BRP Evinrude E-TEC E25DR Product Service Update
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BRP Evinrude E-TEC E25DR Product Service Update

BRP Evinrude E-TEC E25DR Product Service Update

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2009
Product Service Update

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  • Page 1 2009 Product Service Update...

  • Page 3: Product Service Update

    XD100™ Outboard Oil I-Command™ DealerPort® TBX™ Gel-Seal II™ BossWeb Viper™ Printed in the United States ©2008 BRP US Inc. All rights reserved. TM , ® and the BRP logo are registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

  • Page 4: Table Of Contents

    AFTER SALES SUPPORT TEAM ......5 WHO’S WHO ..................... 6 TECHNICAL PUBLICATIONS .
  • Page 5 CONTENTS ENGINE MANAGEMENT MODULE (EMM) ....61 2009 EMM CHANGES ................... . . 62 EMM SERVICE CHART .
  • Page 6 POWERHEAD ......... . 117 POWERHEAD IDENTIFICATION .

  • Page 7: After Sales Support Team

    AFTER SALES SUPPORT TEAM...

  • Page 8: Who's Who

    WHO’S WHO Evinrude/Johnson North American Call Center: Dealer only number: 1-800-888-4662 Customers may call 1-847-689-7090 Administration: Dawn Johnson, Director After Sales Support and Warranty Jeff Cooper, Technical Product Manager Susan Filer, After Sales Support Staff Assistant Dealer Technical Support: Jeff Berg, Technical Team Leader, 2-Cyl, 3-Cyl, and 4-Stroke Products Keith Moody, Technical Team Leader, 60°...

  • Page 9: Technical Support

    TECHNICAL SUPPORT Evinrude/Johnson Field Service and Training – North America Administration: Lynn Gibson, North American Field Service and Training Supervisor Technical Service/Sales Representatives (TSR) – North America United States: Justin Antolini: MN, ND, SD, IA, WI. Dave Belus: NY, NJ, ME, NH, VT, MA, RI, CT. Bob Brown: VA, DE, MD, PA, WV.
  • Page 10 BRP BENELUX, Gerhard Bressers, Technical Representative BRP Australia BRP FRANCE, Rémi Campestrin, Service Manager BRP SPAIN, Manuela Gomez, Service Manager BRP GERMANY, Andreas Klopfleisch, Service Manager BRP UK AND IRELAND, Lou Price, Service Manager, Lloyd Stevens, Technical Representative BRP Training, Bankstown NSW Australia...
  • Page 11 TECHNICAL SUPPORT Before You Call the Service Department The Evinrude/Johnson After Sales Support Group values your call. Your input is essential. Remember, quick problem resolution requires accurate information. In order to provide you with the best service possible, observe the following guide- lines: Confirm the customer complaint.

  • Page 12: Technical Publications

    TECHNICAL PUBLICATIONS Published service information includes: Installation Guides Operator’s Guides Parts Catalogs—Printed and Electronic Parts Catalogs (EPC) which is accessed through DealerPort and PartSmart Service Bulletins Service Manuals Special Tool Catalogs Instruction Sheets User Guides Warranty Procedures Manuals and Flat Rate Guides Consumer and Dealer letters Service publications should be organized and accessible to all technicians.
  • Page 13 TECHNICAL SUPPORT Bulletins There are five categories of bulletins: Administrative (A) • Includes general policy notifications or changes. • Announcements. • Items which do not clearly fall into one of the other four categories. Predelivery (D) • Includes predelivery check lists. •...

  • Page 14: Dealerport

    DEALERPORT * Locations outside of North America may subscribe to BossWeb. What’s on DealerPort? Features: Besides the ability to order parts, register sold engines and submit warranty claims online, there is a gold mine of information available on the DealerPort website. Technical information includes: •...
  • Page 15 TECHNICAL SUPPORT Navigating the DealerPort Website Most technical information is accessible from one page. • Click on Engines link (top) • Click on the Evinrude (or Johnson) link (left) • Links to document families (Bulletins, Performance Reports and other) is on the right side of the page Spend some time exploring DealerPort.

  • Page 16: Notes - Technical Support

    NOTES – TECHNICAL SUPPORT...

  • Page 17: New Models For 2009

    NEW MODELS FOR 2009...

  • Page 18: 25 - 30 Hp Inline Models

    25 – 30 HP INLINE MODELS All Models • Displacement: 35.3 cu in (576 cc / 0.578 L) • Blue, 15 and 20 inch models • Weight: 152 lbs (DR) – 190 lbs (DTL) depending on length and options • Alternator: 15 amps •...
  • Page 19 NEW MODELS FOR 2009 Features Tiller Handle • Forward mount shifter • Touch Troll electronic idle speed adjustment Engine Management • New EMM supports inductive ignition and BIP injectors • Clear case with easy to see LEDs Electrical and Ignition •...

  • Page 20: 115 H.o. - 200 Hp 60° V4 / V6 Models

    115 H.O. – 200 HP 60° V4 / V6 MODELS E115DHL, E115HSL and E115DHX • Displacement: 105 cu in (1727 cc 1.7 L) • White, 20 and 25 inch models with new H.O. styling • Weight: 390 / 405 lbs (177 / 184 kg) •...
  • Page 21 NEW MODELS FOR 2009 Features and Improvements Decals • New H.O. graphics (115 H.O. models only) • New saltwater decal, located on stern bracket Engine Management • New EMM with more powerful processor and increased memory — supports TPS Calibration and BIP injectors Electrical and Ignition •...

  • Page 22: 200 H.o. - 250 Hp 90° V6 (3.3 L) Models

    200 H.O. – 250 HP 90° V6 (3.3 L) MODELS E200HVL • Displacement: 200 cu in (3279 cc 3.3 L) • White, 20 inch model with new H.O. styling • Weight: 518 lbs (235 kg) • Alternator: 50 amps • Gearcase: L2-Type gearcase gearcase with .54 (1.86:1) ratio E225HSL •...
  • Page 23 NEW MODELS FOR 2009 Features and Improvements Decals • New H.O. graphics (200 H.O. and 225 H.O. models only) • New saltwater decal, located on stern bracket Engine Management • New EMM with more powerful processor and increased memory—now sup- ports TPS Calibration and new injectors Electrical and Ignition •...

  • Page 24: 250 H.o. - 300 Hp 90° V6 (3.4 L) Models

    250 H.O. – 300 HP 90° V6 (3.4 L) MODELS E300DSL • Displacement 210 cu. in. (3441cc, 3.4 L) • White 20 inch model added • Weight: 522 lbs (237 kg) • Alternator: 50 amps • Gearcases M2-Type gearcase with .54 (1.85:1) ratio •...
  • Page 25 NEW MODELS FOR 2009 Features and Improvements Decals • New H.O. graphics (250 H.O. models only) • New saltwater decal, located on stern bracket Engine Management • New EMM with more powerful processor and increased memory – supports TPS Calibration and BIP injectors Electrical and Ignition •...

  • Page 26: Notes - New Product Information

    NOTES – NEW PRODUCT INFORMATION...

  • Page 27: Service Information

    SERVICE INFORMATION...

  • Page 28: Rigging

    RIGGING KEY SWITCH INFORMATION Key Switch Accessory Circuit What: Current draw on the accessory circuit (purple wire, on terminal A) must be limited to 5 amps. Use a separate inline fuse (up to 5 amps). Why: Key switches are designed to carry the electrical load of an outboard’s start circuit and primer / choke circuit, plus gauges and dash lighting.

  • Page 29: Outboard Installation Information

    RIGGING OUTBOARD INSTALLATION INFORMATION 25 – 30 HP Inline Models Reference: Predelivery Bulletin 2008-02(D) Service Bulletin 2008-02(D) contains the requirements for installing 2009 Evinrude E-TEC 25 – 30 HP models. Review this information before installing one of these outboards. Additional information about Boat Rigging, Outboard Installation and Predelivery Checks has not changed for these models and can be found in the Predelivery and Installation Guide, P/N 5007085.
  • Page 30 Integrated Flywheel Cover 115 – 200 HP 60° V4 / V6 Models Beginning with 2009 production, the flywheel cover and air baffle have been combined, eliminating cover baffle brackets from the upper injectors. Engine Mounting Screws Hex Head Cap Screws Reference: Parts and Accessories Bulletin 2008-05(P) 1/2 in.

  • Page 31: 2009 Rpm Quick Reference Chart

    RIGGING 2009 RPM QUICK REFERENCE CHART How to Use the RPM Quick Reference Chart Recommended Optimum When selecting a propeller for an outboard and boat Model Operating Range RPM Range application, refer to the recommended wide open 25 HP 5000 – 6000 5400 –...

  • Page 32: Rigging Issues

    RIGGING ISSUES Oil Filter, 115 – 200 HP 60° V4 / V6 Models What you need to know: The arrow on the oil filter used on these models must point toward the oil tank. Why this is important: The filter assembly may trap air if installed incorrectly. 1.
  • Page 33 RIGGING Propeller Selection – .54 versus .58 Ratio Gearcases When repowering an older boat, or rigging a new boat and outboard with an L2- Type gearcase installed, it is important to consider which gear ratio is used when selecting a propeller. Typically, the .58 ratio gearcase requires a propeller with two inches less pitch than the .54 ratio gearcase.

  • Page 34: Throttle Cable Adjustment

    Throttle Cable Adjustment Reference: Appropriate Service Manual – Installation section. With remote control lever in NEUTRAL, pull firmly on throttle cable casing to remove slack. With throttle lever idle stop against the crankcase or stop, place the cable trun- nion into the upper anchor pocket and adjust the trunnion nut so the casing fits onto the throttle lever pin.
  • Page 35 RIGGING Oetiker Clamp Selection Chart inch 0.196 0.393 0.590 0.787 0.984 1.181 1.377 1.574 1.771 fractional 1-1/4 1-1/2 1-3/4...

  • Page 36: Notes - Rigging

    NOTES – RIGGING...

  • Page 37: I-Command

    I-COMMAND...

  • Page 38: I-Command Information

    I-COMMAND INFORMATION I-Command Digital Product Selection Guide, P/N 764677 The I-Command Digital Product Selection Guide, P/N 764677, (or the current I-Command Installation Guides, P/N 354044, or P/N 353571), are the only printed reference materials that should be used to order I-Command compo- nents.
  • Page 39 I-COMMAND Network Tester Kit, P/N 765023 This service tool has been developed to troubleshooting open, shorted and grounded circuits on I-Command networks. The kit contains a Network Tester, P/N 764591, a Single Tee, P/N 764151, and instructions. The tester uses a seven-light display to monitor network voltage and communi- cation, and can help identify a failed backbone cable, connector, sensor or gauge.
  • Page 40 DeviceNet-Style Connectors Reference: Parts and Accessories Bulletin 2008-01(P) Available Connectors This bulletin contains information about the differences in I-Command compati- ble DeviceNet-style connectors. Installation Information Additional installation information is also contained in this bulletin. Special atten- tion must given to tee connector mounting when mixing connector styles because of different mounting boss dimensions.
  • Page 41 I-COMMAND Water Pressure Sensors Water Pressure Sensor Kit, P/N 5006214 This sensor requires the installer to use Evinrude Diagnostics software to acti- vate the water pressure function within the EMM. Water Pressure Sensor Kit, P/N 764195 Reference: I-Command User’s Guide, P/N 765025 (2-inch gauge) or P/N 765026 (3.5-inch gauge).
  • Page 42 Fuel Level Sensor Kits Fluid Level Converter Kit, P/N 764166 Reference: I-Command User’s Guide, P/N 765025 (2-inch gauge) or P/N 765026 (3.5-inch gauge). This is an unconfigured Device Net-style converter which MUST be configured during installation. If installing multiple fluid level converters, connect and config- ure one device at a time.

  • Page 43: Service Issues

    I-COMMAND SERVICE ISSUES Gauge Reset If gauge settings are modified and the results are unsatisfactory, the gauge can be reset to its factory default settings using the Reset Values command. Customize Pages Screen To reset gauge values Audio Setup • Press MENU.

  • Page 44: Fuel Management

    Fuel Management Reference: I-Command User’s Guide, P/N 765025 (2-inch gauge) or P/N 765026 (3.5-inch gauge). Some Fuel Management functions require installation of a Memory Module Kit, P/N 764181, and a GPS antenna, P/N 764179. If fuel management needs to remember anything when the key switch is turned off (i.e. how much fuel has been used this week or season), then a memory module is needed.
  • Page 45 I-COMMAND I-Command Installation and Set Up Tips GPS Antenna Radar Antenna – Gauge installation requires the following size dashboard holes: • 2 inch – 2-1/8 inch (54 mm) • 3.5 inch – 3-3/8 inch (85.7 mm) t-top mounting surface – When installing a GPS module, the PREFERED installation is to locate the GPS module in a lower position than the radar antenna.

  • Page 46: Notes - I-Command

    NOTES – I-COMMAND...

  • Page 47: Evinrude Diagnostics Software

    EVINRUDE DIAGNOSTICS SOFTWARE...

  • Page 48: Technical Skills

    TECHNICAL SKILLS The laptop computer (PC) is the best diagnostics tool for servicing Evinrude / Johnson products. Technical skills must include knowledge of: • Engine Management systems • Computers, operating systems, file systems, and file names • Diagnostics software PC SPECIFICATIONS Technicians must understand computers, operating systems, and file systems Reference: Service Bulletin 2008-05(S)

  • Page 49: Usb To Serial Adapters

    EVINRUDE DIAGNOSTICS SOFTWARE USB TO SERIAL ADAPTERS Many new computers do not have a 9-pin serial port. A USB to serial adapter is used to provide a connection to interface cable, P/N 437955. Installing a USB to serial port adapter can be a detailed procedure. Always refer to the manufacturer’s instructions when installing an adapter.

  • Page 50: New Software Version 3.0

    NEW SOFTWARE VERSION 3.0 Reference: Service Bulletin 2008-05(S) 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 3.0 is required for model year 2009 and older.

  • Page 51: Profile Screens

    EVINRUDE DIAGNOSTICS SOFTWARE Profile Screens Beginning with Evinrude Diagnostics software version 3.3 the profile screens have been placed on their individual tabs. This provides a clear view of all the profile sreens. Additionally, a knock profile screen has been added. The knock profile will only display when connected to an outboard model that uses knock sensors.
  • Page 52 Fuel Control Feature With the release of Evinrude Diagnostics software v.3.0, the Fuel Control feature has changed. For outboards which use BIP injectors, the fuel control feature now adjusts a percentage of fuel flow, up to 12% lean or up to 12% rich. For outboards which use other injectors, the fuel adjustment feature adjusts the “on-time”...
  • Page 53 EVINRUDE DIAGNOSTICS SOFTWARE Adding Battery Charge Kit to 25 – 30 HP Inline DR Models When a Battery Charging Kit, P/N 5007741, is added to an Evinrude E-TEC 25 – 30 HP rope start model, the battery charge feature MUST be turned on. Use Evinrude Diagnostics software “Engine Options”...

  • Page 54: Error Messages

    ERROR MESSAGES Requires Windows NT Version 5.0 Reference: Service Bulletin 2008-05(S) If attempting to install Evinrude Diagnostics software on a laptop using Microsoft Windows 95 or 98, the following error message will display: “This program requires Windows NT version 5.0 or later.” If you see this error message, it means the laptop needs to have the operating system upgraded to Windows 2000, XP or Vista.
  • Page 55 EVINRUDE DIAGNOSTICS SOFTWARE SPECIAL TOOL Diagnostic Power Supply, P/N 587005 Unlike Evinrude E-TEC 40 HP rope start models, the 25 – 30 HP DR models do not have a starter solenoid installed. For this reason, there is no point to connect a battery to power up the EMM and use the diagnostic program.

  • Page 56: Notes - Evinrude Diagnostics Software

    NOTES – EVINRUDE DIAGNOSTICS SOFTWARE...

  • Page 57: Engine Management Software

    ENGINE MANAGEMENT SOFTWARE...

  • Page 58: Software Versions & Revisions

    SOFTWARE VERSIONS & REVISIONS Each engine family and horsepower uses Engine Management Software with unique software version and revision numbers. There are two types of engine management software updates: • When a typical update is made, a new software revision number is assigned to the software.

  • Page 59: Software Version Updates

    ENGINE MANAGEMENT SOFTWARE Software Version Updates Software version updates are “stand-alone” programs which are installed with a laptop computer. Evinrude Diagnostics software must NOT be running when installing one of these updates. IMPORTANT: Version updates cannot be used with a PDA. Software updates can be found on DealerPort: •...
  • Page 60 Inline Update 2 The Inline Update has been revised to version 1.0.0.2 and includes current soft- ware changes to May 16, 2008. If using the previous version (1.0.0.1), delete it and download the revised package from DealerPort. The Inline Update adds a new diagnostics feature (TPS Calibration) and permits the following older outboards to benefit from model year 2007 software features: •...
  • Page 61 ENGINE MANAGEMENT SOFTWARE Important Engine Management Software Update, 250 H.O. and 300 HP 90° (3.4L) V6 Models Reference: Warranty Bulletin 2008-03(W) 300 HP models and Warranty Bulletin 2008-04(W) 250 H.O. models. Also see Water Pump Installation on p. 112. Reference: Warranty Bulletin 2008-06(W) 250 H.O. and 300 HP models. These bulletins contain information regarding an important EMM software update.

  • Page 62: Notes - Engine Management Software

    NOTES – ENGINE MANAGEMENT SOFTWARE...

  • Page 63: Engine Management Module (Emm)

    ENGINE MANAGEMENT MODULE (EMM)

  • Page 64: 2009 Emm Changes

    2009 EMM CHANGES 115 H.O. – 300 HP V4 / V6 Models EMMs for 2009 models have been upgraded with a more powerful processor, increased memory and to support inductive ignition. Notes: • All 115 H.O. – 300 HP models model outboards use the same service EMM, P/N 587048.

  • Page 65: Emm Service Chart

    EMM SERVICE CHART References: Administrative Bulletin 2008-01(A) and Parts and Accessories Bulletin 2008-02(P). Administrative Bulletin 2008-01(A) outlines the policies and procedures for the Warranty Replacement of Evinrude E-TEC EMMs. Parts and Accessories Bulletin 2008-02(P) the policies and procedures for Service Replacement of Evinrude E-TEC EMMs. Model 2004 2005...

  • Page 66: Notes - Emm

    NOTES – EMM...

  • Page 67: Service Codes

    SERVICE CODES...

  • Page 68: Service Codes Information

    SERVICE CODES INFORMATION Code 1 through 6; Excessive Knock Detected – 250 H.O. and 300 HP 90° V6 (3.4 L) Models Code 1 through 6 are new service codes starting with 2009 F-suffix production. The code number is also the cylinder number (i.e. code 2 is for cylinder 2). Symptom: Evinrude Diagnostics software reveals one or more Code 1 through 6;...
  • Page 69 SERVICE CODES Code 40; Engine Overheat, Low Speed (Port or Single) Code 70; Engine Overheat, Low Speed (Starboard) Code 40 and Code 70 are new codes which support dual-zone temperature monitoring features on some models. Code 40 supports inline models and the port cylinders on V-model outboards.
  • Page 70 Code 81 thru 86; Ignition Timing Circuit Open Detected Symptom: Engine not running on all cylinders. Evinrude Diagnostics software reveals one or more, Code 81, 82, 83, 84, 85 or 86; Ignition Timing Open Circuit. Troubleshooting procedure: The EMM counts missed ignition events. Check wiring.
  • Page 71 SERVICE CODES Code 101 thru 106; Ignition Timing Circuit Short Detected – False Setting on 2009 Models False code 101 through 106 issues have been reported on some models. False faults are most likely to occur during cranking. This issue is currently under investigation.

  • Page 72: Notes - Service Codes

    NOTES – SERVICE CODES...

  • Page 73: Ignition And Electrical

    IGNITION AND ELECTRICAL...

  • Page 74: Improvements

    IMPROVEMENTS Inductive Ignition – New for 2009 115 H.O. – 300 HP V4 / V6 Models The inductive ignition system is a proven design, used in the automotive industry for years. This design has been adapted to provide ignition spark with a fast rise time like CD ignition, and a long, continuous duration spark, compared to the multi-strike cd ignition used on older models.
  • Page 75 IGNITION AND ELECTRICAL Ignition Coil Mounting Location, 200 – 300 HP 90° V6 Models What you need to know: Beginning with 2009 production the ignition coil mounting locations on 90° V6 models has changed. The ignition coil extends below the powerhead mating surface. Why you need to know: When removing or installing a powerhead with induc- tive ignition, the ignition coil for number 6 cylinder can be damaged if the power- head is improperly set down.
  • Page 76 New Engine Harness on 115 H.O. – 300 HP V4 / V6 Models Models New engine wiring harnesses are used on all 115 H.O. – 300 HP V4 and V6 models. Harness changes support the addition of inductive ignition to these models. Har- ness improvements include: •...
  • Page 77 IGNITION AND ELECTRICAL Oil Pump Wire Harness Routing Revised 40 HP Inline Rope Start Models A running change has been made to the harness routing for the oil pump. This change prevents harness chafing and eliminates the J-clamp and screw. The wiring is now routed around the starboard side of the powerhead.

  • Page 78: Spark Plugs

    SPARK PLUGS Champion QC10WEP spark plugs, introduced in 2007, are now used on all 2009 models, 40 – 200 HP 60° Models. This new spark plug uses iridium pads on the electrodes and offers longer spark plug life. • Individually wrapped P/N 5007419 •...

  • Page 79: Starter Motors

    IGNITION AND ELECTRICAL STARTER MOTORS Service Parts Electric starter motor service parts have changed. Available service parts consist of starter assemblies, drive kits, and brush and spring sets. Check the Electronic Parts Catalogs (EPC) for the latest parts information. Refer to the Electronic Parts Catalog for service parts availability 60°V4 and 60°V6/90°V6 Electric Starter Differences The electric starters for 2007 and newer V4 and V6 models look the same, but they are not.

  • Page 80: Service Issues

    SERVICE ISSUES Cylinder Head Temperature Sensor Installation Reference: Service Bulletin 2008-01(S) What: A production change which affects 2008 Evinrude E-TEC 40 - 300 HP models and increases the amount of heat sink compound in the temperature sensor cavity . Why: This change improves the reaction time of the engine’s overheat warning system (S.A.F.E.).
  • Page 81 IGNITION AND ELECTRICAL Starter Cable Service Kit, P/N 5007851 – 2007 / 2008 115 – 200 HP 60° V4 / V6 Models Beginning with 2009 production, a longer starter cable is used. The longer cable and re-routing help to improve starting by minimizing Radio Frequency Interfer- ence (RFI) issues with the Crankshaft Position Sensor.
  • Page 82 Melted Wiring and Bonding Wires The Problem: Melted wiring and / or melted bonding wires between the power- head and midsection. This condition indicates an excessive electrical load Ground through the circuit. Stud Battery The Cause: This is most commonly caused by a loose ground. The dashed line Powerhead shows ground path when there is a poor ground connection at the powerhead ground stud.

  • Page 83: Tps Calibration

    IGNITION AND ELECTRICAL TPS Calibration TPS Calibration is a function of Evinrude Diagnostics software. This function was developed to improve engine performance by synchronizing the TPS with the throttle plates. The Evinrude E-TEC engine management software is calibrated for throttle plate(s) to open from 21.5 to 24% of throttle position.
  • Page 84 Corrosion Definitions Galvanic Corrosion: Corrosion resulting from an electrochemical reaction, or electric current flow between dissimilar metals that are in contact with the same electrolyte. One of the metals must be more chemically active, or less stable for a reaction to occur. Stray Current Corrosion: Similar to galvanic corrosion, but is caused by an out- side source.
  • Page 85 IGNITION AND ELECTRICAL Stray Current Corrosion Stray current corrosion occurs when metal with an electrical current flowing into it is immersed in water that is grounded (i.e. any body of water where customers use their boats). The current leaves the metal and flows through the water to ground.
  • Page 86 How Shore Power Can Cause Stray Current Low-voltage galvanic currents (DC) can pass through shore power ground wires and have a disastrous effect for any boat connected to shore power. Normally, alternating current does not create corrosion problems, but because the boat, pier, and shore power wiring are all connected, direct current, if present, has a path to follow.
  • Page 87 IGNITION AND ELECTRICAL Corrosion Protection Testing To determine if corrosion is occurring, measure the hull potential. Corrosion test kits are available commercially, but a more economical option may be a digital multimeter and a commercially available silver / silver chloride reference elec- trode (also known as a silver –...

  • Page 88: Notes - Ignition And Electrical

    NOTES – IGNITION AND ELECTRICAL...

  • Page 89: Fuel System

    FUEL SYSTEM...

  • Page 90: Fuel Quality Issues

    FUEL QUALITY ISSUES Reference: Service Bulletin 2006-06(S) Unleaded Fuels Evinrude and Johnson outboards are certified to operated on high-quality unleaded automotive gasoline. Use FRESH fuel. The use of old or poor quality fuel can lead to engine damage. Minimum Octane •...
  • Page 91 FUEL SYSTEM Fuel Related Issues Continue to Plague the Marine Industry Remember, ethanol acts as a solvent, dissolving residues and increasing con- taminants in the fuel. These particles are put into suspension and drawn into fuel filters and fuel system components. High concentrations of ethanol can damage rubber hoses and corrode the metal components.
  • Page 92 Maintenance Inspect fuel systems often. If you smell fuel, find the source and repair leaks immediately. Check: • For leaks. • For deteriorated rubber or plastic components. • Fuel filters. • Condition of all fuel connections and hose clamps. Replace stiff, cracked, or softened hoses Replace hoses and primer bulbs with signs of permeation (black residue on sur- faces, comes off on hands).

  • Page 93: Improvements And Changes

    FUEL SYSTEM IMPROVEMENTS AND CHANGES Spin-on Fuel Filter Standard on 2009 115 – 200 HP 60° V4 / V6 Models Beginning with 2009 production, the spin-on water separating fuel filter is stan- dard on all 115 – 200 HP 60° V4/V6 models. Water Separating Fuel Filter Kit, P/N 5007045, is available to retro-fit older mod- els if desired.
  • Page 94 Injector Seal Kits What you need to know: Fuel injector crush rings MUST be replaced if an injector is installed in a different cylinder head or in a different cylinder location. There are now two Injector seal kits; P/N 5007895 for 25 – 30 HP models P/N 5007017 for 40 –...

  • Page 95: Service Issues

    FUEL SYSTEM SERVICE ISSUES Fuel Injector and Vapor Separator Servicing, 25 – 30 HP Inline Models Reference: Service Bulletin 2008-07(S) Unlike other Evinrude E-TEC models, the 25 – 30HP models do not use fuel supply or return rails. The vapor separator mounts directly to the fuel injectors, which requires special attention to minimize potential fuel leaks.
  • Page 96 Fuel Pressure and Vacuum Tests Reference: Service Bulletin 2008-06(S) What you need to know: Fuel systems must meet minimum specifications to insure the proper delivery of fuel to the outboard. Inadequate fuel flow to out- boards can result in serious powerhead damage. VACUUM In.

  • Page 97: Fuel Control Adjustment

    FUEL SYSTEM Fuel Control Adjustment Fuel control adjustment can be used to temporarily change the flow rate of an injector. See Fuel Control Feature on p. 50 Check Fuel Injectors When Water is Found in Fuel If water is found when troubleshooting the fuel system, remove fuel injectors from engine.

  • Page 98: Notes - Fuel System

    NOTES – FUEL SYSTEM...

  • Page 99: Oiling System

    OILING SYSTEM...

  • Page 100: Oil Information

    OIL INFORMATION Oil Requirements Evinrude/Johnson XD100, XD50, or XD30 outboard oils are offered for use in Evinrude E-TEC outboards. If these oils are not available, a TC-W3 certified oil must be used. Evinrude / Johnson XD-100 Outboard Oil • Is highly recommended for use in Evinrude E-TEC and DI outboards. •...
  • Page 101 OILING SYSTEMS Oil Type Setting Evinrude Diagnostics software provides an option to change the oil type setting for some outboard models. Use SET OIL TYPE as follows. Set TC-W3 The TC-W3 oil type setting is the standard setting for all outboards and may be used with XD30, XD50, or XD100 outboard oil.
  • Page 102 Multi-Point Oiling V-Models: Use a primary oil distribution manifold to provide crankcase lubrica- tion. The primary oil manifold also supplies oil to an auxiliary, or rear oil manifold which provides cylinder lubrication. Inline Models: Since inline models have fewer cylinders, only one oil distribution manifold is required to provide both crankcase and cylinder lubrication.

  • Page 103: Service Issues

    OILING SYSTEMS SERVICE ISSUES 200 – 300 HP 90° V6 Models - Pinched Oil Lines Be careful to avoid pinching oil hoses when re-installing components on power- heads. Check the following: • air silencer • starter motor • oil supply hose routing Refer to the appropriate service manual and installation instruction supplied with service replacement powerheads.
  • Page 104 Air Bubbles in Oil Line, 40 – 90 HP Inline Models Symptom: Recurring air bubble in oil line closest to oil pump assembly wire har- ness. No notable run quality symptoms, the NO OIL alarm has NOT sounded, no oil related codes found. Why: This oil port is physically located higher on the oil manifold than the other oil ports.
  • Page 105 OILING SYSTEMS Over Oiling Issue 115 HP 60° V4 Models The Symptom: Oil dripping from throttle body when engine is tilted up. The Cause: Excessive oil puddling in the lower main bearing cavity. The Fix: A running change was made to 115 – 130 HP 60° V4 models beginning with 2009 production.

  • Page 106: Oil Recirculation System Changes

    OIL RECIRCULATION SYSTEM CHANGES 25 – 30 HP Inline Models 25 – 30 HP models use only crankcase recirculation.
  • Page 107 OILING SYSTEMS 60° V4 Models Recirculation system changes for 2009 and newer, removed oil supply line from auxiliary oil manifold to upper main bearing recirculation line. 2008 & older 2009 & newer Port Side View Port Side View Oil from auxiliary oil manifold...

  • Page 108: Notes - Oiling System

    NOTES – OILING SYSTEM...

  • Page 109: Cooling Systems

    COOLING SYSTEMS...

  • Page 110: Water Pressure

    WATER PRESSURE Overboard Indicator All models: DO NOT restrict water flow from overboard indicator. The stream may be re-directed but must NOT be restricted. Restricting of the overboard indi- cator can result in engine or EMM overheating. 40 – 90 HP Inline, and 115 – 200 HP 60° V models use an unrestricted over- board indicator.
  • Page 111 COOLING SYSTEMS 2009 Water Pressure Chart This chart lists typical water pressure readings for 2009 model outboards and is provided as a general guide for use when troubleshooting over-heating or over-cooling issues. Water pressure readings may vary depending on water inlet screen type, hull design, set up, and operating conditions. Model Idle 1000...

  • Page 112: External Water Screens And Applications

    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...

  • Page 113: Improvements

    COOLING SYSTEMS IMPROVEMENTS 2009 & newer 2008 & older P/N 5007556 P/N 5001595 New Water Pump Kit, P/N 5007556 and Impeller Housing, P/N 5007554 115 H.O. – 130 HP 60° V4 Models Beginning with S-suffix 2009 production, the water pump and impeller housing for 115 H.O.

  • Page 114: Service Issues

    SERVICE ISSUES Water Pump Installation Reference: Warranty Bulletin 2008-04(W) This bulletin contains information regarding an important EMM software update and a required cooling system service procedure. Two key points MUST be observed when installing water pump: • After water pump is assembled completely, rotate driveshaft counter clock- wise 1/4 turn to unlock and release impeller and key from driveshaft.
  • Page 115 COOLING SYSTEMS Temperature Sensor and Clamp Servicing – 250 H.O. – 300HP 90° V6 Models 1 inch Reference: Warranty Bulletin 2008-02(W). (25 mm) This bulletin addresses an important engine update procedure. This procedure corrects a possible cooling system water leak and improves the reaction time of the engine’s overheat warning system (S.A.F.E.).
  • Page 116 Aerated Cooling Water Symptom: Engine or EMM overheat. Troubleshooting: Check cooling system for blockage. Verify water pressure under all operating conditions, see 2009 Water Pressure Chart on p. 109 for water pressure guidelines. Check water flow for aeration: • Remove water inlet hose from EMM •...
  • Page 117 COOLING SYSTEMS Melting Propeller Hub / Gearcase Seals Pushing Out 250 H.O. – 300 HP (3.4 L) 90° V6 Models The Problem: Melted propeller hub and / or propeller shaft seal pushed out. The Cause: Excessive exhaust gas temperatures due to cooling water passage obstruction.

  • Page 118: Notes - Cooling Systems

    NOTES – COOLING SYSTEMS...

  • Page 119: Powerhead

    POWERHEAD...

  • Page 120: Powerhead Identification

    POWERHEAD IDENTIFICATION What you need to know: Some outboards may have been serviced with a com- plete (dressed) powerhead. Why this is important: Service and Parts personnel must properly identify pow- erheads for service and parts information. Identification methods: • Red Powerhead Label attached to the diagnostics connector.
  • Page 121 POWERHEAD Compare the model number on the model and serial number tag on the swivel bracket with the model number stored in the EMM. • Use the model number stored in the EMM for powerhead servicing. • Use the model number located on the transom bracket for servicing the remainder of the outboard.

  • Page 122: Replacement Powerheads

    REPLACEMENT POWERHEADS Replacement powerheads may include additional parts to update older products. 60° V4 & V6 Models: The included instruction sheets indicate revised oil hose routings. Note: 2008 and newer 60° V6 replacement powerheads are NOT interchange- able with older models. 90°...

  • Page 123: Installation

    POWERHEAD INSTALLATION Powerhead Installation, 115 – 130 HP 60° V4 Models When installing the powerhead to the exhaust housing on 115 H.O. – 130 HP 60° V4 models, sealer must be applied to the exhaust housing, as well as the powerhead base gasket.

  • Page 124: Returning Outboard To Service

    RETURNING OUTBOARD TO SERVICE What you need to know: Be sure all items are checked and correct before returning outboard to customer. Pay particular attention to the following: • Set timing pointer. • Index all spark plugs. • Use Evinrude Diagnostics software to start oil break-in cycle. •...
  • Page 125 POWERHEAD Oil Break-In Cycle Engine management software is used to provide additional oil for new power- head break-in. Use Evinrude Diagnostics software to set the oil break-in cycle. Extra oil is provided only when the engine is run above 2000 rpm. The chart below lists the break-in oil period.

  • Page 126: Notes - Powerhead

    NOTES – POWERHEAD...

  • Page 127: Midsection

    MIDSECTION...

  • Page 128: Improvements And Changes

    IMPROVEMENTS AND CHANGES 3.3L vs 3.4L Powerhead to Adapter Gaskets 200 H.O. – 250 HP 3.3 L models and 250 H.O. – 300 HP 3.4 L 90° V6 models use different powerhead to adapter gaskets. 3.3 L models require P/N 351535, while 3.4 L models require P/N 353224. The gasket for 3.4 L models, P/N 353224, has three unique features: •...
  • Page 129 MIDSECTION V4 Exhaust Adapter and Exhaust Valve Improvements Beginning with 2009 production (S-suffix models), 115 H.O. and 130 HP 60° V4 models (20 and 25 inch) now have a one-piece lost foam exhaust housing. The 25 inch models use an extension between the exhaust housing to gearcase. This change eliminates a significant number of parts, providing improved perfor- mance and weight savings.
  • Page 130 Identification of 90° V6 Exhaust Adapters, 200 – 250 HP (3.3 L) and 250 H.O. – 300 HP (3.4 L) Models Multiple exhaust adapters have been used on the 200 – 300 HP models. Notes: • The 3.3 L and 3.4 L exhaust adapters are NOT interchangeable. •...
  • Page 131 MIDSECTION New Inner Exhaust Housing, P/N 354148 150 – 200 HP 60° V6 Models A running change to the inner exhaust housing was made in 2008 production. Inner Exhaust Housing, P/N 354148, allows more water into the exhaust to bet- ter cool propeller hub.

  • Page 132: Trim And Tilt Systems

    TRIM AND TILT SYSTEMS New Trim and Tilt Assembly 40 – 60 HP Inline Models Beginning with 2009 production an improved hydraulic unit, P/N 5007774, is used. This unit features new valving to help prevent leak down and a new man- ual release valve.
  • Page 133 MIDSECTION Hydraulic Unit Improvements 2008 and Newer 200 – 300 HP 90° V6 Models Running changes have been made to the valving of hydraulic unit, P/N 5007662. These changes help improve both forward and reverse thrust hold in high load conditions.

  • Page 134: Notes - Midsection / Tilt And Trim Systems

    NOTES – MIDSECTION / TILT AND TRIM SYSTEMS...

  • Page 135: Gearcases

    GEARCASES...

  • Page 136: 2009 Gearcase Application Chart

    2009 GEARCASE APPLICATION CHART Assembly Shaft Reverse Type Color Model Family Gear Ratio Gear Set Part No. Length Gear H-Type 5006487 Blue 25 – 30 HP 15” / 20” 13:28 (.465) 2.15:1 392475 (F), 351147 (P) 327655 F-Type 5006558 Blue 40 –...
  • Page 137 GEARCASES Assembly Shaft Reverse Type Color Model Family Gear Ratio Gear Set Part No. Length Gear M2-Type 5007705 Blue 60° V6 25” 13:24 (.542) 1.85:1 5007389 (F,P,R) 5007669 White 60° V6 25” 13:24 (.542) 1.85:1 5007389 (F,P,R) 5007705 Blue 90° V6 (3.3L) 20”...

  • Page 138: Gearcase Identification

    GEARCASES GEARCASE IDENTIFICATION S-Type / S2 Type: I3 75 / 90 HP and V4 H-Type: I2 25 – 30 HP 14.24” 19.079 361.65mm 3.22” 4.124 81.81mm O-Type: F-Type: I2, 40 – 65 HP 19.20 17.46 4.06 4.918...
  • Page 139 L-Type: M-Type: 19.20 19.20 4.918 5.078 L2-Type: M2-Type: 19.20 19.20 4.918 5.082...
  • Page 140 Identifying Gearcases A running change was made to L2-Type and S-Type / S-2 Type gearcases to ease identification of gearcase and ratio. Remove the trim tab or trim tab cover to view etching which identifies the follow- ing: • L2-Type, manufacturing part number, date code and gear ratio (.54 or .58) •...
  • Page 141 GEARCASES How to Identify an S-Type / S2-Type Gearcase by the Driveshaft If etched information does not exist under the trim tab, identification requires removing the gearcase. A part number should be etched on the upper driveshaft. • S-Type - P/N 345880 •...

  • Page 142: Gearcase Improvements

    GEARCASE IMPROVEMENTS New Pinion Bearing, P/N 5007751 A running change was made to 2008 production V6 gearcases. This change increased the taper of the pinon bearing, and improves stability of the bearing / driveshaft loading, resulting in improved gearcase durability. Models •...
  • Page 143 GEARCASES Driveshaft Bearing Housing O-Ring 75 – 300 HP Models A running change was made to 2008 production. The material for the driveshaft bearing housing o-ring, P/N 314728, has changed. This change improves seal- ing and gearcase durability. 1. O-ring, P/N 314728 Improved Shift Lever, P/N 5007292 - 115 –...

  • Page 144: Service Issues

    SERVICE ISSUES Fastener Torque S2-Type Pinion Screw A running change has been made to the torque specification for the pinion bolt used on the S2-Type gearcase. Torque value has been increased to 47 to 51 ft. lbs (63.7 to 69 N·m). Mounting Screws, All Models Be sure to tighten gearcase mounting screws to specified value (refer to appro- priate service manual), when installing gearcase to outboard.
  • Page 145 GEARCASES S2-Type Gearcase; Stuck Driveshaft The Issue: Upper driveshaft stuck into the lower driveshaft. The Cause: Assembled with used retainers. The Fix: To get driveshafts apart use driveshaft puller, P/N 390706, and backing plate, P/N 325867. Due to the length of the splines, it may be necessary to reset the puller and pull the shaft in two segments.

  • Page 146: Gearcase Tools

    GEARCASE TOOLS New Tools for M2-Type and L2-Type Gearcases Reference: Service Bulletin 2008-03(S) New service tools have been developed for 2008 Model Year outboards. The fol- lowing tools are required for servicing the new “L2” and “M2” gearcase assem- blies used on V6 model outboards. These tools will NOT be shipped automatically as part of the essential tool pro- gram and must be ordered as needed.
  • Page 147 GEARCASES Propeller Shaft Seal Tools Reference: Service Bulletin 2008-02(S) Use these tools to remove and install propeller shaft seals without removing the propeller shaft bearing housing from the gearcase. PROPELLER SHAFT SEAL TOOLS Remover Remover Seal Handle Outboard Model / Gearcase Type Spacer Installer Kit Installer...

  • Page 148: Notes - Gearcases

    NOTES – GEARCASES...

  • Page 149: Parts And Accessories

    PARTS AND ACCESSORIES...

  • Page 150: P&A Information

    EPC when they happen.This information is then used to create the PartSmart disc. Report any errors in the EPC by sending an e-mail to ejepc@brp.com. Any required changes are usually posted within a week. Inquiries About Stern Drive Parts...

  • Page 151: Service Parts And Accessories

    SERVICE PARTS AND ACCESSORIES 4-Stroke Outboard Accessory Kits and Service Kits The Parts and Accessories Catalog includes a 4-Stroke section which contains most of the 4-stroke related kits and service parts for these outboards. This section provides one convenient location for everything from rigging acces- sories, such as tiller kits, and other engine add on kits, to filters, sensors, timing belts water pumps and complete gearcases.

  • Page 152: Accessory Kits

    ACCESSORY KITS New for Evinrude E-TEC 25 – 30 HP Inline Models The following new accessory kit have been developed for the Evinrude E-TEC 25 – 30 HP models: • Tiller Kit, P/N 5007834 – Adds tiller steering to DPL and DEL models. Includes steering friction device •...
  • Page 153 SERVICE PARTS AND ACCESSORIES Stars & Stripes Decal Kits Although no longer offered as a production option, Evinrude E-TEC Stars & Stripes Kits are still available: • White 200 – 250 HP 90° V6 models P/N 763708 • White 150 – 200 HP 60° V6 models P/N 764342 •...

  • Page 154: Service Issues

    SERVICE ISSUES After-Market Fuel Filter Issues The seals on Evinrude / Johnson Genuine fuel filters are crimped in place. Some after-market fuel water separating filters do not crimp the seal in place. In areas where alcohol fuel is a concern, too much alcohol in the fuel may cause the seal to swell, resulting in a fuel leak.
  • Page 155 SERVICE PARTS AND ACCESSORIES TBX Torsion Bushing Damage To prevent damage to the torsion bushing, be sure to tighten the propeller nut as specified in installation instructions. • Without keeper – 120 to 144 in. lbs (13.6 to 16.3 N·m) •...

  • Page 156: Notes - Service Parts And Accessories

    NOTES – SERVICE PARTS AND ACCESSORIES...
  • Page 158 *5007979*...

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