BRP Evinrude E-TEC Manuel utilisateur

Printed in the United States.

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

BRP US Inc.

Technical Publications

P.O. Box 597

Sturtevant, Wisconsin 53177 United States

www.evinrude.com or www.johnson.com

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

are registered trademarks of Tyco International, Ltd.

† Amphenol is a registered trademark of The Amphenol Corporation.

† BEP is a registered trademark of Actuant Corporation.

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

† Deutsch is a registered trademark of The Deutsch Company.

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

† Fluke is a registered trademark of The Fluke Corporation

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

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

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

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

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

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

† Packard is a registered trademark of Delphi Automotive Systems.

† Permatex is a registered trademark of Permatex.

† STP is a registered trademark of STP Products Company.

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

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

Original Instructions

Evinrude ® Twist Grip™

Johnson ® Nut Lock™

Evinrude ® E-TEC ® Screw Lock™

FasTrak™ Ultra Lock™

S.A.F.E.™ Moly Lube™

SystemCheck™ Triple-Guard ® Grease

I-Command™ DPL™ Lubricant

Evinrude ® ICON™ 2+4 ® Fuel Conditioner

Evinrude ® / Johnson ® XD30™ Outboard Oil Carbon Guard™

Evinrude ® / Johnson ® XD50™ Outboard Oil Gel-Seal II™

Evinrude ® / Johnson ® XD100™ Outboard Oil HPF PRO™ Gearcase Lubricant

Service Manual

Contents

Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page

1 Reference Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Routine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3 Engine Cover Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4 Engine Management Module (EMM) . . . . . . . . . . . . . . . . 59

5 System Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

6 Electrical and Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

8 Oiling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

9 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

10 Powerhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

11 Midsection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

12 Trim and Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

13 Manual Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S–325

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I–349

Trouble Check Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . T–357

Diagrams

IMPORTANT: For complete outboard rigging and control installation information, refer to the current

Installation and Predelivery Guide included with the service manual set.

All special tools referenced in this manual can be found in the current Special Tools Guide, included

with the service manual set.

Reference Information

Table of Contents

Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Abbreviations Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Product Reference and Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Emission-Related Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Manufacturer’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Dealer’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Owner’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

EPA Emission Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Model Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Service Specifications, 40 – 60 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Service Specifications, 60 H.O. – 90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Wire Size Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

American Wire Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Metric Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Safety Notice

Before working on any part of the outboard, read the SAFETY section at the end of this manual.

This publication is written for qualified, factory-

trained technicians who are already familiar with

the use of Evinrude/Johnson Special Tools. The

included information is not a substitute for work

experience. It is an organized guide for reference,

repair, and/or maintenance.

The following symbols and/or signal words

may be used in this document:

These safety alert signal words mean:

ATTENTION!

BECOME ALERT!

YOUR SAFETY IS INVOLVED!

IMPORTANT: Identifies information that controls

correct assembly and operation of the product.

DO NOT perform any work until you have read

and understood these instructions completely.

Torque wrench tightening specifications must

strictly be adhered to.

Should removal of any locking fastener (lock tabs,

locknuts, or patch screws) be required, always

replace with a new one.

When replacement parts are required, use Evin-

rude/Johnson Genuine Parts or parts with equiva-

lent characteristics, including type, strength and

material. Use of substandard parts could result in

injury or product malfunction.

Always wear EYE PROTECTION AND APPRO-

PRIATE GLOVES when using power tools.

Unless otherwise specified, engine must be OFF

when performing this work.

Always be aware of parts that can move, such as

flywheels, propellers, etc.

Some components may be HOT. Always wait for

engine to cool down before performing work.

If you use procedures or service tools that are not

recommended in this manual, YOU ALONE must

decide if your actions might injure people or dam-

age the outboard.

This document may be translated into other lan-

guages. In the event of any discrepancy, the

English version shall prevail.

DANGER

Indicates a hazardous situation which, if not

avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not

avoided, could result in death or serious

injury.

CAUTION

Indicates a hazardous situation which, if not

avoided, could result in minor or moderate

personal injury.

NOTICE

Indicates an instruction which, if not fol-

lowed, could severely damage engine com-

ponents or other property.

ENVIRONMENTAL NOTE

A note which provides tips and behaviors related

to protecting the environment.

DANGER

Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine

and prop area is clear of people and objects before starting engine or operating boat. Do not

allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propel-

ler can continue to turn even after the engine is off. Remove propeller before servicing and when

running the outboard on a flushing device.

DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to

accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can

cause serious brain damage or death.

WARNING

Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172

kPa).

The motor cover and flywheel cover are machinery guards. Use caution when conducting tests

on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and clothing

away from rotating parts.

During service, the outboard may drop unexpectedly. Avoid personal injury; always support the

outboard’s weight with a suitable hoist or the tilt support bracket during service.

To prevent accidental starting while servicing, disconnect the battery cables at the battery. Twist

and remove all spark plug leads.

The electrical system presents a serious shock hazard. DO NOT handle primary or secondary

ignition components while outboard is running or flywheel is turning.

Gasoline is extremely flammable and highly explosive under certain conditions. Use caution

when working on any part of the fuel system.

Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve

fuel system pressure.

Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular phones

in the vicinity of a fuel leak or while fueling.

Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and

causing an explosion.

Always work in a well ventilated area.

Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Defi-

nite resistance to tightening must be felt when reusing a locking fastener. If replacement is indi-

cated, use only authorized replacement or equivalent.

Reference Information

Abbreviations Used In This Manual

Units of Measurement List of Abbreviations

A Amperes

amp-hr Ampere hour

fl. oz. fluid ounce

ft. lbs. foot pounds

HP horsepower

in. inch

in. Hg inches of mercury

in. lbs. inch pounds

kPa kilopascals

ml milliliter

mm millimeter

N·m Newton meter

P/N part number

psi pounds per square inch

RPM revolutions per minute

°C degrees Celsius

°F degrees Fahrenheit

ms milliseconds

µs microseconds

ΩOhms

VVolts

VAC Volts Alternating Current

VDC Volts Direct Current

ABYC American Boat & Yacht Council

ATDC after top dead center

AT air temperature sensor

BPS barometric pressure sensor

BTDC before top dead center

CCA cold cranking amps

CFR Code of Federal Regulations

CPS crankshaft position sensor

EMM Engine Management Module

EPA Environmental Protection Agency

ICOMIA International Council of Marine

Industry Associations

ID Inside dimension

MCA marine cranking amps

MWS modular wiring system

NMEA National Marine Electronics Assoc.

ROM read only memory

S.A.F.E. speed adjusting failsafe electronics

SAC start assist circuit

SAE Society of Automotive Engineers

SYNC synchronization

TDC top dead center

TPS throttle position sensor

USCG United States Coast Guard

WOT wide open throttle

WTS water temperature sensor

Reference Information

Standard Torque Specifications

Standard Torque

Specifications Product Reference

and Illustrations

BRP US Inc. reserves the right to make changes

at any time, without notice, in specifications and

models and also to discontinue models. The right

is also reserved to change any specifications or

parts, at any time, without incurring any obligation

to equip same on models manufactured prior to

date of such change. Specifications used are

based on the latest product information available

at the time of publication.

The continuing accuracy of this manual cannot be

guaranteed.

All photographs and illustrations used in this man-

ual may not depict actual models or equipment,

but are intended as representative views for refer-

ence only.

Certain features or systems discussed in this

manual might not be found on all models in all

marketing areas.

All service technicians must be familiar with nauti-

cal orientation. This manual often identifies parts

and procedures using these terms.

Size In. Lbs. Ft. Lbs. N·m

No. 6 7–10 0.58–0.83 0.8–1.1

No. 8 15–22 1.25–1.83 1.7–2.5

No. 10 24–36 2–3 2.7–4.0

No. 12 36–48 3–4 4.0–5.4

1/4 in. 60–84 5–7 7-9.5

5/16 in. 120–144 10–12 13.5–16.5

3/8 in. 216–240 18–20 24.5–27

7/16 in. 336–384 28–32 38–43.5

M3 15–22 1.25–1.83 1.7–2.5

M4 24–35 2–2.9 2.7–4.0

M5 35–60 2.9–5 4.0–6.8

M6 84–106 7–8.8 9.5–12

M8 177–204 14.7–17 20–23

M10 310–336 25.8–28 35–38

IMPORTANT: These values apply only when

a specific torque for a specific fastener is not list-

ed in the appropriate section. When tightening

two or more screws on the same part, DO NOT

tighten screws completely, one at a time.

WARNING

Torque wrench tightening specifications

must be strictly adhered to. Replace any lock-

ing fastener (locknut or patch screw) if its

locking feature becomes weak. Definite resis-

tance to turning must be felt when reusing a

locking fastener.

If replacement is specified or required

because the locking fastener has become

weak, use only authorized Evinrude Genuine

Parts.

Nautical Orientation 006411

Reference Information

Emission-Related Installation Instructions

Emission-Related Installation

Instructions

Failing to follow these instructions when installing a certified engine in a vessel violates federal

law (40 CFR 1068.105 (b)), subject to fines or other penalties as described in the Clean Air Act.

A repair shop or person of the owner's choosing may maintain, replace, or repair emission control

devices and systems. These instructions do not require components or service by BRP or authorized

Evinrude dealers. Although an authorized Evinrude dealer has the in-depth technical knowledge and

tools to service Evinrude outboard engines, the emission-related warranty is not conditioned on the use

of an authorized Evinrude dealer or any other establishment with which BRP has a commercial relation-

ship.

For emission-related warranty claims, BRP is limiting the diagnosis and repair of emission-related parts

to authorized Evinrude dealers. For more information, please refer to the US EPA EMISSION-RELATED

WARRANTY contained in the Operator’s Guide. Proper maintenance is the owner's responsibility. A

warranty claim may be denied if, among other things, the owner or operator caused the problem through

improper maintenance or use.

You must follow the instructions for fuel requirements in the FUEL REQUIREMENTS section of this man-

ual. Even if gasoline containing greater than ten volume percent ethanol is readily available, the US EPA

has issued a prohibition against the use of gasoline containing greater than 10 vol% ethanol that applies

to this engine. The use of gasoline containing greater than 10 vol% ethanol with this engine may harm

the emission control system.

Manufacturer’s Responsibility

Beginning with 1999 model year outboards, manufacturers of marine outboards must determine the

exhaust emission levels for each outboard horsepower family and certify these outboards with the

United States of America Environmental Protection Agency (EPA). An emissions control information

label, showing emission levels and outboard specifications, must be placed on each outboard at the time

of manufacture.

Dealer’s Responsibility

When performing service on all 1999 and more recent Evinrude outboards that carry an emissions con-

trol information label, adjustments must be kept within published factory specifications.

Replacement or repair of any emission related component must be executed in a manner that maintains

emission levels within the prescribed certification standards.

Dealers are not to modify the outboard in any manner that would alter the horsepower or allow emission

levels to exceed their predetermined factory specifications.

Exceptions include manufacturer’s prescribed changes, such as altitude adjustments, for example.

Owner’s Responsibility

The owner/operator is required to have outboard maintenance performed to maintain emission levels

within prescribed certification standards.

Reference Information

Emission-Related Installation Instructions

The owner/operator is not to, and should not allow anyone to, modify the outboard in any manner that

would alter the horsepower or allow emissions levels to exceed their predetermined factory specifica-

tions.

Tampering with the fuel system to change horsepower or modify emission levels beyond factory settings

or specifications will void the product warranty.

EPA Emission Regulations

All new 1999 and more recent Evinrude outboards are certified to the EPA as conforming to the require-

ments of the regulations for the control of air pollution from new watercraft marine spark ignition out-

boards. This certification is contingent on certain adjustments being set to factory standards. For this

reason, the factory procedure for servicing the product must be strictly followed and, whenever practical,

returned to the original intent of the design. The responsibilities listed above are general and in no way a

complete listing of the rules and regulations pertaining to the EPA requirements on exhaust emissions

for marine products. For more detailed information on this subject, you may contact the following loca-

tions:

U.S. Environmental Protection Agency

Office of Transportation and Air Quality

Certification Division

Gasoline Engine Compliance Center

2000 Traverwood Drive

Ann Arbor, MI 48105

EPA Internet Web Site:

www.epa.gov/otaq

Reference Information

Model Designation

Engine Identification

Model and serial numbers are located on the swivel bracket and on the powerhead.

1. Model and serial number

2. Serial number 010518

010519

B E 90 DG X AF A

STYLE:

AAlternate

Feature

JJohnson

EEvinrude

HORSEPOWER SHAFT LENGTH:

15 in. Std.

L20 in. Long

X25 in. X-long

Z30 in. XX-long

MODEL IDENTIFICATION *

The first two characters identify

Model Version:

AA A First major variant

AB A Second major variant

AF A Third major variant

Outboards built after April 2012:

• follow the model identification shown

above.

• subsequent versions continue through

the alphabet as AG, AH etc.

• will not use letters from the word

INTRODUCES to identify models.

*Refer to Administrative Bulletin 2012-03(A)

for additional information.

DESIGN FEATURES:

CCounter Rotation

DEvinrude E-TEC

EElectric Start w/Remote Steering

GGraphite Paint

HHigh Output

JJet Drive

MMilitary

NPontoon Series, No Oil Tank

PPower Trim and Tilt

RRope Start w/Tiller Steering

SSaltwater Approved

TTiller Steering

PREFIX:

BBodensee model

DICON model

The third character identifies

Model Revision:

AA A First revision

AA B Second revision

Subsequent revisions continue

through the alphabet in order

(A through Z).

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