting (if equipped) X
Electrical and ignition wires (inspect for wear or chafing) X Oil filters remote tank / engine (115 – 300 HP models) X
(1) Average recreational use. Commercial use, heavy use or use in salt or polluted water requires more frequent inspection and maintenance.
(2) Boat mounted fuel water separating filters should be replaced annually
(3) Emission-related component.
(4) Annually in salt water applications
A – HPF Pro Gearcase Lubricant

B – Trim and Tilt Fluid, use Biodegradeable Fluid on single ram hydraulic systems, use Power Trim and Tilt Fluid on three ram hydraulic systems
C – Triple Guard Grease
D – Use Starter Bendix Lube only
29
ELECTRICAL SYSTEM
Starter Drive Gear Engagement, 115 – 300 HP Models
The problem: A limited quantity of starter drive gears may be machined with the
wrong chamfer (beveled edge) on the teeth of the gears. If this condition exists, 1
the starter drive gear (bendix) may not engage the ring gear of the flywheel and
the starting process can fail. Service replacement starter motor assemblies,
P/N 586957 and P/N 586890, could experience this issue.
The Fix: Remove starter motor assembly and identify the chamfer on the teeth
of the starter drive gear. Refer to Warranty Bulletin 2010-08(W), for complete
instructions.
1. Chamfer
FAQ: Spark Plugs – All Models

The Service Teams are frequently asked if it is permissible to substitute spark
plugs. the answer is NO, unless there is an APPROVED substitution.
At this time, the only approved substitution is 2005 – 2006 Evinrude E-TEC 200
– 250 HP 90° V6 (3.3 L) models.
U.S. EPA regulations prohibit modification to any system, that could effect the
engine’s exhaust emissions level. This includes spark plugs. Engine emission
certification REQUIRES only approved spark plugs be used in the engine. 1
Refer to the Evinrude E-TEC Spark Plug Service Chart on p. 68, the appropri-
ate Parts Catalog, or the Emissions Control Information (ECI) Label on the
swivel bracket of the outboard for correct spark plug information.
ECI Label
1. Spark plug information
30
SERVICE INFORMATION
V–
Voltage Drop Test
NEG V A voltage drop test is an effective and easy to perform electrical test. The pur-
1 pose of this test is to make sure the load in the circuit consumes the maximum
amount of voltage. An excessive voltage drop in a circuit will result in the load
not performing at its maximum potential.
Use a digital voltmeter to measure the voltage drop on each section of the start
circuit. Always connect the voltmeter leads with the positive (+)/red lead closest
3
to the positive terminal and the negative (–)/black lead closest to the negative
terminal of the battery.
2 4
+ If any voltage reading is greater than 0.5 VDC check that connections are clean,
tight and free of corrosion. Clean or replace any corroded or damaged cables or
connections.
1. Negative battery cable
2. Positive battery cable Note: Disconnect the Crankshaft Position Sensor (CPS) to prevent the engine
3. Solenoid from starting.
4. Starter cable
STEP 1: Connect voltmeter positive (+) lead to the terminal for the negative (–)
battery cable at powerhead. Connect voltmeter negative (–) lead to negative (–)
battery post.
• Activate starter motor and observe voltage reading.
STEP 2: Connect positive (+) lead to battery positive (+) terminal. Connect neg-
ative (–) lead to starter solenoid terminal.
STEP 3: First, activate starter motor. Connect positive (+) lead to starter solenoid
terminal. Connect negative (–) lead to opposite starter solenoid terminal.
• Observe voltage reading.
STEP 4: Connect positive (+) lead to starter cable of solenoid terminal. Connect
negative (–) lead to starter motor terminal.
31
Inductive Ignition System 1 2 3
The inductive (IDI) ignition system provides ignition spark with a fast rise time
and a long, continuous duration spark, compared to the multi-strike cd ignition
used on older models. The benefit is a smoother running engine under a variety
of load conditions.
The inductive ignition uses an ignition coil which contains an internal circuit
board to control current flow through the primary winding.
How it works: System voltage (55 volts) is supplied through the white/red wire
to the primary winding. Ground is provided through the black wire to the circuit
board and to the coil primary. The EMM provides a low voltage control signal
through orange wire to the circuit board.
When the circuit board receives the control signal, it momentarily stops current CDI Multi - Strike Ignition
flow through the coil primary winding. The surrounding magnetic field collapses, 1. Fast rise time
2. Short spark duration
creating high voltage in the coil secondary winding. 3. No spark in gap
IDI Ignition Coil Tests: Because the ignition coil contains an internal circuit
board, there are no simple ignition coil tests available.
1 2
Before replacing an ignition coil, be sure:
• 55 V is supplied to the white/red wire of the ignition coil connector.
• A control signal is present on the orange wire of the ignition coil connector.
Refer to Ignition Control Circuit Tests in the appropriate service manual.
• The black wire of the ignition coil connector provides continuity to ground.
• The secondary spark plug lead provides continuity.
Refer to Ignition Output Tests in the appropriate service manual for other igni-
tion system test procedures.
Evinrude E-TEC IDI

1. Fast rise time
2. Long spark duration
32
SERVICE INFORMATION
FUEL SYSTEM
Injector Coefficient Database
Dealers can now download the coefficient files for new service fuel injectors from
a database available on the internet.
This process eliminates the need for a 3.5 inch floppy drive on the service laptop
computer and the problems created when the disk is packaged with a service
1 fuel injector is damaged.
Refer to the serial number label attached to the fuel injector electrical connector.
2 ACCURATELY record the 14-digit Serial Number (SN) and the 5-digit Checksum
(CS) number from the injector serial number label.
Injector Serial Number Label

Log on to DealerPort or BossWeb to download injector coefficient files from the
1. Serial number internet. Refer to Service Bulletin 2010-07(S) for complete instructions. A copy
2. Checksum number
of this bulletin is packaged with each service fuel injector.
Internet Browser Blocks Download of Injector

Coefficient File
The problem After entering injector serial number and checksum, nothing hap-
pens after pressing the “Download Injector Coefficient File” button.
1 The cause: Internet browser security settings are blocking download of the coef-
ficient file and displays a security message bar above the screen.
The fix: Click on the security message bar that reads “Click here for options.”
Select “Download File” to start the download process.
1. Click here for options
33
Fuel Issues
Reports received by the After Sales Department indicate fuel related problems
persist in areas where alcohol extended fuels are used.
These problems include:

• Excessive alcohol content in fuel
• Water or other contaminants in the fuel tank
• Phase separation
These problems can result in:
• Corrosion of fuel system metal parts
• Deteriorated fuel hoses
• Blockage in the fuel system
• Engine damage
Deteriorated fuel hose and primer bulb
As part of routine maintenance, inspect fuel hoses from the tank to the outboard.
Make sure fuel supply hoses have not deteriorated. Replace deteriorated fuel
hoses. Routine inspection of fuel hoses can help prevent expensive repairs.
Refer Service Bulletin 2006-06(S) and to the 2008 and 2009 Product Service
Update books for additional information and recommendations.
These problems can occur with all brands and types of outboards and are
related to fuel blending, contaminants, and atmospheric conditions.
Blockage in the fuel system
34
SERVICE INFORMATION
OILING SYSTEM
Code 36; Rear Oil Injection Pump Circuit OPEN
Code 36 is a new service code for Evinrude E-TEC 250 – 300 HP 90° V6 (3.4L)
models with the new rear oil pump. The rear oil pump is powered by the 12 V
electrical circuit. The EMM controls pump operation by rapidly connecting and
disconnecting the pump’s internal coil to ground.
1 Refer to the 2011 Service Manual for code description.
Possible Causes: Damaged wire harness or electrical connector between EMM

and oil pump. Failed internal coil of oil pump. Failed circuit in EMM.
Troubleshooting procedure: Use the correct service manual to check the fol-
1. Rear oil injection pump
lowing:
• Rear oil pump voltage and control signal. Refer to Cylinder Oil Pump Voltage
Tests.
• Oil injection pump circuit resistance. Refer to Cylinder Oil Pump Resistance
Test.
35
COOLING SYSTEM
Gearcase Flushing Adapter
Cover auxiliary water inlet holes on the gearcase when a gearcase flushing
adapter is used to flush the outboard. If auxiliary water inlet holes on the gear-
case are not covered, water can drain from them, resulting in engine overheat. 1
To insure enough water travels to the powerhead from the water intakes, tempo-
rarily cover auxiliary water inlets as follows:
15 – 30 HP Models – Temporarily cover the two small auxiliary water inlet holes
on each side of the gearcase with waterproof tape.
150 – 300 HP Models (equipped with an M2-Type gearcase) – Temporarily

cover the six auxiliary water inlet holes on the front of the gearcase with water- 15 – 30 HP Models
proof tape. 1. Auxiliary water inlets
Be sure to remove waterproof tape from auxiliary water inlets when flushing is
complete.
150 – 300 HP Models (M2-Type Gearcase)

1. Auxiliary water inlets
36
SERVICE INFORMATION
TRIM AND TILT

Single Piston Hydraulic Trim and Tilt Assemblies
Identification
Dealers must correctly identify single piston hydraulic trim and tilt assemblies to
order the correct service parts.
The single piston hydraulic trim and tilt assembly is used on 75–90 HP (20 inch)
1 models in 2005 and on 115–130 HP V4 (20 inch) models in 2007.
Hydraulic Trim and Tilt Assembly, P/N 5005756 superseded to P/N 5007776,
starting in 2008.
Some service parts for these hydraulic trim and tilt assemblies are NOT inter-
changeable. Use the table below and the appropriate Parts Catalog to correctly
identify the hydraulic trim and tilt assembly.
Hydraulic Trim and Tilt Assembly
1. P/N 5007776, Black anodized manifold Hydraulic
Manifold Use Parts
Model Year Models Trim and Tilt
Description Catalog
Assembly P/N
1 2005–2008 75 – 90 2005–2008
Painted Gloss
5005756
2007–2008 115 – 130 Black 2007–2008
75 – 90 Anodized Flat 2009 or newer
2009 & newer 5007776
115 – 130 Black 2009 or newer
Manual Release Issue
2 If a hydraulic trim and tilt assembly, P/N 5007776, cannot be lifted manually,
replace the manual release valve, P/N 5007782. The replacement manual
release valve is identified by its red anodized color.
Manual Relief Valves

1. P/N 5006321, use in hydraulic trim and tilt assembly, P/N 5005756
2. P/N 5007782 (red anodized), use in hydraulic trim and tilt assembly,
P/N 5007776
37
GEARCASE 1
Exhaust Housing to Gearcase Alignment Pins
Current production M2-Type gearcases are fitted with exhaust housing to gear-
case alignment pins, P/N 350943.
If installing a replacement M2-Type gearcase on a 2008 or older engine, inspect

the exhaust housing. Make sure it is machined to accept the exhaust housing to
gearcase alignment pins.
If the exhaust housing is not machined to accept the alignment pins, remove the
alignment pins from the replacement gearcase.
NOTICE Failure to remove the exhaust housing to gearcase alignment

pins can damage the exhaust housing mounting flange and prevent cor- 1. Exhaust housing to gearcase alignment pins
rect installation of the gearcase.
Use Gearcase Alignment Kit, P/N 5007231 to accurately align gearcase housing
to exhaust housing on engines where the exhaust housing is not machined to 1
accept the alignment pins.
Exhaust Housing
1. machined to accept exhaust housing to gearcase alignment pins
38
EVINRUDE DIAGNOSTICS SOFTWARE
39
IMPROVEMENTS AND CHANGES
New Software Version 5.1
Evinrude Diagnostics software is a Windows based diagnostic tool developed for
Evinrude E-TEC outboards. The latest version will communicate with DI engines
back to 1997.
Model year changes require the release of new software versions. Version 5.1 is
required for model year 2012 and older.
New diagnostics software (version 5.1, P/N 5008689) automatically shipped to

all authorized U.S. and Canadian service dealers as part of the North American
Essential Tools and Software Program. Existing dealers are charged a reduced
price for this software as an annual software license renewal and update.
Evinrude Diagnostics software version 5.1 Minimum Hardware Requirements:

• Personal Computer: IBM-compatible laptop computer.
• Operating System: Microsoft Windows 7, Vista, XP, 2008 or 2003.
• CPU Speed: Pentium II 133 MHz or higher.
• Memory: 64 megabyte or more.
• Hard disk: 40 megabyte or more of free space. Evinrude Diagnostics software (version 5.1)
• Floppy drive: necessary for injector coefficient file installations, but not required if
user has internet access to DealerPort or BOSSWeb.
Refer to Service Bulletin 2010-07(S).
• Display resolution: 800 x 600 (1024 x 768 preferred), font size 96 dpi.
• Interface Port:
•Computer RS-232 (9-pin) Serial Port.
•USB to RS-232 (9-pin) Serial Adapter: Configured to ComPort 1 through 9.
•CardBus/PCMCIA to RS-232 (9-pin) Serial Adapter: Configured to ComPort 1
through 9.
• Communications Cable: Use Interface Cable, P/N 437955.
IMPORTANT: Version 5.1 software MUST be installed using the program CD,
P/N 5008689. Version 5.1 software is NOT available online.
40
EVINRUDE DIAGNOSTICS SOFTWARE
Important Information for Evinrude Diagnostics
Software Version 5.1 Program Installation
Initial Setup
The first time the program is run, an Initial Setup form will appear. Initial setup
items are set to default conditions. Possible changes are as follows:
• Unless directed by BRP do not uncheck "Automatically Save Engine Data File
(EDF) Upon Engine Connection".
• If computer normally has an internet connection then check the "Use Auto-
matic Website Updates".
• Verify assigned website (DealerPort or BossWeb, depending on your sub-
scription service).
Changes to these selections may be made at any time, by selecting the “Tools”
Initial Setup
menu and selecting “Options”.
Software Registration
Software registration is required to run this program.
• After the Initial Setup is complete, the program will check for a prior version of
Evinrude Diagnostics registration. If prior version registration information is
found, Evinrude Diagnostics version 5.1 will automatically use the existing reg-
istration information.
• If a prior version is not found, the user MUST complete the registration, Enter
your dealer number, dealership name, address and country. An internet con-
nection is NOT needed to complete this registration.
Note: Registration information is only used for identification purposes on printed

reports.
Software Registration
41
NOTES – EVINRUDE DIAGNOSTICS SOFTWARE
42
EVINRUDE ICON REMOTE CONTROL SYSTEM
43
ICON KITS
ICON Rigging Kits
ICON rigging kits are designed to make rigging kit selection an easy three or four
step process. Refer to the ICON Rigging Kit Selection Chart on p. 45, for rig-
ging kit selection.
Each ICON rigging kit includes all the boat related ICON components needed to
rig a single station or an optional second station, plus the appropriate ICON
remote control for the number of engines installed on the boat.
ICON Rigging Kit
ICON Conversion Kits

ICON Conversion Kits add digital electronic shift and throttle control to 2008 and
newer Evinrude E-TEC 150 – 300 HP models. To add digital electronic shift and
throttle control to an Evinrude E-TEC outboard, order:
• ICON Conversion Kit, P/N 764979, for 200 – 300 HP 90° V6 models.
• ICON Conversion Kit, P/N 765304, for 150 – 200 HP 60° V6 models.
ICON conversion kits must be:
• installed by a dealer using Evinrude Diagnostics software.
• used on a boat equipped with an ICON remote control network.
• used with ICON, I-Command, or other NMEA 2000 compliant CANbus instru-
ments.
Update engine management software on 2008 – 2010 engines to ensure ICON

compatibility. Refer to the Installation Instructions provided with the kit.
ICON Conversion Kit
Note: 2007 and older models are NOT compatible with the ICON remote control
system.
44
ICON RIGGING KIT SELECTION CHART

Step 1: Select number of engines. 1 2 3 4 5
Concealed Single Lever
Step 2: Select appropriate remote control. Side Mount Binnacle Mount
Dual Lever Binnacle Mount
Step 3: Order P/N for main or single station Rigging Kit Rigging Kit Rigging Kit Rigging Kit Rigging Kit Rigging Kit
rigging kit. P/N 764990 P/N 764980 P/N 764982 P/N 764984 P/N 764986 P/N 764988
Main Station Rigging Kits include:
ICON Remote Control, P/N 765412 765381 765382 765383 765384 765385
Master Power/Key Switch, P/N 765371 765373 765374 765371 765371 765371
Start/Stop Switch Panel, P/N 765378 – 765375 765376 765377
Trim Switch Panel, P/N – 765388 765389 765390
Network Power Cable, P/N 764921
ICON Gateway Module Kit, P/N 764922
ICON Accessory Power Relay, P/N 765296
ICON Hubs (2), P/N 764943
Buss Cable Extension 15ft (4.57m), P/N
764948
(Kit includes 1 buss cable per engine)
Buss Cable Backbone 20ft (6.1m), P/N 764950 –

Buss Cable Backbone 25ft (7.4m), P/N – 764951
Engine Identity Plug ID#1, P/N – 764916
ICON Remote Control User’s Guide 765410 764954
Installation Instructions included:
ICON Remote Controls, P/N 355248 355084
ICON Switch Panels, P/N 355085 355085
ICON Gateway Module & Cable Kit, P/N 355086 355086
ICON Accessory Power Relay Kit, P/N 355087 355087
ICON Quick Connect Guide, P/N 765409 764953
45
Concealed
Step 4 (optional): Order P/N for Side Mount Rigging Kit Rigging Kit Rigging Kit Rigging Kit Rigging Kit
second station rigging kit. Rigging Kit P/N 764981 P/N 764983 P/N 764985 P/N 764987 P/N 764989
Not Available
Second Station Rigging Kits Include:
ICON Remote Control, P/N – 765381 765382 765383 765384 765385
Emergency Stop Switch Panel, P/N – 765379 765380 765372 765372 765372
Start/Stop Switch Panel, P/N – – 765375 765376 765377
Trim Switch Panel, P/N – – 765388 765389 765390
Buss Cable Extension 15ft (4.57m), P/N – 764948
Buss Cable Extension 20ft (6.1m), P/N – – 764949
Installation Instructions included:
ICON Remote Controls, P/N – 355084
ICON Switch Panels, P/N – 355085
ICON Quick Connect Guide, P/N – 764953
46
1
ICON INSTALLATION TIPS
Buss Cable Issues
Incorrect alignment and assembly of ICON buss cables can result in a non-func-
tional ICON network. Use the following information to avoid network communica-
tion issues.
Assemble connectors dry. Do NOT use Electrical Grease on this style connector.
Visually check the alignment and assembly of connectors. Align tabs and sock-
ets of the female connector to the grooves and pins of the male connector.
Tighten locking rings of connectors finger-tight.
Do not rotate the connectors to align pins to sockets. This can damage the pins
1. Damaged pins
of the connector. A damaged connector can cause an electrical short in the net-
work, resulting in a failed 3 Amp fuse at the master power key switch.
It is possible for the pins of one connector to enter the sockets of the other con-
nector when the tabs and grooves of the connector are misaligned. This dam-
1 ages the connector housing and makes an extra groove in the misaligned
connector.
2
Misaligned connectors can cause the 3 Amp fuse at the master power key
switch to blow and disrupt or eliminate communication on the network.
Improper network communication can create non-recoverable fault codes and

activate S.A.F.E.
1. Groove
2. Extra groove in the misaligned connector
47
150 – 200 HP 60° V6 Models,
Code 152; Shift Actuator Motion Fault
The problem: After installing an ICON conversion kit, P/N 765304, on a 150 –
200 HP 60° V6, Code 152; Shift Actuator Motion Fault occurs when the engine is
shifted into forward gear, due to incorrect shift actuator calibration.
The fix: Use Evinrude Diagnostic software (version 4.0 or higher) to verify shift
actuator calibration. Refer to the installation instructions provided with the con-
version kit.
If the problem persists, perform the following adjustment:

• Turn the master power key switch to the ON position.
• Position control levers to the NEUTRAL detent.
• Move the control lever to the FORWARD detent.
Code 152; Shift Actuator Motion Fault
• Manually turn the propeller shaft to confirm FORWARD gear engagement.
• Move the control lever to the REVERSE detent. Manually turn the propeller
shaft to confirm REVERSE gear engagement.
• Move the control lever to the NEUTRAL detent. Rotate the propeller shaft
back and forth to ensure the face of the clutch dog does not contact FOR-
WARD or REVERSE gear.
If gear engagement is NOT correct, a shift actuator motion fault can occur when
the control lever is moved to FORWARD or REVERSE.
Use Evinrude Diagnostic software “Settings” screen and select the “EST Calibra-
tion” tab. Use the “Nudge” buttons to adjust the shift stroke to the forward or
backward direction. Be sure to press the “Save” button after completing the
adjustment.
After using the “Nudge” feature, repeat the gear verification process.
Note: Do NOT preload the shift actuator calibration toward FORWARD gear on
outboards with a counter rotation gearcase.
48
ICON Conversion Kit Installation
200 – 300 HP 90° V6 Models
When installing an ICON conversion kit on 2011 and newer 200 – 300 HP 90° V6
models the shift switch must be removed. Install protective cover, P/N 586821,
on shift switch connector of the engine harness.
1
Refer to the installation instructions provided with ICON conversion kit,
P/N 764979.
1. Neutral switch
49
ICON SERVICE TIPS
ICON Troubleshooting Guide, P/N 356076
The ICON Troubleshooting Guide, P/N 356076, will automatically ship to all
authorized U.S. and Canadian service dealers.
The ICON Troubleshooting Guide contains installation tips to help avoid com-
mon problems. Simple, effective troubleshooting flow charts are also included to
help dealers efficiently troubleshoot and make repairs to an ICON network.
Additional copies may be ordered from Evinrude/Johnson Genuine Parts and
Accessories.
ICON Troubleshooting Guide
Remote Control Neutral Position

1
Before attempting to change ICON network settings, set shift and throttle calibra-
tion adjustments, or perform troubleshooting steps: 15.0°
• Turn master power/key switch to the ON position (engine OFF) 15.0°
• Place control lever(s) in the NEUTRAL position 85.5°
40.5°
Failure to follow these steps could result in false warnings or service codes, or
can disrupt network communication.
14.5°
9.5°
1. Neutral position
50
Battery Voltage
13.25
VDC Battery voltage of 13.25 VDC or higher is required for stable ICON network oper-
ation. Inconsistent voltage on the ICON network can effect operation.
Use Evinrude Diagnostics software “Monitor” screen or a NMEA 2000 gauge

(I-Command or ICON) to monitor voltage. Perform the following steps if ICON
network voltage is below 13.25 VDC.
Identify which battery is powering the ICON network. Test battery connections
and charge. Run the engine connected to the battery for the ICON network or
use a battery charger to support the battery voltage.
+
Visually inspect the 3A fuse for the master power key switch and the 10A fuse
for the power supply cable. Check network voltage at the 10A fuse of the ICON
power supply cable.
Look for an Accessory Power Relay Kit, P/N 765296, in the ICON network. This
(optional) power relay kit connects to one of the 6-port hubs and is required to
power any accessory controlled by the master power key switch.
Connect only the positive lead of an accessory to the terminal board provided
with the accessory power relay kit. Do NOT connect accessory wiring to the
master power key switch.
Accessory Power Relay Kit
51
Failed 3 Amp Fuse (Master Power/Key Switch)
A failed 3 amp fuse for the master power/key switch is normally caused by one OFF
RUN
of the following:
• Failed or damaged master power/key switch
• Damaged master power/key switch wire harness
3 Amp Fuse
• Damaged or faulty buss cable or back bone cable
• Damaged or faulty hub
Follow these steps to troubleshoot a failed 3 amp fuse: FUSE
Step 1: Inspect master power/key switch for damage. Test key switch function
with an ohm meter. Refer to MWS Key Switch Diagram in the service
manual.
+
Step 2: Inspect master power/key switch wire harness for damage or short cir-
cuit. 1.
Repair or replace damaged master power/key switch or wire harness. If the mas-
ter power key switch or wire harness is not damaged or the fuse fails again, con-
tinue with Step 3.
Step 3: Turn the master power/key switch OFF. Replace 3 amp fuse.
Step 4: Disconnect ALL hubs, the back bone cable and buss cables (including
buss cables for ESM, gateway module and accessory power relay) from
the ICON network.
Step 5: Reconnect one hub or buss cable to the ICON network.
Step 6: Turn master power/key switch ON.
Step 7: If the fuse does not fail, turn the master power/key switch OFF. Repeat
steps 5 through 7 until the faulty hub or cable is reconnected and the 3
amp fuse fails.
Repair or replace the hub or buss cable that causes the 3 amp fuse to fail.
Step 9: Replace 3 amp fuse.
Verify remaining hubs or buss cables are not faulty. Repeat steps 5 through 9
until all hubs and buss cables are reconnected to the ICON network.
52
I-COMMAND
53
I-COMMAND INFORMATION
Instancing
I-Command digital gauges with software version 2.1 or higher, support up to five
engines and eight fuel tanks.
A NMEA 2000 network can be configured to support many instances of duplicate

or similar devices on the same network. Additional devices must be added
through careful network configuration. Instance numbers are used to represent
similar devices on a common network.
When adding devices to the NMEA 2000 network:

• Unconfigured devices MUST be added one device at a time.
• Preconfigured device kits can be added to the network all at one time.
• In either case, if a device is associated with an engine the device instance Engine Instance (Transom Position) Information
number MUST match the engine instance number.
Engine / Device Association
Port Starboard
Port Center Starboard
Center Center
Number of
Outboards Instance Numbers
1 0
2 0 1
3 0 1 2
4 0 1 2 3
5 0 1 2 3 4
Use Evinrude Diagnostics software to confirm engine instance, or transom posi-

tion.
54
I-COMMAND
I-Command Water Pressure Sensor Kit, P/N 5008300
Use this kit to provide water pressure data to I-Command or other instruments
on a NMEA 2000 network. Install this kit on Evinrude E-TEC 115 – 300 HP out-
boards only.
The water pressure sensor used in this kit is capable of providing water pressure
readings from 0 to 30 psi (0 to 206 kPA).
Refer to the installation instructions provided with the kit for correct installation.
The water pressure sensor MUST be installed in a vertical position. Hose instal-
lation MUST provide complete drainage of water from the sensor.
Software for I-Command Devices

Software is available to update I-Command digital gauge and device software.
Log into DealerPort (www.dealerport.com) or BOSSWeb (www.boss-

web.brp.com) to download the latest I-Command software and information.
Refer to I-Command Software Update Kit, P/N 765357 on p. 63.
DealerPort
55
I-Command Bulletins
This list of bulletins provides a reference to specific I-Command issues.
Bulletin
Subject Affected Models Problem
Number
Certain I-Command Classic instruments may

All I-Command Classic instruments
I-Command Classic accumulate moisture internally and experience
2006-04(P) with date codes prior to and including
Instruments excessive lens fogging. Instruments with an accu-
date code 089/06 are suspect.
mulation of internal moisture should be replaced.
NMEA 2000 Lowrance † depth-finders and GPS

All Evinrude E-TEC 115–250 HP out- units can interfere with engine management mod-
Evinrude E-TEC CAN-
2006-04(S) boards using CANBus network com- ule (EMM) functions on certain Evinrude
Bus Software Update
munications. E-TEC outboards during certain CANBus commu-
nication modes.
2005 & newer 200 - 250 HP 90° V6 This bulletin provides information related to a
I-Command Network
2007-01(P) 2007 & newer 115 - 200 HP 60° V4/V6 change in I-Command network connectors. (Blue
Connector(s)
2008 & newer 40 - 90 HP to Red connectors)
I-Command and NMEA This bulletin provides information related to the dif-
2008-01(P) 2000 Network Connec- ALL ferences in I-Command compatible DeviceNet-
tors style connectors.
This bulletin provides information related to the
I-Command Water
2008-03(P) ALL selection and installation of I-Command water
Pressure Sensor Kits
pressure sensors kits.
I-Command Fuel Level This bulletin provides information related to the

2008-04(P) ALL
Converter Kits configuration of I-Command fuel level converters.
This bulletin provides recommended service pro-

I-Command Digital
2010-01(P) ALL cedures and information to update software and to
Gauges
submit warranty allowance requests.
56
PARTS AND ACCESSORIES
57
P&A INFORMATION
Tiller Handle Kits Evinrude E-TEC 15 – 30 HP Models
Tiller Handle Kits for 15 – 30 HP models are available as follows:
Color Blue White Note
Model Year
2009–2010 5007834 not available 5-pin electrical connector
2011 & newer 5008256 5008237 6-pin electrical connector
Uses a 5-pin electrical connector. The neutral switch is attached. Refer to the
2009 or 2010 Accessory Parts Catalog for parts information.
Uses a 6-pin electrical connector. Refer to the 2011 Parts Catalog for order
information. Refer to the 2011 Accessory Parts Catalog for service parts infor-
mation.
Tiller handle kits for 2009/10 models are not interchangeable with 2011 model.
Frequently Requested Part Numbers

The following items are frequently requested part numbers and should be
ordered as needed:
• Predelivery Checklist, P/N 5008381, 10/pack
• Warranty Allowance Requests (warranty claim forms), P/N 773629, 25/pack
• RCM Form (form for return of unused, saleable parts), P/N 11111, 10/pack
• Model Year Reference Guide, P/N 5006145
• 2011 Predelivery and Installation Guide, P/N 5008506 *
• ICON Installation Guide, P/N 764952 *
• I-Command Users Guide, P/N 355917 (3.5 inch) *
• I-Command Users Guide, P/N 355918 (2 inch) *
• I-Command Product Selection Guide, P/N 764677 *
* Available for download from DealerPort or BossWeb.
58
PARTS AND ACCESSORIES
Propeller Shaft Failures
Propeller shaft failures can occur when incorrect propeller hardware is installed.
1 The thrust bushing provided with some competitor’s propeller and removable
hub kits may be significantly thinner than the thrust bushing provided with BRP
propeller kits.
The surface area of the thrust bushing which contacts the propeller shaft does
not provide sufficient clamp load after the propeller hardware and propeller are
installed.
2
Insufficient clamp load causes the propeller to loosen and can result in scoring of
the propeller shaft by the thrust bushing. The area that is scored by the thrust
bushing will weaken. Because the loose propeller puts an abnormal amount of
1. BRP thrust bushing
stress on the propeller shaft, the failure occurs at the weak point created by the
2. Competitor’s thrust bushing insufficient clamp load on the thrust bushing. This type of failure also results in
the loss of the propeller and propeller hardware.
Note: Incorrect installation of any manufacturer’s propeller and propeller hard-

ware that results in the failure of the propeller shaft is not a condition which will
be covered under the BRP Limited Warranty.
Propeller Shaft Failure
59
NOTES – PARTS AND ACCESSORIES
60
SERVICE TOOLS
61
NEW SERVICE TOOLS
New service tools have been developed for 2011 Model Year outboards. New
tools were announced in Service Bulletin 2010-09(S).
Fuel Flow Test Kit, P/N 5008371

The Fuel Flow Test Kit, P/N 5008371, is used to check a boat’s fuel system for
fuel flow restrictions and air leaks without having to start the outboard or run the
vessel through the water. Developed for Evinrude E-TEC 115 – 300 HP out-
boards.
This tool was shipped automatically as part of the essential tool program.
Refer to Service Bulletin 2010-09(S) and the instructions for additional informa-
tion. Fuel Flow Test Kit, P/N 5008371
62
SERVICE TOOLS
I-Command Software Update Kit, P/N 765357
Use I-Command Software Update Kit, P/N 765357, to update I-Command digital
gauge software.
Software to run the update kit is available for use with Windows XP or Windows
Vista/Windows 7.
Log into DealerPort (www.dealerport.com) or BOSSWeb (www.boss-

web.brp.com) to download the latest I-Command software and information.
This tool was shipped automatically as part of the essential tool program.
Refer to Parts and Accessories Bulletin 2010-01(P) or the instruction sheet

provided with the kit.
I-Command Software Update Kit, P/N 765357
63
NOTES – TOOLS
64
REFERENCE
65
PAINT
Paint codes have been added to the paper parts catalogs and to the Electronic Parts Catalogs (EPC) for the 2011 model year.
Color Spray Can PPG Paint Code Application
Paint / Catalyst
PRIMER 777172 – Midsection & Gearcase
PRIMER (Gray) – W42650 / W29741 Use for white engines
PRIMER (Black) – SEP61993 / W29585 Use for blue engines
BLACK (Gloss) 777179 W28610 / W28792 Engine cylinder/crankcase
BLACK (Military) 351066 W43653 / W26790 Covers, Midsection, & Gearcase
WHITE 777171 W28502 / W45315 Base coat
CLEARCOAT 772414 W29461 / W26790 Use with base coat on upper & lower engine covers
BLUE (Evinrude E-TEC) 351907 SAC61243 / W45315 Base coat
ELECTRICAL INFORMATION
Battery Cable Length Guide Battery Recommendations
Battery cable must be of the correct gauge to carry the electrical Each outboard requires its own starting battery. Use the chart
current required to start the outboard. Use the chart below to select below to select a battery that meets or exceeds the minimum
the correct gauge battery cable. requirements.
Outboard Model Outboard Model Battery Rating

Battery Cable Length 15–30 HP 40–300 HP 675 CCA (845 MCA), or 800 CCA
115–300 HP (1000 MCA) below 32°F (0°C)
1 to 10 Ft. (.3 to 3 m) 6 Gauge 4 Gauge
107 amp-hr in extreme applications
11 to 15 Ft. (3.4 to 4.6 m) 4 Gauge 2 Gauge
640 CCA (800 MCA), or 800 CCA
16 to 20 Ft. (4.9 to 6.1 m) 2 Gauge 1 Gauge 15–90 HP (1000 MCA) below 32° F (0° C)
107 amp-hr in extreme applications
66
REFERENCE
1
FUSES
2
The chart below list all fuses available from Evinrude/Johnson Genuine Parts
and Accessories.
Fuse Fuse Amp Fuse Fuse Package
4 Dimensions
3 P/N Type Rating Color
(Length x Diameter)
Qty
114509 AGA 3 Glass 0.625 x 0.25 1
512129 AGA 5 Glass 0.625 x 0.25 5
510884 AGA 20 Glass 0.625 x 0.25 10
5 5031911 AGA 25 Glass 0.625 x 0.25 1
6 511386 AGA 30 Glass 0.625 x 0.25 1
123852 AGC 1 Glass 1.25 x 0.25 1
Fuse Types
5030348 AGC 20 Glass 1.25 x 0.25 1
1. AGA 512672 AGU 40 Glass 1.5 x 0.411 1
2. AGC/SFE
3. AGU 3850985 AGU 50 Glass 1.5 x 0.411 1
4. ATC/ATO 982019 AGU 50 Glass 1.5 x 0.411 10
5. ATM/Mini
6. JT 763640 ATC/ATO 1 Black 1
764538 ATC/ATO 3 Violet 1
763641 ATC/ATO 5 Tan 10
ATC/ATO Fuse ATM/Mini Fuse 967545 ATC/ATO 10 Red 1
0.760”
19.3 mm
0.430”
10.82 mm
5032215 ATC/ATO 15 Blue 1
0.15” 514021 ATC/ATO 20 Yellow See Fuse 5
0.207”
3.81 mm
5.25 mm Dimension
0.460”
5032230 ATC/ATO 30 Green Diagram 1
11.7 mm
514764 ATM/Mini 5 Tan 5
514766 ATM/Mini 10 Red 5
514767 ATM/Mini 15 Blue 1
0.347”
8.81 mm
514768 ATM/Mini 20 Yellow 1
0.492”
12.5 mm 0.642” 5032630 ATM/Mini 30 Green 1
0.752” 16.31 mm
19.1 mm 0.295”
7.50 mm
5033633 JT 60 Yellow 1
0.263”
6.67 mm 304980 SFE 20 Glass 1.25 x 0.25 1
Fuse Dimension Diagram
67
EVINRUDE E-TEC SPARK PLUG SERVICE CHART
Model 2004 2005 2006 2007 2008 2009 2010 2011
15 H.O. – 30 HP QC10WEP QC10WEP QC10WEP
40 – 50 HP QC12PEP† QC12PEP† QC12PEPB† QC12PEPB† QC10WEP QC10WEP QC10WEP QC10WEP
115 – 130 HP
QC10PEPB† QC10WEP QC10WEP QC10WEP QC10WEP
60° V4
150 – 200 HP
QC10PEPB† QC10WEP QC10WEP QC10WEP QC10WEP
60° V6
200 – 250 HP
QC10WEP* QC10WEP* QC10WEP QC10WEP** QC8WEP QC8WEP QC8WEP
90°V6 (3.3L)
250 HO – 300 HP
QC8WEP QC8WEP QC8WEP QC8WEP
90°V6 (3.4L)
† DO NOT substitute spark plugs on these models.
* QC10WEP may be substituted for QC10PEPB on 2005/2006 200 - 250 HP 90° V6 models.
** H suffix models use QC8WEP
Spark Plug Part Numbers

P/N
Spark Plug
(4-pack) (6-pack) (24-pack)
QC12PEP 5001866 775983
QC12PEPB 5006525 763689
QC10WEP 5007419 764643
QC8WEP 5007597
QC10PEPB 5006308 778874
68
REFERENCE
EMM SERVICE CHART

EMMs cannot be ordered as a regular parts order, since they must be programmed before shipping.
BEFORE ordering a replacement EMM:

• Review Administrative Bulletin 2009-02(A) for the policies and procedures for the Warranty Replacement of Evinrude E-TEC EMMs.
• Review Parts and Accessories Bulletin 2008-02(P) for the policies and procedures for Service Replacement of Evinrude E-TEC EMMs.
Model 2004 2005 2006 - 2007 2008 2009 2010 2011
15 – 30 HP 587062 587062 587062

40 – 50 HP 586759 586759 586759 586968 586968 586968 586968
60 – 65 HP 586759 586862 586970 586970 586970 586970
75 – 90 HP 586759 586759 586759 586970 586970 586970 586970
115 HP 60° V4 586867 586982 5869821
115 – 130 HP 60° V4 5870482 587048 587067
150 – 200 HP 60° V6 586707 586982 587048 587048 587067

200 – 250 HP 90° V6 (3.3 L) 586707 586707 586982 587048 587048 587067
250 – 300 HP 90° V6 (3.4 L) 586982 587048 587048 587115
Notes:
1. 2009 115 HP F suffix ONLY
2. 2009 115 H.O. and 130 HP
IMPORTANT: Do NOT install an EMM from a newer engine on an older engine. Changes in the newer models will result in damage to
the EMM if installed on an older engine.
69
EVINRUDE E-TEC GEARCASE LINE DRAWINGS
S-Type: 75 – 90 HP (20 inch), I3 and
H-Type: 15 H.O. – 30 HP, I2 S2 Type: 115 – 130 HP (20 inch), V4
14.24”
361.65mm 19.079
3.22”
81.81mm 4.124
O-Type: 90 – 130 HP (25 inch), I3 & V4 and

F-Type: 40 – 65 HP, I2 150 – 200 HP (20 inch), 60° V6
19.20
17.46
4.06
4.918
70
REFERENCE
L-Type: No longer produced M-Type: No longer produced
19.20 19.20
4.918 5.078
L2-Type: 150 H.O. 60° V6 (20 inch) and M2-Type: 150 –200 HP 60° V6 (25 inch) and
200 H.O. 90° V6 (3.3L) (20 inch) 200 – 300 HP 90° V6 (20 & 25 inch)
19.20
19.20
4.918 5.082
71
2011 EVINRUDE E-TEC GEARCASE APPLICATION CHART
Assembly Model Shaft Reverse Oil
Type Color Gear Ratio Gear Set
Part No. Family Length Gear Capacity
15”
15 H.O. –
H-Type 5008162 Blue 20” 13:28 (.465) 2.15:1 392475 (F), 351147 (P) 327655 11 oz (325 ml)
30 HP
25”
15”
15 H.O. –
5008214 White 20” 13:28 (.465) 2.15:1 392475 (F), 351147 (P) 327655 11 oz (325 ml)
30 HP
25”
F-Type 5006558 Blue 40 – 60HP 20” 12:32 (.375) 2.67:1 398522 (F,P) 318353 21 oz (620 ml)
5007628 White 40 – 60HP 20” 12:32 (.375) 2.67:1 398522 (F,P) 318353 21 oz (620 ml)
5006126 Blue 65 Comm 22.5” 12:32 (.375) 2.67:1 398522 (F,P) 318353 21 oz (620 ml)
S-Type 5006555 Blue 75 – 90 HP 20” 13:26 (.500) 2:1 436746 (F,P) 345992 31.6 oz (935 ml)
5006426 White 75 – 90 HP 20” 13:26 (.500) 2:1 436746 (F,P) 345992 31.6 oz (935 ml)
S2-Type 5006326 Blue 60° V4 20” 13:26 (.500) 2:1 5006311 (F,P) 352319 31.6 oz (935 ml)
5006520 White 60° V4 20” 13:26 (.500) 2:1 5006311 (F,P) 352319 31.6 oz (935 ml)
O-Type 5007023 White 75 – 90 HP 25” 12:27 (.444) 2.25:1 435123 (F,P) 336574 32.8 oz (970 ml)
5007334 Blue 60° V4 25” 12:27 (.444) 2.25:1 435123 (F,P) 336574 32.8 oz (1250 ml)
5007023 White 60° V4 25” 12:27 (.444) 2.25:1 435123 (F,P) 336574 32.8 oz (970 ml)
5006554 Blue 60° V6 20” 14:26 (.538) 1.86:1 5004218 (F,P,R) 336561 33.1 oz (980 ml)
5007134 White 60° V6 20” 14:26 (.538) 1.86:1 5004218 (F,P,R) 336561 33.1 oz (980 ml)
CORO 5007594 White 60° V4 25” 12:27 (.444) 2.25:1 435932 (F,P) 431702
72
REFERENCE
Assembly Shaft Reverse Oil

Type Color Model Family Gear Ratio Gear Set
Part No. Length Gear Capacity
M2-Type 5007705 Blue 60° V6 25” 13:24 (.542) 1.85:1 5007389 (F,P,R) 347373 38.9 oz (1150 ml)
5007669 White 60° V6 25” 13:24 (.542) 1.85:1 5007389 (F,P,R) 347373 38.9 oz (1150 ml)
5007705 Blue 90° V6 (3.3L) 20” 13:24 (.542) 1.85:1 5007389 (F,P,R) 347373 38.9 oz (1150 ml)
225 HP 90° V6
5007705 Blue 20”/25” 13:24 (.542) 1.85:1 5007389 (F,P,R) 347373 38.9 oz (1150 ml)
(3.3L)
225 HP 90° V6
5007669 White 20” 13:24 (.542) 1.85:1 5007389 (F,P,R) 347373 38.9 oz (1150 ml)
(3.3L)
250 H.O. 90° V6
5007705 Blue 20”/25” 13:24 (.542) 1.85:1 5007389 (F,P,R) 347373 38.9 oz (1150 ml)
(3.4L)
20”/25”/
5007669 White 90° V6 (3.3L) 13:24 (.542) 1.85:1 5007389 (F,P,R) 347373 38.9 oz (1150 ml)
30”
5007669 White 90° V6 (3.4L) 25”/30” 13:24 (.542) 1.85:1 5007389 (F,P,R) 347373 38.9 oz (1150 ml)
CORO 5007670 White 60° V6 25” 13:24 (.542) 1.85:1 5007388 (F,P,R) 5008224 35.8 oz (1060 ml)
5007670 White 90° V6 (3.3L) 25”/30” 13:24 (.542) 1.85:1 5007388 (F,P,R) 5008224 35.8 oz (1060 ml)
5007670 White 90° V6 (3.4L) 25”/30” 13:24 (.542) 1.85:1 5007388 (F,P,R) 5008224 35.8 oz (1060 ml)
L2-Type 5007668 Blue 60° V6 20” 14:26 (.538) 1.86:1 5007663 (F,P) 353544 32.5 oz (960 ml)
5007706 White 60° V6 20” 14:26 (.538) 1.86:1 5007663 (F,P) 353544 32.5 oz (960 ml)
200 H.O. 90° V6
5007668 Blue 20”/25” 14:26 (.538) 1.86:1 5007663 (F,P) 353544 32.5 oz (960 ml)
(3.3L)
200 H.O. 90° V6
5007706 White 20” 14:26 (.538) 1.86:1 5007663 (F,P) 353544 32.5 oz (960 ml)
(3.3L)
73
EVINRUDE E-TEC SHIFT ROD CHART
Shaft Gearcase Gear Shift Height Adjustment Shift Rod
Model Year
Length Type Ratio Rod P/N (±1/2 turn) Dimension (A)
2004-2011 20 S .50 351179 21 1/4 in (53.975 cm) 31.0 in (78.74 cm)
75 – 90 HP 2004-2005 25 O .44 351180 26 1/4 in (66.675 cm) 36.0 in (91.44 cm)
2006-2011 25 O .44 352886 26 1/4 in (66.675 cm) 35.85 in (91.05 cm)
2007-2011 20 S2 .50 350464 20 15/16 in (53.20 cm) 30.57 in (77.65 cm)

115 – 130 HP
2007-2011 25 O .44 352957 25 15/16 in (65.90 cm) 35.55 in (90.29 cm)
2007-2011 20 L / L2 .54 350464 20 15/16 in (53.20 cm) 30.57 in (77.65 cm)
150 – 200 HP
2007-2011 20 O .54 350464 20 15/16 in (53.20 cm) 30.57 in (77.65 cm)
60° V6
2007-2011 25 M / M2 .54 352808 25 15/16 in (65.90 cm) 35.32 in (89.71 cm)
2005-2011 20 L / L2 .54 / .58 329864 21 29/32 in (55.60 cm) 31.49 in (79.98 cm)
2005-2010 25 L / L2 .54 / .58 329865 26 29/32 in (68.30 cm) 36.49 in (92.68 cm)
200 – 300 HP
2005-2011 20 M / M2 .54 347300 21 29/32 in (55.60 cm) 31.25 in (79.37 cm)
90° V6
2005-2011 25 M / M2 .54 347301 26 29/32 in (68.30 cm) 36.25 in (92.07 cm)
2005-2011 30 M / M2 .54 347391 31 29/32 in (81.00 cm) 41.25 in (104.77 cm)
74
REFERENCE
EXTERNAL WATER SCREENS AND APPLICATIONS

This chart lists standard and available optional water screens. For applications which may require additional cooling water, select optional
water screens based on the type of application.
M-Type, M2-Type and L2-Type Gearcases
Water Screen Kit † Port Starboard Height Application
High Performance, P/N 5005124 (L2 Standard) 348479 348480 Flush High Speed (over 60 MPH)
High Flow, P/N 5005063 350264 350265 0.060 General
Ultra High Flow, P/N 5006337 (M2 Standard) 350946 350945 0.160 Aerated
Ultra High Flow +1/4, P/N 5007081 350790 350791 0.410 Severely aerated
Screws, P/N 337061
† Note: Kits include both screens, screws and instruction sheet.
O-Type Gearcase
Individual Water Screens †† Port Starboard Height Application
Standard 337778 337778 0.023 General
Optional 339247 339247 0.055 Aerated
Screws, P/N 337061
†† Note: Screens are symmetrical, use two per outboard.
S-Type and S2-Type Gearcases

Individual Water Screens †† Port Starboard Height Application
Standard (through 2006) 340495 340495 Flush General
Standard (2007 and newer) 337778 337778 0.058 Aerated / Weedy
Optional 339247 339247 0.200 Severely aerated
Screws, P/N 340665
†† Note: Screens are symmetrical, use two per outboard.
75
2011 RPM QUICK REFERENCE CHART How to Use the RPM Quick
Reference Chart
Recommended Optimum RPM @
Model When selecting a propeller for an outboard and boat
Operating Range RPM Range Rated HP
application, refer to the recommended wide open
15 H.O. 5500 – 6100 5400 – 5800 5800 throttle operating range for the outboard model.
25 HP 5500 – 6100 5400 – 5800 5800
When determining propeller selection, choose a pro-
30 HP 5500 – 6100 5400 – 5800 5800 peller that will best suit the customer’s needs. For
example:
40 HP 5000 – 6000 5400 – 5600 5500
• choose a higher pitch propeller for low-to-mid rpm
50 HP 5500 – 6000 5600 – 5750 5750 for light load cruising.
60 HP 5500 – 6000 5600 – 5750 5750 • choose a lower pitch propeller to attain top rpm for
water skiing or other high load applications.
65 HP Commercial 5500 – 6000 5600 – 5750 5750
For best overall performance choose a propeller that
75 HP 4500 – 5500 5000 – 5200 5000
allows the outboard to run in the optimum rpm range,
90 HP 4500 – 5500 5000 – 5200 5000 which is usually the point of peak horsepower.
115 – 130 HP 60° V4 5500 – 6000 5500 – 5750 5750 Remember, only a thorough water test will determine
150 HP/150 H.O. 60° V6 4850 – 5850 5500 – 5600 5350 which propeller works best for a particular application.
175 HP 60° V6 4850 – 5850 5500 – 5600 5350
200 HP 60° V6 4850 – 5850 5600 – 5850 5350
200 H.O. 90° V6 (3.3L) 4500 – 5800 5500 – 5700 5150
225 HP/225 H.O. 90° V6 (3.3L) 4500 – 5800 5500 – 5700 5150
250 HP 90° V6 (3.3L) 4500 – 5800 5500 – 5700 5150
250 H.O. 90° V6 (3.4L) 4500 – 6000 5500 – 5850 5250
300 HP 90° V6 (3.4L) 5000 – 6000 5500 – 5850 5500
76
REFERENCE
2011 WATER PRESSURE CHART

This chart lists typical water pressure readings for 2011 model outboards for boat speeds up to 50 mph (80 kph/43 knots) and is provided
as a general guide for use when troubleshooting over-heating or over-cooling issues.
Water pressure readings can vary depending on water inlet screen type, hull design, set up, and operating conditions.
RPM Idle 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Model Water Pressure (psi/kpa)
4-5 5-6 7-9 10-11 14-15 15-17 16-18 16-18 14-16 12-14 10-12
40 – 65 HP
(27-34) (34-41) (48-62) (68-75) (96-103) (103-117) (110-124) (110-124) (96-110) (82-96) (68-82)
5-6 10-11 12-14 15-17 16-18 16-18 13-15 15-17 16-18 19-21 20-22
75 – 90 HP
(34-41) (68-75) (82-96) (103-117) (110-124) (110-124) (89-103) (103-117) (110-124) (131-144) (137-151)
115 – 130 HP 5-6 9-10 12-14 15-17 18-20 20-21 20-22 21-23 21-23 21-23 21-23
60° V4 (34-41) (62-68) (82-96) (103-117) (124-137) (137-144) (137-151) (144-158) (144-158) (144-158) (144-158)
150 – 200 HP 4-5 9-11 14-16 17-19 19-21 20-22 20-22 21-23 22-24 23-25 24-26
60° V6 (27-34) (62-75) (96-110) (117-131 (131-144) (137-151) (137-151) (144-158) (151-165) 158-172) (165-179)
200 – 250 HP 3-5 7-9 8-10 9-11 10-12 11-13 12-14 13-15 14-16 15-17 16-18
90° V6 (3.3L)1 (27-34) (48-62) (55-68) (62-75) (68-82) (75-89) (82-96) (89-103) (96-110) (103-117) (110-124)
250 HO – 300 HP 4-6 7-11 9-12 10-14 12-15 14-16 15-18 16-19 18-20 18-25 20-30
90° V6 (3.4L)1 (27-41) (48-75) (62-82) (68-96) (82-103) (96-110) (103-124) (110-131) (124-137) (124-172) (137-207)
Notes:
1. Water pressure readings in excess of 40 psi (275 kpa) are possible for these models at boat speeds above 50 MPH (80 KPH/43 knots).
77
SERVICE LITERATURE
2011
Description English French Parts English French
Operator’s Operator’s Catalog Service Service
Guide Guide Manual Manual
Evinrude Models
15 - 30 HP 215992 215993 5008317 5008326 5008327
40 - 60 HP 215994 215995 5008318 5008328 5008329
65 HP Commercial 216018 216019 5008318 5008328 5008329
55 HP MFE 215996 215997 5008319 5008330 5008331
75 - 90 HP 215998 215999 5008320 5008328 5008329
115 - 130 HP 60° V4 216000 216001 5008321 5008332 5008333
150 - 200 HP 60° V6 216000 216001 5008322 5008332 5008333
200 - 300 HP 90° V6 216002 216003 5008323 5008334 5008335
Literature Sets Reference

2011 Illustrated Parts & Accessory Catalog 5008324 2011 Flat Rate Guide – English 5008492
2011 Parts Catalog Set – Paper 5008325 2011 Flat Rate Guide – French 5008493
2011 Service Manual Set – English 5008340 2011 Warranty Procedures – English 5008494
2011 Service Manual Set – French 5008341 2011 Warranty Procedures – French 5008495
2011 Service Manual CD – English 5008336 2011 Product Service Update – English 5008496
2011 Service Manual CD – French 5008337 2011 Product Service Update – French 5009497
2011 Update CD – English 355838
2011 Update CD – French 355839
Special Tools Catalog 5008526
Predelivery & Installation – All Models – English 5008506
Predelivery & Installation – All Models – French 5008507
Predelivery & Installation – All Models – Spanish 5008508
78
REFERENCE
2010
Description English French Parts English French
Operator’s Operator’s Catalog Service Service
Guide Guide Manual Manual
Evinrude Models
25 - 30 HP 215932 215933 5007997 5008146 5008147
40 - 60 HP 215920 215921 5007998 5008148 5008149
65 HP Commercial 215922 215923 5007998 5008148 5008149
75/90 HP 215926 215927 5008000 5008148 5008149
115 - 130 HP 60° V4 215928 215929 5008001 5008152 5008153
150 - 200 HP 60° V6 215928 215929 5008002 5008152 5008153
200 - 300 HP 90° V6 215930 215931 5008003 5008154 5008155
Literature Sets Reference

2010 Illustrated Parts & Accessory Catalog 5008005 2010 Special Tools Catalog 5007858
2010 Parts Catalog Set – Paper 5008004 2010 Flat Rate Guide – English 5007856
2010 Service Manual Set – English 5008158 2010 Flat Rate Guide – French 5007860
2010 Service Manual Set – French 5008159 2010 Warranty Procedures – English 5008129
2010 Service Manual CD – English 5008156 2010 Warranty Procedures – French 5008130
2010 Service Manual CD – French 5008157 2010 Product Service Update – English 5008168
2010 Product Service Update – English 5008169
2010 Update CD – English 355139
2010 Update CD – French 355140
Predelivery & Installation – All Models – English 5007857
Predelivery & Installation – All Models – French 5007861
79
BULLETINS
2010 Bulletin Index
Bulletin
Models Subject / Description
Number
Administrative (A)
2010-01(A) 2010 Model Year Outboard Engines Inbox Components
2010-02(A) Evinrude ICON Flat Rate Table
2010-03(A) ALL EPA Campaign Label
2010-04(A) ALL BEST Warranty
Predelivery (D)
2010-01(D) ALL Predelivery Checklist
2010-02(D) 2011 Evinrude E-TEC 250 – 300 HP (3.4 L) Outboards New Installation and Predelivery Procedure
Parts and Accessories (P)
2010-01(P) I-Command Digital Gauges Updating Software
Service (S)
2010-01(S) 2009 Evinrude E-TEC 75 – 90 HP Outboards Incorrect Wiring Diagram in Service Manual, P/N 5007811
Damaged Wiring Resulting from Improper Rigging or Faulty Connec-
2010-02(S) Evinrude E-TEC 15 – 300 HP Outboards
tions
Gearcase Alignment Gauge Kit, P/N 5006349
2010-03(S) Evinrude E-TEC 75-90 HP Outboards
Replaces Service Bulletin 2004-09(S)
2010-04(S) Evinrude E-TEC 15 – 300 HP Outboards Warranty Powerhead Identification
2010-05(S) Evinrude E-TEC 150 – 200 HP 60° V6 Outboards Oil Distribution Hose Routing
2010-06(S) ALL Operation in Oil Contaminated Water
Evinrude E-TEC 15 – 300 HP outboards,
2010-07(S) 1999 – 2001 Evinrude Ficht 75 – 250 HP outboards, and Injector Coefficient Database
2002–2006 Evinrude DI 75 – 250 HP outboards
2010-08(S) Evinrude E-TEC 15 – 30 HP Outboards Torque Change for Flywheel Nut
2010-09(S) ALL New Service Tools – 2011 Model Year
2010-10(S) Evinrude E-TEC 40 – 90 HP Outboards Installing Replacement Lower Engine Covers
80
REFERENCE
Bulletin
Models Subject / Description
Number
Warranty (W)
2010-01(W) 2010 Evinrude E-TEC 75 HP – 130HP Outboards Trim and Tilt Hydraulic Assembly Replacement
2010-02(W) 2010 Evinrude E-TEC 115 – 300 HP Outboards Oil Pump Assembly Replacement and Oil Hose Routing
2009 and 2010 Evinrude E-TEC 15 – 65 HP, and
2010-03(W) EPA CAMPAIGN: Fuel Hose and Primer Bulb Assembly Replacement
2009 Evinrude MFE 55 HP Outboards
2010-04(W) 2010 and 2011 Evinrude E-TEC 40 - 90 HP Outboards SAFETY CAMPAIGN: Incorrectly Installed Clamps on Fuel Hoses
2011 Evinrude E-TEC 200 HP – 250 HP 90° V6 (3.3 L)
2010-05(W) Shift Lever Cam
Outboards
2010-06(W) 2011 Evinrude E-TEC 15 – 30 HP Outboards Shift Lever Screws
2010-07(W) This bulletin was not issued.
2010 and 2011 Evinrude E-TEC 115 – 300 HP
2010-08(W) Starter Drive Gear Engagement
Outboards
2010-09(W) 2011 Evinrude E-TEC 15 – 30 HP Outboards EPA CAMPAIGN: Engine Management Software Update
81
NOTES – REFERENCE
82
APPENDIX
83
TOPIC REFERENCE INDEX
Model
25 – 30 HP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
40 HP and larger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
60 – 65 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
75 – 90 HP and larger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
115 HP and larger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
115 H.O. – 130 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
150 – 200 HP 60° V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
150 – 300 HP 60° V6 and 90° V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
200 H.O. – 250 HP 90° V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
250 H.O. – 300 HP 90° V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
300 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4-Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
ICON Remote Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
I-Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Stern Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
84
APPENDIX
The table provides a reference to information presented in previous Product Service Updates.
Model Topic Where to Find (Book Year /Section) Other References

15 – 30 Flywheel servicing 2010 - Service Tips
15 – 30 Water pump servicing 2010 - Service Tips
Predelivery Bulletin
25 – 30 New model rigging information 2009 - Rigging
2008-02(D)
25 – 30 New model warning system information 2009 - Rigging
25 – 30 Step required to install battery charge module 2009 - Diagnostic Software
25 – 30 EMM Light Emitting Diodes (LEDs) 2009 - Engine Management Module
25 – 30 Code 120; Oil level switch open circuit detected 2009 - Service Codes
25 – 30 Fuel injector seal kits 2009 - Fuel System
Fuel injector and vapor separator servicing, new Service Bulletin
25 – 30 2009 - Fuel System
procedure 2008-07(S)
25 – 30 Oil recirculation diagram (new model) 2009 - Oiling Systems
25 – 30 New accessory kits for Evinrude E-TEC 25/30 HP 2009 - Parts & Accessories
40 Tilt assist kit for manual tilt models 2008 - Parts & Accessories
40 Rope start models - revised oil pump wire harness routing 2009 - Ignition & Electrical
40 – 60 Water pump o-ring eliminated 2008 - Cooling System
40 – 60 Vented water pump housing 2008 - Cooling System
40 – 60 Melted propeller hardware or Hydrus exhaust ring 2008 - Cooling System
40 – 60 Cover design change 2008 - Engine Covers
40 – 60 Oil recirculation changes 2004/2005 to 2006 & newer 2008 - Oiling System
New trim and tilt assembly, P/N 5007774 - manual relief
40 – 60 2009 - Midsection
valve improved
Service Bulletin
40 – 90 Engine idle temperature 2008 - Cooling System
2006-07(S)
40 – 90 Engine cover material 2008 - Engine Covers
40 – 90 Spark plug replacement - inductive ignition models 2008 - Ignition & Electrical
Service Bulletin
40 – 90 Spark plug life 2008 - Ignition & Electrical
2006-07(S)
85
40 – 90 Starter mounting screw installation 2008 - Ignition & Electrical
40 – 90 Exhaust relief muffler filter service 2008 - Midsection
40 – 90 Oil to fuel hose eliminated 2008 - Oiling System
40 – 90 Service oil pump assemblies 2007 & older 2008 - Oiling System
40 – 90 Service oil pump assemblies 2008 & newer 2008 - Oiling System
40 – 90 Rigging grommet installation tip 2008 - Rigging
40 – 90 Code 117; Critical low oil level - 2008 & newer models 2008 - Service Codes
40 – 90 Air bubbles in oil line 2009 - Oiling Systems
40 – 90 Lower motor cover installation 2008 - Engine Covers
40 – 90 Repairing scratches to motor covers 2008 - Engine Covers
40 – 90 Inductive ignition information 2008 - Ignition & Electrical
40 – 90 Inductive ignition testing 2008 - Ignition & Electrical
40 – 90 Code 38; Oil pressure feedback not detected 2008 - Service Codes
40 – 90 Change to flywheel service procedures 2009 - Ignition & Electrical
40 – 90 New oil tank and oil pump assemblies 2010 - Product Improvements
40 – 90 Neutral switch 2010 - Product Improvements
40 – 90 Installing a second battery 2010 - Service Tips
40 – 115 Single ram trim and tilt assemblies 2008 - Midsection
40 – 115 Tiller kits 2008 - Parts & Accessories
40 – 115 SystemCheck gauge recommendation 2008 - Parts & Accessories
40 – 115 Steering friction kit 2008 - Parts & Accessories
40 – 115 Missing on acceleration - propeller 2008 - Rigging
40 – 200 Inline and 60° V Models - Cylinder Head Changes 2010 - Service Tips
Parts & Accessories
40 – 300 Longer engine mounting screws 2009 - Rigging
Bulletin 2008-05(P)
Service Bulletin
40 – 300 Cylinder head temperature sensor installation change 2009 - Ignition & Electrical
2008-01(S)
40 – 300 TNT models - Melted wiring and bonding wires 2009 - Ignition & Electrical
40 – 300 Fuel injector seal kits 2009 - Fuel System
40 – 300 Vapor separator filter, P/N 354190, now available 2009 - Fuel System
86
APPENDIX

60 – 65 Water valve operation 2008 - Midsection
60 – 65 Water valve tests 2008 - Midsection
65 Tilt assist kit for manual tilt models 2008 - Parts & Accessories
75 – 90 Oil recirculation changes 2004/2005 to 2006 & newer 2008 - Oiling System
75 – 90 Upper mount screw change and service tip 2008 - Powerhead
75 – 90 2008 and newer - Changes to temperature monitoring 2009 - Engine Management Software
75 – 90 New starter motor 2010 - Product Improvements
New trim and tilt assembly, P/N 5007776 - manual relief
75 – 130 2009 - Midsection
valve improved
75 – 250 2008 - Cooling System
External water screen chart
75 – 300 Code 40; Engine overheat, low speed (port or single) 2009 - Service Codes
75 – 300 Driveshaft bearing housing change to o-ring 2009 - Gearcase
75 – 300 Code 70; Engine overheat, low speed (starboard) 2009 - Service Codes
75 – 300 O-ring, P/N 314728, supersedes to P/N 354731 2010 - Product Improvements
90 Manual tilt midsection not compatible with trim and tilt 2008 - Midsection
90 – 250 Water pump grommet and seal application 2008 - Cooling System
115 S2-Type Gearcase - information 2008 - Gearcase
115 Exhaust valve operation 2008 - Midsection
115 Exhaust valve testing 2008 - Midsection
115 Exhaust valve relay module testing 2008 - Midsection
115 Over-oiling issue 2009 - Oiling Systems
115 – 130 How to identify S2-type gearcase 2009 - Gearcase
115 – 130 Oil recirculation changes 2008 & older/2009 & newer 2009 - Oiling Systems
115 – 130 S2-Type gearcase - Pinion screw torque 2009 - Gearcase
115 – 130 S2-Type gearcase - Stuck driveshaft 2009 - Gearcase
115 – 130 Air Intake and Air Silencer 2010 - Product Improvements
60° models only - Melted propeller hub, modification to
help prevent
115 – 200 60° models only - Steering arm to cover bumper 2008 - Engine Covers
115 – 200 60° models only - Rear oil manifold; multi-point oiling 2008 - Oiling System
87
115 – 200 60° models - Water separating fuel filter kit 2008 - Parts & Accessories
115 – 200 60° models - revised oil hose routing 2008 - Powerhead
115 – 200 60° models - Upper mount screw change and service tip 2008 - Powerhead
60° models - Powerhead replacement kits have revised oil
115 – 200 2009 - Powerhead
hose routing
115 – 200 60° models - New flywheel cover 2009 - Rigging
60° models - Ignition coil mounting bracket, mounting
115 – 200 2009 - Ignition & Electrical
location changed
115 – 200 60° models - Starter cable service kit, improves starting 2009 - Ignition & Electrical
60° models - water separating fuel filter added to 2009
115 – 200 2009 - Fuel System
models
60° models - vapor separator, P/N 5006084, pressure test
115 – 200 2009 - Fuel System
port changed
115 – 200 60° models - Rear oil manifold bracket 2009 - Oiling Systems
115 – 200 60° models - Improved shift lever, eliminates lost motion 2009 - Gearcase
2008 - Rigging
115 – 200 60° models only - Oil filter installation
2009 - Rigging
115 – 200 60° models only - Flywheel Stud 2010 - Product Improvements
115 – 250 60° V4 and 60° V6/90° V6 starter motors are different 2008 - Ignition & Electrical
60° V4 and 60° V6/90° V6 starter motors differences and
changes
115 – 250 Exhaust relief muffler not serviceable 2008 - Midsection
115 – 250 Oil switch improvement 2008 - Oiling System
115 – 250 Auxiliary battery charge kit 2008 - Parts & Accessories
115 – 250 Trim switch extension kit 2008 - Parts & Accessories
115 – 250 Exhaust back pressure sensor damage 2008 - Powerhead
115 – 250 Code 38 issue 2008 - Rigging
2008 and newer - Service fuel injector electrical
115 – 300 2009 - Fuel System
connectors
Code 77; Start assist circuit over current detected - false
115 – 300 2009 - Service Codes
setting
88
APPENDIX

115 – 300 New engine wiring harnesses 2009 - Ignition & Electrical
115 H.O. – 130 New water pump kit, P/N 5007556 2009 - Cooling Systems
115 H.O. – 130 New impeller housing, P/N 5007554 2009 - Cooling Systems
115 H.O. – 130 V4 Exhaust adapter improvements 2009 - Midsection
115 H.O. – 300 EMM changes 2009 - Engine Management Module
115 H.O. – 300 Inductive ignition new on these models 2009 - Ignition & Electrical
60° models only - Air silencer change can improve
150 – 200 2008 - Fuel System
performance
150 – 200 60° models - Powerhead alignment 2009 - Powerhead
60° models - New inner exhaust housing, P/N 354148,
150 – 200 2009 - Midsection
improved water flow
150 – 250 M2-Type Gearcase - information 2008 - Gearcase
150 – 250 L2-Type Gearcase - information 2008 - Gearcase
150 – 250 Forward gear and bearing changes 2008 - Gearcase
150 – 250 Propeller shaft bearing housing retainer tabs 2008 - Gearcase
150 – 250 White "Stars and Stripes" decal kits 2008 - Parts & Accessories
150 – 250 "Stars and Stripes" decal kits 2009 - Parts & Accessories
150 – 300 How to identify L2-type gearcase 2009 - Gearcase
150 – 300 Powerhead installation, apply Permatex #2 to gasket area 2009 - Powerhead
200 – 250 90° models - New trim and tilt assembly 2008 - Midsection
200 – 250 Engine idle temperature 2008 - Cooling System
Service Bulletin
200 – 250 Thermostat venting 2008 - Cooling System
2005-03(S)
Service Bulletin
200 – 250 Melted propeller hub, modifications to help prevent 2008 - Cooling System
2005-04(S)
Warranty Bulletin
200 – 250 Fuel inlet hose clip 2008 - Engine Covers
2005-01(W)
DI models only - Alternate spark plug for extended low
speed operation
89
Service Bulletin
200 – 250
2005-05(S)
Spark plug life 2008 - Ignition & Electrical
Service Bulletin
200 – 250
2006-02(S)
90° models - Oil recirculation changes 2004-2006 to 2007
200 – 250 2008 - Oiling System
& newer
200 – 250 90° models - Flushing adapter 2008 - Parts & Accessories
2008 - Powerhead
200 – 250 90° models - Powerhead replacement kits
2009 - Powerhead
Service Bulletin
200 – 250 2005 models - Oil priming issue 2008 - Rigging
2004-02(D)
200 – 250 90° models - Adapter kit, P/N 5007589 2009 - Midsection
200 – 250 90° (3.3 L) models - Adapter, P/N 5001496 2009 - Midsection
200 – 250 Issue with flushing adapter, P/N 775385 2009 - Cooling System
200 – 250 Knock sensors added to these models 2010 - Product Improvements
200 – 250 3.3 L Models - Water plate, P/N 347251 2010 - Service Tips
200 – 300 90° models - Ignition coil mounting location, coil damage 2009 - Ignition & Electrical
200 – 300 90° models - Pinched oil lines 2009 - Oiling Systems
200 – 300 90° models - Powerhead to adapter gaskets different 2009 - Midsection
200 – 300 90° models - Trim and tilt assembly improvements 2009 - Midsection
200 – 300 90° models - New pinion bearing, P/N 5007751 2009 - Gearcase
200 – 300 90° models - Trim Limit Rod, P/N 354185 2010 - Product Improvements
Warranty Bulletin
250 H.O. Important engine management software update 2009 - Engine Management Software
2008-04 (W)
Warranty Bulletin
250 H.O. Water pump installation 2009 - Cooling Systems
2008-04(W)
Warranty Bulletin
250 H.O. – 300 Important engine management software update 2009 - Engine Management Software
2008-06 (W)
250 H.O. – 300 Codes 1 through 6: Excessive knock detected 2009 - Service Codes
90
APPENDIX

250 H.O. – 300 Codes 7 and 8; Knock sensor open circuit detected 2009 - Service Codes
250 H.O. – 300 Knock sensors added to these models 2009 - Ignition & Electrical
Warranty Bulletin
250 H.O. – 300 Temperature sensor and clamp servicing 2009 - Cooling Systems
2008-02(W)
Warranty Bulletin
250 H.O. – 300 Temperature sensor and clamp servicing 2009 - Cooling Systems
2008-02(W)
Melted propeller hub with gearcase seals pushed out, tip
250 H.O. – 300 2009 - Cooling Systems
to check for blocked cooling water passage
250 H.O. – 300 90° (3.4 L) models F suffix - Adapter, P/N 5007973 2009 - Midsection
250 H.O. – 300 90° (3.4 L) models C or S suffix - Adapter, P/N 5007971 2009 - Midsection
Warranty Bulletin
300 Important engine management software update 2009 - Engine Management Software
2008-03 (W)
300 M2-Type gearcase, alignment pins 2009 - Gearcase
4-stroke 4-Stroke accessories and service kits 2009 - Parts & Accessories
2008 - Cooling System
All Overboard indicator requirements
All 2008 Water pressure chart 2008 - Cooling System
All 2009 Water pressure chart 2009 - Cooling System
All Pressure relief valve improvement 2008 - Cooling System
All Melted propeller hub, modifications to help prevent
All EMM LEDs 2008 - Engine Management Module
All 2008 EMM not compatible with older engines 2008 - Engine Management Module
All Fuel injectors - Ball In Plunger (BIP) 2008 - Fuel System
2008 - Fuel System Service Bulletin
All Unleaded gasoline
2009 - Fuel System 2006-06(S)
All Alcohol extended fuels 2009 - Fuel System
91
All Fuel related problem prevention 2009 - Fuel System
All Fuel contamination 2008 - Fuel System
All Fuel additives 2008 - Fuel System
2008 - Fuel System
All Fuel system maintenance
2009 - Fuel System
All Fuel flow compensation 2008 - Fuel System
Do NOT mix and match fuel injectors - Nozzle and seat
All 2008 - Fuel System
angles
All Injector service kit - Fuel injector crush ring 2008 - Fuel System
All Fuel pressure test fittings changed 2008 - Fuel System
All Relieving fuel system pressure 2008 - Fuel System
All Fuel pressure gauge kits 2008 - Fuel System
All Fuel lift pump 2008 - Fuel System
All Fuel pressure and vacuum tests 2008 - Fuel System
All Fuel control adjustment not available 2008 - Fuel System
All 2008 Gearcase application chart 2008 - Gearcase
All 2009 Gearcase application chart 2009 - Gearcase
All Gearcase identification chart 2009 - Gearcase
All How to identify gear ratios 2009 - Gearcase
2008 - Ignition & Electrical
All Spark plug chart
Service Bulletin
All Spark plug life 2008 - Ignition & Electrical
2006-01(S)
All No lubricant on TPS linkage 2008 - Ignition & Electrical
All TPS installation tip 2008 - Ignition & Electrical
All TPS calibration
All Starter motor service parts
All Neutral switch and shift interrupt switch functions 2008 - Ignition & Electrical
All Circuit testing with inductive pick-up timing light 2008 - Ignition & Electrical
92
APPENDIX

2008 - Oiling System
All Oil requirements
2009 - Oiling System
All Oil type setting 2008 - Oiling System
2008 - Powerhead
All Powerhead identification tag
2009 - Powerhead
All Powerhead rebuilding 2008 - Powerhead
Engine model number on serial number tag different than 2008 - Powerhead
All
model number stored in EMM 2009 - Powerhead
All Connecting rod screw installation 2008 - Powerhead
All Improper Gel-Seal II application 2008 - Powerhead
Checklist to return outboard to service after powerhead 2008 - Powerhead
All
replacement/rebuild 2009 - Powerhead
2008 - Powerhead
All Break-in oil cycle
2009 - Powerhead
Different WOT rpm on multiple engine applications - OMC Service Bulletin
All 2008 - Rigging
propeller 2092
All Poor acceleration - propeller 2008 - Rigging
All Stern bracket alternate mounting holes eliminated 2008 - Rigging
2008 - Rigging
All Key switch accessory circuit (Amperage limit)
2009 - Rigging
2008 - Rigging
All Key switch orientation (water drain)
2009 - Rigging
All Flywheel cover isolator installation 2008 - Rigging
All Lower motor cover installation 2008 - Rigging
All Cable retainer clips - proper installation 2008 - Rigging
All Oil priming tip 2008 - Rigging
All Tie bar adjustment 2008 - Rigging
All RPM Quick reference chart 2008 - Rigging
2008 - Rigging
All Throttle cable adjustment
2009 - Rigging
All Code 11; TPS out of idle range 2008 - Service Codes
93
All Code 17; 55 volt circuit below range 2008 - Service Codes
All Code 37; Water in fuel 2008 - Service Codes
All Code 97; Intermittent switched B+ detected 2008 - Service Codes
All RPM Quick reference chart 2009 - Rigging
All How to use RPM quick reference chart 2009 - Rigging
All Oetiker clamp selection 2009 - Rigging
All Oetiker clamp selection chart 2009 - Rigging
All Freeze frame data feature 2009 - Diagnostic Software
All Changes to profile screens 2009 - Diagnostic Software
All Two-minute history report, new feature on v 3.0 2009 - Diagnostic Software
All Changes to fuel control feature 2009 - Diagnostic Software
All Stop break-in feature removed 2009 - Diagnostic Software
All Ignition voltage display - inductive ignition models 2009 - Diagnostic Software
All Error message - Windows NT v 5.0 2009 - Diagnostic Software
All Error message - Invalid Chipset 2009 - Diagnostic Software
All Diagnostic power supply, P/N 587005 2009 - Diagnostic Software
All EMM service chart 2009 - Engine Management Module
All Codes 81 through 86; Ignition timing circuit open detected 2009 - Service Codes
All Code 97; Intermittent switched B+ detected 2009 - Service Codes
Codes 101 through 106; Ignition timing circuit short
All 2009 - Service Codes
detected
All New crankshaft position sensor, P/N 587014 2009 - Ignition & Electrical
All Troubleshooting 5 volt sensor circuit 2009 - Ignition & Electrical
Service Bulletin
All Change to starter solenoid servicing 2009 - Ignition & Electrical
2008-04(S)
All Corrosion 2009 - Ignition & Electrical
All Galvanic corrosion 2009 - Ignition & Electrical
All Stray current corrosion 2009 - Ignition & Electrical
All Corrosion protection testing 2009 - Ignition & Electrical
All Fuel control adjustment not available 2009 - Fuel System
All Check fuel injectors when water found in fuel 2009 - Fuel System
94
APPENDIX

All Evinrude / Johnson XD-100 outboard oil 2009 - Oiling Systems
All Oil type setting, H.O. models XD-100 setting not available 2009 - Oiling Systems
Oil type setting, use TCW-3 setting with XD-100 oil
All 2009 - Oiling Systems
(extreme applications)
All Multi-point oiling 2009 - Oiling Systems
All Tip to check for aerated cooling water 2009 - Cooling Systems
All Mounting screw torque 2009 - Gearcase
All Gear oil smell 2009 - Gearcase
All Propeller shaft bearing housings 2010 - Product Improvements
All Use of electrical grease 2010 - Service Tips
All Electrical test adaptors 2010 - Service Tips
All Water vapor from exhaust relief 2010 - Service Tips
All Engine cover care 2010 - Service Tips
ICON Control Features 2010 - Evinrude ICON Remote Control
ICON Control ICON rigging kits 2010 - Evinrude ICON Remote Control
ICON Control ICON conversion kits 2010 - Evinrude ICON Remote Control
ICON Control ICON rigging kit selection chart 2010 - Evinrude ICON Remote Control
ICON Control ICON remote control system installation 2010 - Evinrude ICON Remote Control
ICON Control Master power/key switch 2010 - Evinrude ICON Remote Control
ICON Control Dual lever binnacle mount remote controls 2010 - Evinrude ICON Remote Control
ICON Control ICON buss cables 2010 - Evinrude ICON Remote Control
ICON Control Engine identity 2010 - Evinrude ICON Remote Control
ICON Control Setting up multiple engine applications 2010 - Evinrude ICON Remote Control
ICON Control Station Protect 2010 - Evinrude ICON Remote Control
ICON Remote control system and engine management
ICON Control 2010 - Evinrude ICON Remote Control
software
ICON Control ICON remote control trim plates 2010 - Evinrude ICON Remote Control
ICON Control ICON accessory power relay 2010 - Evinrude ICON Remote Control
95
ICON Control ICON gateway module 2010 - Evinrude ICON Remote Control
ICON Control ICON hubs (6-port) 2010 - Evinrude ICON Remote Control
ICON Control Shift and throttle actuator calibration 2010 - Evinrude ICON Remote Control
ICON Control ICON switch panels 2010 - Evinrude ICON Remote Control
ICON Control Code 107; Control communication error 2010 - Evinrude ICON Remote Control
ICON Control Code 108; ICON failsafe mode 2010 - Evinrude ICON Remote Control
ICON Control Code 109; Control hardware fault 2010 - Evinrude ICON Remote Control
ICON Control Code 110; Trim switch module communication fault 2010 - Evinrude ICON Remote Control
ICON Control Code 111; Electronic servo-module communication fault 2010 - Evinrude ICON Remote Control
ICON Control Code 149; Throttle actuator sensor fault 2010 - Evinrude ICON Remote Control
ICON Control Code 150; Throttle actuator motion fault 2010 - Evinrude ICON Remote Control
ICON Control Code 151; Shift actuator sensor fault 2010 - Evinrude ICON Remote Control
ICON Control Code 152; Shift actuator motion fault 2010 - Evinrude ICON Remote Control
I-Command Fuel Level Does Not Display 2008 - Rigging
I-Command Alternator voltage incorrect display 2008 - Rigging
I-Command Trim level does not display or is inaccurate 2008 - Rigging
I-Command I-Command digital product selection guide 2009 - I-Command
I-Command I-Command network design and gauge simulator tool 2009 - I-Command
I-Command Network tester kit, P/N 765023 2009 - I-Command
I-Command GPS Head Unit Kit, P/N 764592 2009 - I-Command
Parts & Accessories
I-Command Device-net style connectors 2009 - I-Command
Bulletin 2008-01(P)
I-Command Water pressure sensor kit, P/N 5006214 2009 - I-Command
I-Command Water pressure sensor kit, P/N 764195 2009 - I-Command
Parts & Accessories
I-Command Pre-programmed water pressure sensor kits 2009 - I-Command
Bulletin 2008-03(P)
Parts & Accessories
I-Command Pre-programmed fuel level converter kits 2009 - I-Command
Bulletin 2008-04(P)
I-Command Fluid level converter kit, P/N 764166 2009 - I-Command
I-Command How to set up fuel management options 2009 - I-Command
I-Command I-Command gauge installation (dashboard hole size) 2009 - I-Command
96
APPENDIX

I-Command How to reset I-Command gauge to factory default settings 2009 - I-Command
I-Command Avoid radar antenna when installing GPS module 2009 - I-Command
Fuel level sender resistance different in North America and
I-Command 2009 - I-Command
Europe
I-Command Installing oil level converter kit 2009 - I-Command
I-Command Low battery voltage when configuring fuel level converter 2009 - I-Command
I-Command Instancing 2010 - I-Command
I-Command I-Command and 15 – 90 HP models 2010 - I-Command
I-Command Power supply kits, P/N 764157 or P/N 764159 2010 - I-Command
I-Command Warranty procedures for I-Command digital gauges 2010 - I-Command
I-Command I-Command bulletins 2010 - I-Command
P&A OMS rebuild kits available 2009 - Parts & Accessories
P&A Water separating fuel filter gasket issue 2009 - Parts & Accessories
P&A OMS replacement checklist 2009 - Parts & Accessories
P&A TBX Torsion bushing damage 2009 - Parts & Accessories
Parts & Accessories
P&A Rectifier/regulator, no purple wire 2009 - Parts & Accessories
Bulletin 2001-01(P)
P&A Frequently requested part numbers 2010 - Parts & Accessories
P&A Reverse gear availability 2010 - Parts & Accessories
Parts & Accessories
Propeller Hydrus propeller exhaust ring 2009 - Rigging
Bulletin 2005-01(P)
Gear ratio and propeller selection (.54 vs. .58 ratio
Propeller 2009 - Rigging
gearcases)
Propeller Demo-prop program 2009 - Parts & Accessories
Propeller Propellers for 15 – 30 HP models 2010 - Parts & Accessories
Propeller New aluminum propellers 2010 - Parts & Accessories
Propeller Installation tip: Interchangeable hub propeller 2010 - Parts & Accessories
Propeller Identifying correct propeller part numbers 2010 - Parts & Accessories
2008 - Diagnostic Software
Software PC Specifications for diagnostic software
2009 - Diagnostic Software
Software USB to serial adapters for diagnostic software 2008 - Diagnostic Software
97
Software New USB to serial adapters for diagnostic software 2009 - Diagnostic Software
Software USB to serial adapter set up 2008 - Diagnostic Software
Software Evinrude Diagnostic software program update, v 2.0 2008 - Diagnostic Software
Service Bulletin
Software Evinrude Diagnostic software program update, v 3.0 2009 - Diagnostic Software
2008-05(S)
Software Evinrude Diagnostic software program update, v 4.0 2010 - Evinrude Diagnostic Software
2008 - Engine Management Software
Software Software versions and revisions
Software Software revision updates
Software Software revision number changes
Software Software version updates
Software Inline update - adds TPS calibration 2008 - Engine Management Software
Inline update 2 - adds TPS calibration and improved
Software 2009 - Engine Management Software
calibrations
Software I-Command and engine management software updates 2009 - Engine Management Software
Software Mismatch error received during software upload 2008 - Engine Management Software
Warranty Bulletin
Software 90° V6 software update - dual temperature monitoring 2008 - Engine Management Software
2007-01(W)
Software Fuel adjustment feature not available 2008 - Engine Management Software
Software Data Logging 2010 - Evinrude Diagnostic Software
Software Understanding Knock Profiles 2010 - Evinrude Diagnostic Software

Stern Drive Stern drive parts inquiries 2009 - Parts & Accessories
98
APPENDIX

Service Bulletin
Tools Gearcase alignment pin kit 2008 - Gearcase
2006-03(S)
Service Bulletin
Tools S-2 driveshaft tools 2008 - Gearcase
2005-06(S)
Service Bulletin
Tools 60° models - Powerhead alignment tool 2008 - Powerhead
2006-03(S)
Service Bulletin
Tools New tools for M2-Type and L2-Type gearcases 2009 - Gearcase
2008-03(S)
Propeller shaft seal tools, allow replacement of seals Service Bulletin
Tools 2009 - Gearcase
without gearcase disassembly 2008-02(S)
Service Bulletin
Tools Gearcase alignment gauge 2008 - Gearcase
2004-011(S)
Predelivery Bulletin
Tools Enigne lift kit, P/N 354717 2010 - Service Tools
2008-02(D)
Tools Stator test adaptor, P/N 354719 2010 - Service Tools Service Manual
Tools Diagnostic power supply, P/N 587005 2010 - Service Tools Service Manual
Tools Accessory power cable kit, P/N 5008092 2010 - Service Tools
Tools Bearing Installers, P/N 321428 and P/N 335820 2010 - Service Tools
Tools Alignment gauge puller, P/N 354718 2010 - Service Tools Service Manual
Tools Wrist pin retainer tool, P/N 354720 2010 - Service Tools Service Manual
99
NOTES – APPENDIX
100

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† AMP is a registered trademark of Tyco International, Ltd.

Printed in the United States

2011 PRODUCT IMPROVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

EVINRUDE DIAGNOSTICS SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

EVINRUDE ICON REMOTE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .43

PARTS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Refer to Administrative Bulletin 2010-04(A) for complete details

WARRANTY INFORMATION – Predelivery Checklist Included in Shipping

Refer to Predelivery Bulletin 2010-01(D) for complete details.

A technician can take a missed exam at any time to have Certified

Update engine management software on engines with serial numbers 5283875

1. Engine management software version and revision

Engine Wiring Harness Change 15 – 30 HP Models

1. 6-pin AMP connector (tiller harness)

Also refer to Service Bulletin 2010-08(S), or the 2011 Service Manual.

Lower Mount 15 – 30 HP Models

1. Bump stop washer

The throttle body assembly features a nickel-plated throttle valve, which

Exhaust Housings 40 – 65 HP Models

Exhaust housing, P/N 5008275, services 2006 and newer 40 – 50 HP models.

Oil Pressure Sensor 115 – 300 HP Models

1. Clamp, oil sensor to housing, P/N 982115

Rear Oiling System 250 – 300 HP 90° (3.4 L) Models

IMPORTANT: Correct oil priming procedure is required when installing a new

1. Rear oil pump

Cooling System Change 250 – 300 HP 90° V6 (3.4 L)

1. Cooling water hose

L2-Type Gearcase ( .58 Ratio) Replaced by M2-Type

Gearcase ( .54 Ratio) on 225 – 300 HP 90° Models

gearcase (with .54 gear ratio) on all 225 – 300 HP models.

Also see Exhaust Housing to Gearcase Alignment Pins on p. 38. 1

Fuel Hoses – All Models

Fuel Rail (Typical)

Refer to the Operator’s Guide for a complete explanation of warning system 0 7

Engine Overheat Damage

Loss of performance will result from a damaged exhaust housing megaphone.

IMPORTANT: REPLACE the pressure relief valve and thermostat springs

Installation of Oil Pump Assembly

1. Oil pick up assembly

115 – 300 HP 60°/90° V4/V6 MODELS

Exhaust Back Pressure Fitting

Clean or replace the exhaust back pressure fitting if it is blocked. Clean it by

Because a gearcase conversion kit is required, existing part numbers do not

Order the following parts:

Refer to the installation instructions for the following:

Gearcase Conversion Kit (Typical)

A – HPF Pro Gearcase Lubricant

FAQ: Spark Plugs – All Models

Evinrude E-TEC IDI

Injector Serial Number Label

Internet Browser Blocks Download of Injector

Select “Download File” to start the download process.

1. Click here for options

These problems include:

Blockage in the fuel system

Possible Causes: Damaged wire harness or electrical connector between EMM

150 – 300 HP Models (equipped with an M2-Type gearcase) – Temporarily

150 – 300 HP Models (M2-Type Gearcase)