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BRP Evinrude E-Tec Series Installation Manual

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Installation and Predelivery

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  • Page 1 Installation and Predelivery...
  • Page 3 † 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: Twist Grip™ ®...

  • Page 4: Table Of Contents

    INSTALLATION & PREDELIVERY INSTALLATION & PREDELIVERY TABLE OF CONTENTS BOAT RIGGING REMOTE CONTROLS CONTROL SYSTEM SELECTION ............. . . 8 CONTROL INSTALLATION .
  • Page 5 INSTALLATION & PREDELIVERY OUTBOARD INSTALLATION HULL PREPARATION ............. . 31 TRANSOM MEASURING AND DRILLING .
  • Page 6 INSTALLATION & PREDELIVERY SAFETY INFORMATION This pu blication is written fo r qualified, facto ry- DO NOT perform any work unt il yo u have read trained technicia ns who ar e alrea dy familiar with and understood these instructions completely. the use of Evinrude/Johnson Special Tools.
  • Page 7 INSTALLATION & PREDELIVERY DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off.
  • Page 8 INSTALLATION & PREDELIVERY ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Units of Measurement List of Abbreviations Amperes ABYC American Boat & Yacht Council amp-hr Ampere hour ATDC after top dead center fl. oz. fluid ounce air temperature sensor ft.
  • Page 9 INSTALLATION & PREDELIVERY EMISSION-RELATED INSTALLATION INSTRUCTIONS EMISSION-RELATED Owner’s Responsibility The owner/operator is required to have outboa rd INSTALLATION maintenance performed to maintain emission lev- els within prescribed certification standards. INSTRUCTIONS The owner/operator is not to, and should not allow Failing to follow these instructions when anyone to, modify the outboard in any manner installing a certified engine in a vessel violates that wo uld a lter th e horsepower or a llow e mis-...

  • Page 10: Remote Controls

    BOAT RIGGING REMOTE CONTROLS BOAT RIGGING Several re mote contro l options, including bo REMOTE CONTROLS mechanical and e lectronic systems, are available in the Evinrude/Johnson Genuine Parts and Control System Selection Accessories catalog. Outboard remot e cont rol systems pro vide the operator with tools for: Mechanical control systems use push/pull...

  • Page 11: Control Installation

    BOAT RIGGING REMOTE CONTROLS Control Installation Plan the inst allation of re mote co ntrols carefully, NEUTRAL 15.0° following all instructions provided with the control. 15.0° 85.5° Select an appropriate location based on the boat 40.5° configuration. 2.5 in (64 mm) 007920 Typical control clearances Use an app ropriate drill template to cut mo unting...

  • Page 12: Control Cable Routing

    BOAT RIGGING REMOTE CONTROLS Control Cable Routing Evinrude ICON Networks All control infor mation is transferred between the Control cables and harnesses should be routed outboard and an Evinrude ICON system through a along a protected path to the rea r of the boa t and single network cab le.

  • Page 13: Information Display Systems

    BOAT RIGGING INFORMATION DISPLAY SYSTEMS INFORMATION DISPLAY I-Command Displays I-Command dig ital displays are designed spe cifi- SYSTEMS cally fo r NMEA 2000 cer tified Evinrude E-TEC outboards. Th ese displays provide enh anced Engine Monitor System engine and bo at p erformance information . Multi- ple f unctions a re integra ted into th e e asy-to-use All remote controlled outboards must be equipped displays.

  • Page 14: Systemcheck (Mws) Harness Connections

    BOAT RIGGING INFORMATION DISPLAY SYSTEMS SystemCheck (MWS) Harness Connections +12V WATER TEMP CHECK ENGINE 007989 Typical MWS wiring with a side-mount mechanical remote control 1. 6-Pin Connector – Connect to a pre-wired remote control or to a dash-mounted key switch. 2.

  • Page 15: I-Command Harness Connections With Mechanical Remote Control

    BOAT RIGGING INFORMATION DISPLAY SYSTEMS I-Command Harness Connections With Mechanical Remote Control x 100 Water 3550 15.2 M E N U M E N U BUSS BUSS BUSS BUSS BUSS BUSS BUSS BUSS BUSS BUSS EP- 85 Memory Module BUSS BUSS BUSS BUSS...

  • Page 16: Evinrude Icon / I-Command Harness Connections

    BOAT RIGGING INFORMATION DISPLAY SYSTEMS Evinrude ICON / I-Command Harness Connections Second 30 40 30 40 30 40 30 40 Information Station x 100 Display x 100 x 100 x 100 3550 Control 3550 3550 3550 Trim Switch Panel Start/Stop Switch Panel Emergency Stop Switch...

  • Page 17: Battery Installation

    BOAT RIGGING BATTERY INSTALLATION BATTERY INSTALLATION Battery Connections Each o utboard requ ires it s own starting ba ttery. WARNING Select a batt ery th at meet s or exceeds the mini- Keep the battery connections clean, tight, mum requirements. and insulated to prevent their shorting or arcing and causing an explosion.

  • Page 18: Battery Cable Requirements

    BOAT RIGGING BATTERY INSTALLATION Dual outboard installations can utilize the oppos- Battery Cable Requirements ing outboard's primary battery as a secondary bat- Evinrude outbo ards are shippe d with stranded tery for emergency starting only. copper bat tery ca bles for typical inst allations in which the starting battery is close to the transom.

  • Page 19: Auxiliary Battery Charging

    BOAT RIGGING BATTERY INSTALLATION Battery Switch Operation Select the primary battery for normal operation. • Secondary batteries should only be selected for • emergency starting. ALL or BOTH switch position is fo r emergency • starting only. Provide operator with the documentation sup- plied by the battery switch manufacturer.

  • Page 20: Battery And Switch Wiring Diagrams

    BOAT RIGGING BATTERY INSTALLATION Battery and Switch Wiring Diagrams Single outboard BOTH BOTH PRIMARY SECONDARY PRIMARY SECONDARY PRIMARY Accessory charge wire (V models) Positive (+) Battery Cable 50 amp fuse Negative (–) Battery Cable 1. Single starting battery with ON/OFF switch 008056 2.
  • Page 21 BOAT RIGGING BATTERY INSTALLATION Two outboards: One primary battery each; one isolated accessory battery Positive (+) Battery Cable Negative (–) Battery Cable Accessory charge wire (V models) 50 amp fuse BOTH BOTH PRIMARY PRIMARY ACCESSORY 008053 Two outboards: One primary battery each; two isolated accessory batteries Positive (+) Battery Cable Negative (–) Battery Cable Accessory charge wire (V models)

  • Page 22: Fuel System Requirements

    BOAT RIGGING FUEL SYSTEM REQUIREMENTS FUEL SYSTEM NOTICE Do not use portable fuel tanks for outboards larger than 115 HP. Inadequate fuel REQUIREMENTS flow to high horsepower outboards can result in serious powerhead damage. Regulations and Guidelines Vessel man ufacturer, and /or inst aller of an EP A Fuel Hose certified outboard, must meet minimum specifica- All fuel hoses used for rigging outboards manufac-...

  • Page 23: Fuel System Primer

    BOAT RIGGING FUEL SYSTEM REQUIREMENTS The filter mu st be mou nted to a rigid surface Fuel System Primer above the full level of the fuel tank and accessible Outboards re quire a priming system to refill the for servicing. fuel system after periods of non-u se.

  • Page 24: Fuel Flow Requirements

    BOAT RIGGING FUEL SYSTEM REQUIREMENTS Fuel Flow Requirements 15 – 30 HP 40 – 90 HP 115 – 300 HP Fuel tank pickup tube 1/4 in. (6.4 mm) min. ID 5/16 in. (7.9 mm) min. ID 3/8 in. (9.5 mm) min. ID Fuel fittings 5/32 in.

  • Page 25: Remote Oil Tank Installation (V4 - V6)

    BOAT RIGGING REMOTE OIL TANK INSTALLATION (V4 – V6) REMOTE OIL TANK NOTICE Be sure box includes drain holes so it does not fill with water and contaminate oil. INSTALLATION (V4 – V6) Location NOTICE Consider the installation location of the oil tank carefully.
  • Page 26 BOAT RIGGING REMOTE OIL TANK INSTALLATION (V4 – V6) Place floor bracke t on ce nter line be tween e nd 1.8 G ALLON lines. Use the inner bracket holes as guides to drill Place rods in to floor bracket and se cure flo or two 5/32 in.

  • Page 27: Remote Oil Fill Kit (Optional)

    BOAT RIGGING REMOTE OIL TANK INSTALLATION (V4 – V6) Oil Tank Profiles 1.8 Gallon Tank 3 Gallon Tank P/N 176995 P/N 176996 Remote Oil Fill Kit (Optional) The remot e oil fill kit (P/N 176461) provide s a deck-mounted fill tube, cap, a tank-mounted tube, and nut that replace t he origin al o il t ank cap assembly.

  • Page 28: Cable And Hose Installation

    BOAT RIGGING CABLE AND HOSE INSTALLATION CABLE AND HOSE Boat Cable and Harness Routing INSTALLATION WARNING Improper installation and routing of out- Before in stallation, id entify all re quired wiring, board controls could wear, bind, and dam- cables, and hoses: age components, causing loss of control.

  • Page 29: Protective Sleeve/Conduit

    BOAT RIGGING CABLE AND HOSE INSTALLATION Fuel Hose The fuel ho se may be route d ou tside of the p ro- tective sleeve or conduit. Electric primers or man- ual primers may not require this consideration. Route f uel h oses with en ough slack to allo w th e primer bulb arrow to point “up”...

  • Page 30: Oetiker Clamp Servicing

    BOAT RIGGING CABLE AND HOSE INSTALLATION Oetiker Clamp Servicing Clamp Identification Use Oetiker clamps for making hose connections. These clamps provide co rrosion resistance, mini- mize the potential for abrasion of rigging compo- nents, and provide solid, permanent connections. The selection and installation of an Oetiker clamp is essential in the p roper sealing of h ose connec- tions.
  • Page 31 BOAT RIGGING CABLE AND HOSE INSTALLATION Clamp Installation Clamp Removal A const ant st ress sho uld be ap plied to close the Method 1: Position Oetiker pincers across clamp ear clamps. This method ensures a positive stress ear and cut clamp. on the hose and does not result in excessive com- pression or expansion of the band material.
  • Page 32 BOAT RIGGING NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

  • Page 33: Outboard Installation

    OUTBOARD INSTALLATION HULL PREPARATION OUTBOARD INSTALLATION The stern brackets must contact the flat surface of HULL PREPARATION the transom. Modify trim that prevents th e ste rn brackets from resting against the transom surface. Maximum Capacity Do not modify stern brackets. WARNING WARNING Do not overpower the boat by installing an...
  • Page 34 OUTBOARD INSTALLATION HULL PREPARATION Whenever possible, use mounting hardware sup- Transom Brackets and Jack plied with the outboard to install jack plate on tran- Plates som. Tighten to a torque of 40 ft. lbs. (54 N·m). When mounting an outboard on a jack plate: Refer to t he manufa cturer's recommend ations •...

  • Page 35: Transom Measuring And Drilling

    OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING If the standard spacing does not allow full steering TRANSOM MEASURING travel in a p articular installation, it ma y be n eces- sary to increase the spacing. AND DRILLING Some s teering systems m ay IMPORTANT: Hull Centerline require additional sp acing.
  • Page 36 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING Transom Height Transom Drilling Locations Make sure the transom height matches the length 75–300 HP, A ODELS of the outboard to be installed. 40–60 HP, P OWER RIM MODELS A 19 to 21 in. (48.3 to 53 .3 mm) transom height •...
  • Page 37 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING Before drilling any mounting holes: Make sure the hole locations provide enou gh • clearance for mounting bolts and washers. Check the inside area of the transom for • obstructions. Check transom height(s) at centerlines. •...
  • Page 38 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING Drilling and Hardware Diagrams 75–300 HP, A ; 40–60 HP, P ; 25–30 HP, P ODELS OWER RIM MODELS OWER ODELS This is not a template. IMPORTANT: 2 in. 2 in. (50.8mm) (50.8mm) 6 7/16 in. 6 7/16 in.
  • Page 39 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING This is not a template. IMPORTANT: 90°...
  • Page 40 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING 40 HP, M ANUAL ODELS This is not a template. IMPORTANT: 4.031 in. (4 1/32) 4.031 in. (4 1/32) (102.4 mm) (102.4 mm) 1. Center of Transom 2. Top of Transom 3. 5/16” Bolt Hole Locations...
  • Page 41 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING This is not a template. IMPORTANT: 2.09 in. (53.08 mm) 8.99 in. (228.34 mm) 90°...
  • Page 42 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING 25–30 HP, M ANUAL ODELS This is not a template. IMPORTANT: (126.2 mm) (126.2 mm) 4 3/4 4 3/4 (121.2 mm) (121.2 mm) (19 mm) 1. Center of Transom 2. Top of Transom 3. 5/16” Bolt Hole Locations...
  • Page 43 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING This is not a template. IMPORTANT: (50.2 mm) 3 3/4 3 1/2 (95.25 mm) (91 mm) (19 mm)
  • Page 44 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING 15 HP, P OWER ODELS This is not a template. IMPORTANT: 1. Center of Transom 2. Top of Transom 3. 5/16” Bolt Hole Locations...
  • Page 45 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING This is not a template. IMPORTANT:...

  • Page 46: Lifting The Outboard

    OUTBOARD INSTALLATION LIFTING THE OUTBOARD LIFTING THE 60° V4 V6 M ODELS Position lif ting to ol o n cra nkshaft and tig hten th e OUTBOARD center ret aining screw securely using a 1/4 in. Allen wrench. Lifting Fixtures WARNING To avoid personal injury, make sure the lift- ing capacity of the hoist is at least twice...
  • Page 47 OUTBOARD INSTALLATION LIFTING THE OUTBOARD 15–30 HP M ODELS NOTICE To avoid damage to the outboard, Use an approp riate chain , at least 36 in ches (91 lift the outboard in one smooth motion. DO cm) long with a sna p hook, capable of lifting 500 NOT allow the outboard to bounce.

  • Page 48: Steering Systems

    OUTBOARD INSTALLATION STEERING SYSTEMS STEERING SYSTEMS Manual Hydraulic Steering Manual h ydraulic steeri ng systems use hydra ulic Mechanical Cables fluid to transfer mo tion and load from the helm to the outboard. All Evinrude outboards equipped with tilt tubes are compatible with mechanical steering systems t hat Use only a hydraulic steering system designed for meet ABYC Standard P-17.
  • Page 49 OUTBOARD INSTALLATION OUTBOARD MOUNTING OUTBOARD MOUNTING Drag Links Use the correct dra g link to allow full steering Some riggin g compo nents, such IMPORTANT: travel: as steering cables, must b e fitted to the outboard before the outb oard is moun ted to the tran som. Model Drag Link Determine what equipment will be installed before...

  • Page 50: Outboard Mounting

    OUTBOARD INSTALLATION OUTBOARD MOUNTING 75–300 HP, A 40 HP, M ODELS ANUAL ODELS 40–60 HP, P Manual tilt models require Transom Mounting Kit, OWER RIM MODELS 25–30 HP, P P/N 394219. The kit includes a transom mounting OWER ODELS Assemble tran som mounting pla tes on mounting plate and hardware for fastening outboard to tran- bolts.
  • Page 51 OUTBOARD INSTALLATION OUTBOARD MOUNTING Install the mounting bolts through the stern brack- ets and transom. Install round backing plates and locknuts onto bolts and tighten securely. 1. Transom mounting plate 008015 2. Round backing plates 3. Locknuts 25–30 HP, M ANUAL ODELS 15 HP, P...
  • Page 52 OUTBOARD INSTALLATION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

  • Page 53: Outboard Rigging

    OUTBOARD RIGGING COMMON PRACTICES – ALL MODELS OUTBOARD RIGGING COMMON PRACTICES – Cable Retainer Clip Installation When installing retainer clips on contro l arm link- ALL MODELS age pins, clips should be locked and must not be bent or deformed. Control Cable Identification For proper installation, review the following steps: Identify co ntrol cable...

  • Page 54: Evinrude E-Tec 90° Vmodels 200-300 Hp

    OUTBOARD RIGGING EVINRUDE E-TEC 90° V MODELS 200–300 HP Refer to the following d iagram to ensure prop er EVINRUDE E-TEC 90° V positioning of rigging components in grommet. MODELS 200–300 HP Cable, Hose, and Wire Routing CAUTION To prevent accidental starting while servic- ing, disconnect the battery cables at the battery.
  • Page 55 OUTBOARD RIGGING EVINRUDE E-TEC 90° V MODELS 200–300 HP same path to the starboard side of the powerhead. Hold the shift linkage in NEUTRAL. Secure all cables with clamps. Push and p ull on the shift cable and observe the cable slack.
  • Page 56 OUTBOARD RIGGING EVINRUDE E-TEC 90° V MODELS 200–300 HP Make sure that idle stop of the throttle lever is Battery Cable Connections against the crankcase. Install battery cables on starter solenoid and main ground stud. 1. Throttle lever stop 003968 1.
  • Page 57 OUTBOARD RIGGING EVINRUDE E-TEC 90° V MODELS 200–300 HP Connect outboard main wire harness to boat wire If using a mechanical control system, con nect the harness. Secure connectors in bra cket. Refer to I-Command En gine Interface Cable to the EMM the diagram inside of the electrical cover.
  • Page 58 OUTBOARD RIGGING EVINRUDE E-TEC 90° V MODELS 200–300 HP For an I-Command oil level d isplay, an accessory Do not force conn ectors or lock- IMPORTANT: CANbus oil level sende r must be inst alled in the ing rings. Prop erly aligne d conne ctors a ssemble oil t ank.
  • Page 59 OUTBOARD RIGGING EVINRUDE E-TEC 90° V MODELS 200–300 HP To send wat er pre ssure da ta to the EMM, alon g current, resulting in erratic operation of the with an I-Command d isplay, in stall a water pres- remote control system. sure transducer kit.

  • Page 60: Evinrude E-Tec 60° Vmodels 115-200 Hp

    OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP Refer to the following d iagram to ensure prop er EVINRUDE E-TEC 60° V positioning of rigging components in grommet. MODELS 115–200 HP Cable, Hose, and Wire Routing CAUTION To prevent accidental starting while servic- ing, disconnect the battery cables at the battery.
  • Page 61 OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP same path to the starboard side of the powerhead. Make sure the remote control, gearcase, shift link- Secure all cables with clamps. age, and shift cable are in NEUTRAL. Hold the shift linkage in NEUTRAL. Push and p ull on the shift cable and observe the cable slack.
  • Page 62 OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP Make sure that idle stop of the throttle lever is Battery Cable Connections against the crankcase. Install battery cables on starter solenoid and main ground stud. 1. Throttle lever stop 004947 1.
  • Page 63 OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP Connect outboard main wire harness to boat wire NOTICE BE SURE all harnesses and wires harness. Secure connectors in brackets. are not pinched, cannot contact flywheel, and do not interfere with moving throttle or shift linkages.
  • Page 64 OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP Route the harness under the front of the EMM and switch is on. Newer, quick connect-style networks around the port side of the powerh ead. Secure do not use this connection. with tie straps.
  • Page 65 OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP Use Evinrude Diagnostics software to adjust net- To assemble the connectors: work settings in th e EMM. From the Settings Use the large t abs and small t abs to carefully •...
  • Page 66 OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP To send wat er pre ssure da ta to the EMM, alo ng Water Pressure Gauge with an I-Command d isplay, in stall a water pres- To displa y engine water p ressure, in stall a water sure transducer kit.

  • Page 67: Evinrude E-Tec Models 40-90 Hp

    OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP When g rommet is in p lace and all cables have EVINRUDE E-TEC been installed, tighten a tie strap around the out- side of the gromme t to form a watertight sea l MODELS 40–90 HP around the cables.
  • Page 68 OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP nion into the lower anchor pocket. Adjust the trun- nion nut so the casing fits onto the shift lever pin. 1. Throttle lever stop – 3 Cylinder models 005111 1. Shift lever pin 002100 2.
  • Page 69 OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP Arrange connectors in flywheel cover. SystemCheck Harness Connections Place th e wirin g harne ss through notch in lower motor cover a nd ro ute t o the recess in th e fly- wheel cover.
  • Page 70 OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP Connect the I-Command Engine Inte rface Cable I-Command Network Connections to the EMM CANbus connector. If the outbo ard will be used with I-Command, or other NMEA 2000 compliant CANbus instruments, use the following connections to su pply informa- tion to the network: Remove lower motor covers.
  • Page 71 OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP If connecting to an existing Deutsch-style I-Com- YLINDER ODELS mand network, connect the purple wires between EMM CANbus connector cap is clipp ed to EMM the I-Command Ignition and Trim Harness and the cooling water h ose.
  • Page 72 OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP Use Evinrude Diagnostics software to adjust net- Water Pressure Gauge work settings in th e EMM. From the Settings To display engine water pre ssure, in stall a wa ter screen, select Engine Options. pressure hose fitting in th e cylind er block as shown.

  • Page 73: Evinrude E-Tec Models 15-30 Hp

    OUTBOARD RIGGING EVINRUDE E-TEC MODELS 15–30 HP When g rommet is in p lace and all cables have EVINRUDE E-TEC been installed, tighten a tie strap around the out- side of the gromme t to form a watertight sea l MODELS 15–30 HP around the cables.
  • Page 74 OUTBOARD RIGGING EVINRUDE E-TEC MODELS 15–30 HP Adjust the shif t ca ble trunnion to align with the adjust the trunn ion nut so the ca sing fits onto the center of the trunnion block. throttle lever pin. 1. Shift linkage 007215 1.
  • Page 75 OUTBOARD RIGGING EVINRUDE E-TEC MODELS 15–30 HP Route trim and tilt connector under air silence r. SystemCheck Harness Use tie strap to secure connector as shown. Connections Before installing electrical connectors, check t hat the seal is in place. Cl ean off any dirt from con- nectors.
  • Page 76 OUTBOARD RIGGING NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

  • Page 77: Fuel And Oil Priming

    FUEL AND OIL PRIMING FUEL REQUIREMENTS FUEL AND OIL PRIMING When using alcoho l-extended fue ls, be aware of FUEL REQUIREMENTS the following: The b oat’s fuel system may h ave different • WARNING requirements regarding the use of alcohol fuels. Refer to the boat’s owner guide.

  • Page 78: Fuel System Priming

    FUEL AND OIL PRIMING FUEL SYSTEM PRIMING FUEL SYSTEM PRIMING Priming the Fuel System WARNING Vent Line Clamp Federal Reg ulations require that a ll o utboards Fuel vapors are highly flammable. Perform with a fuel vapor separator must be shipped with a the following procedure in a well venti- vent line clamp inst alled.

  • Page 79: Oil Requirements

    FUEL AND OIL PRIMING OIL REQUIREMENTS The TC-W3 oil type setting is the standard setting OIL REQUIREMENTS for all outboards. Set TC-W3 for: Operation with a ll TC-W3 outboard oils in clud- • Recommended Lubricants ing XD30, XD50, or XD100. Evinrude/Johnson XD1 00, XD50 , or XD30 out- Applications requiring maximum lubrication.

  • Page 80: Break-In Oiling

    FUEL AND OIL PRIMING OIL REQUIREMENTS Powerhead oil programming la bels a re pr ovided Install decals in a hig hly visible location, su ch as to ident ify EMM oil prog ramming. Inst all the cor- one of the following: rect label to alert user to specific oil requirements.

  • Page 81: Oil Supply Priming

    FUEL AND OIL PRIMING OIL SUPPLY PRIMING Prime the rear oil pump FIRST (cylinder oil pump). OIL SUPPLY PRIMING Use the Prime Cylinder Oiler button o f th e Dynamic Test screen to prime the rear oil pump. WARNING Always use caution while working around machinery with moving parts.
  • Page 82 FUEL AND OIL PRIMING OIL SUPPLY PRIMING Prime the front oil pump assembly LAST. Repair any fuel or oil leaks. Use the Prime Oil S ystem button of the Dynamic 115 – 200 HP 60° V4/V6 and Test screen to prime the front oil pump. 200 –...
  • Page 83 FUEL AND OIL PRIMING OIL SUPPLY PRIMING Use the Prime Oil System button of the Dynamic Make sure that oil flows through the rear oil distri- Test screen to prime the oil pump. bution manifold to the cylinder block fittings. 1.
  • Page 84 FUEL AND OIL PRIMING OIL SUPPLY PRIMING 15 – 90 HP Models Use Evinrude Diagnostics software to m ake sure the EMM is pro grammed for the type of oil being used. Start the outboard. Use th e oil priming function in the sof tware to mak e sure the s ystem i s co m- pletely primed.

  • Page 85: Predelivery

    PREDELIVERY BEFORE START-UP PREDELIVERY BEFORE START-UP Trim and Tilt Fluid CAUTION Gearcase Lubricant With out board vertical, check t he gea rcase lub ri- Correct fluid level must be maintained to cant level: ensure operation of the impact protection Remove the lubricant level plug. Lubricant must •...

  • Page 86: Running Checks

    PREDELIVERY RUNNING CHECKS Single Ram System–Add Evinrude/Johnson • RUNNING CHECKS Biodegradable TNT Fluid, a s needed, to bring level to the bottom of the fill plug threads. DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas.
  • Page 87 PREDELIVERY RUNNING CHECKS Emergency Stop / Key Switch I-Command Set up Check emerg ency stop funct ion. With outbo ard Complete b asic se t up of I-Command g auges. running at IDLE, pu ll sa fety lanya rd from emer- Configure engine and fuel tank, set fuel tank...

  • Page 88: Propellers

    PREDELIVERY PROPELLERS When selecting a propeller, consider the following: PROPELLERS Use a n accurate t achometer to determine t he • engine’s full-throttle RPM. Propeller Selection The outboard should be trimmed for top speed. • Select a prope ller that suits the customer’s •...
  • Page 89 PREDELIVERY PROPELLERS If cotter pin h oles in th e nut (without keeper) and Propeller Hardware Installation shaft do not align, tighten further. Do not loosen. WARNING Install keeper (if applicable). Install new cotter pin. To prevent accidental starting while servic- Aluminum or stainless steel ing, twist and remove all spark plug leads.

  • Page 90: Water Test And Final Adjustments

    PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS WATER TEST AND FINAL Engine Mounting Height and Jack Plate Adjustment ADJUSTMENTS Goals include: Engine RPM within the full throttle operating • An in the water test is required to make su re the range outboard(s) and boat are rigged correctly, propel- Best acceleration and top speed...

  • Page 91: Water Pressure Chart

    PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS Water Pressure Chart This chart lists typical water pressure readings for ings can vary depending on water screen typ e, AA model outboards for boat spee ds up to hull design, set up, and operating conditions. 50 mph (80 kph/43 knots).

  • Page 92: Tilt Limit Switch Adjustment (75 - 300 Hp)

    PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS Place the outboard in normal operating position. Tilt Limit Switch Adjustment (75 – 300 HP) Rotate the LOWER adjustment tab UP to reduce the maximum tilt. Rot ate the UPPER adjustment WARNING tab DOWN to increase the maximum tilt position. If the outboard does not clear all boat parts when tilted fully or turned side to side, safety related parts could be damaged in...

  • Page 93: Trim Sending Unit Adjustment (75 - 300 Hp)

    PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS Observe the trim gau ge. If the n eedle does not Trim Sending Unit Adjustment show cen ter position, tilt the outboard up an d (75 – 300 HP) adjust the sending unit by pivoting it up or down. Tilt the outboard and engage the tilt support.

  • Page 94: Trim Sending Unit Adjustment (25 - 60 Hp)

    PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS Trim Sending Unit Adjustment WARNING (25 – 60 HP) To avoid personal injury, do not adjust the The sending unit eccentric cam must be ad justed sending unit eccentric cam while the so that the gauge needle is aligned with the lowest engine is being tilted.

  • Page 95: Trim Tab Adjustment

    PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS Trim Tab Adjustment WARNING Improper trim tab adjustment can cause difficult steering and loss of control. A propeller will generate steering torque when the propeller shaft is not running parallel to the water’s surface. The trim tab is adjustable to compensate for this steering torque.

  • Page 96: Dual-Outboard Alignment

    PREDELIVERY WATER TEST AND FINAL ADJUSTMENTS Dual-Outboard Alignment Alignment Adjustment Various bo at/motor comb inations respond differ- Dual outboards must b e connected with a tie bar ently to dua l-outboard a lignments. Each app lica- and adjuste d to a lign the o utboards for corre ct tion must be thoroughly tested until the idea l water flow to the gearcases and propellers.

  • Page 97: Index

    INDEX INDEX n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Abbreviations 6 Diagnostic Software...
  • Page 98 INDEX Propeller n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Installation 87 I-Command Selection 86...

  • Page 99: Sample Predelivery Checklist

    ICON System Checks Concealed side mount Surface side mnt Mounting hardware - torqued? Start/Stop Switch(es) EV JO BRP shift and throttle cables Water pressure device - installed / set up? Engine Cut–off Switch (2nd station only) Other (list brand) ____________________...
  • Page 102 SKI-DOO SEA-DOO CAN-AM ® ® ® LYNX EVINRUDE JOHNSON ROTAX ® ® ® ® *5009015* November 2012 ® ©2012 Bombardier Recreational Products Inc. (BRP). All rights reserved. and the BRP logo are trademarks of BRP or its affiliates.

This manual is also suitable for:

Evinrude e-tec 30 hpEvinrude e-tec 40 hpEvinrude e-tec 15 hpEvinrude e-tec 115 hpEvinrude e-tec 300 hpEvinrude e-tec 90 hp

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