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Summary of Contents for BRP Evinrude

• 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

  EVINRUDE ICON / I-COMMAND HARNESS CONNECTIONS ........
• Page 5 EVINRUDE E-TEC 90° V MODELS 200–300 HP ........

• Page 6: Safety Information

  DO NOT perform any work until you have read trained technicians who are already familiar with and understood these instructions completely. the use of Evinrude/Johnson Special Tools. The Torque wrench tightening specifications must included information is not a substitute for work strictly be adhered to.
• 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: Abbreviations Used In This Manual

  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 EPA Emission Regulations Manufacturer’s Responsibility All new 1999 and more recent Evinrude/Johnson Beginning with 1999 model year outboards, man- outboards are certified to the EPA as conforming ufacturers of marine outboards must determine to the requirements of the regulations for the con-...

• Page 10: Remote Controls

  REMOTE CONTROLS BOAT RIGGING REMOTE CONTROLS Several remote control options, including both mechanical and electronic systems, are available in the Evinrude/Johnson Genuine Parts and Control System Selection Accessories catalog. Outboard remote control systems provide the operator with tools for: Mechanical control systems use push/pull •...

• Page 11: Control Installation

  BOAT RIGGING REMOTE CONTROLS Control Installation Plan the installation of remote controls 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) Typical control clearances 007920 Use an appropriate drill template to cut mounting holes.

• Page 12: Control Cable Routing

  Evinrude ICON Networks All control information 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 rear of the boat and single network cable. For complete installation secured to prevent movement or damage.

• Page 13: Information Display Systems

  The distance between any two points on the network must not exceed 100 meters (328 ft.). * The EMM on Evinrude E-TEC outboards has a load equivalency number of 1. Less than 50 mA of the network’s power is used by the EMM.

• Page 14: Systemcheck (mws) Harness Connections

  BOAT RIGGING INFORMATION DISPLAY SYSTEMS SystemCheck (MWS) Harness Connections +12V WATER TEMP CHECK ENGINE Typical MWS wiring with a side-mount mechanical remote control 007989 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

  Trim Switch Panel Start/Stop Switch Panel Center Buss Cable Extension Master Power Switch Starboard FUSE (–) ( + ) Gateway Module Backbone Buss Cable Accessory Harness and Relay Kit Typical Evinrude ICON network for three outboards and two control stations 007978...

• Page 17: Battery Installation

  BOAT RIGGING BATTERY INSTALLATION BATTERY INSTALLATION Battery Connections WARNING Each outboard requires its own starting battery. Select a battery that meets 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

  Battery Cable Requirements Dual outboard installations can utilize the oppos- ing outboard's primary battery as a secondary bat- Evinrude outboards are shipped with stranded tery for emergency starting only. copper battery cables for typical installations in which the starting battery is close to the transom.

• Page 19: Auxiliary Battery Charging

  VINRUDE ODELS Evinrude E-TEC V4–V6 outboards are equipped Evinrude E-TEC 40 – 90 HP outboards do not with isolated battery charging capability. The iso- lated charge connection must only be used to have a built in isolator feature. Proper methods charge a single 12-volt battery or two 12-volt bat- must be used to connect a second battery.

• Page 20: Battery And Switch Wiring Diagrams

  BOAT RIGGING BATTERY INSTALLATION Battery and Switch Wiring Diagrams Single outboard BOTH BOTH PRIMARY PRIMARY PRIMARY SECONDARY SECONDARY 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 Fuel Hose Vessel manufacturer, and/or installer of an EPA certified outboard, must meet minimum specifica- All fuel hoses used for rigging outboards manufac- tions for boat fuel systems established by:...

• Page 23: Fuel System Primer

  BOAT RIGGING FUEL SYSTEM REQUIREMENTS Fuel System Primer The filter must be mounted to a rigid surface above the full level of the fuel tank and accessible Outboards require a priming system to refill the for servicing. fuel system after periods of non-use. The most common priming system is a primer bulb in the Fuel Filter Assembly, P/N 174176, meets all fuel supply hose.

• 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) 1.8 G Place floor bracket on center line between end ALLON lines. Use the inner bracket holes as guides to drill Place rods into floor bracket and secure floor two 5/32 in. (4 mm) pilot holes. bracket with lag bolts.

• 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 remote oil fill kit (P/N 176461) provides a deck-mounted fill tube, cap, a tank-mounted tube, and nut that replace the original oil tank cap assembly.

• 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 installation, identify all required wiring, board controls could wear, bind, and dam- cables, and hoses: age components, causing loss of control. •...

• Page 29: Protective Sleeve/conduit

  Protective Sleeve/Conduit Oil Supply Hose Make sure all cables, wiring, and hoses have Evinrude E-TEC V4–V6 outboards use a single oil been identified and fitted to the appropriate supply hose connected to the outboard and to the lengths. Refer to OUTBOARD RIGGING on p. 51.

• 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 corrosion 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 proper sealing of hose connec- tions.
• Page 31 IMPORTANT: Use only Oetiker recommended tools to close Oetiker stepless clamps. Oetiker pincers are available in the Evinrude/ Johnson Genuine Parts and Accessories Catalog. 000108 Method 2: Lift end of stepless clamp with screw- driver.
• 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 HULL PREPARATION The stern brackets must contact the flat surface of the transom. Modify trim that prevents the stern brackets from resting against the transom surface. Maximum Capacity Do not modify stern brackets. WARNING WARNING Do not overpower the boat by installing an DO NOT install an outboard on a curved or...
• Page 34 If alternate bolt lengths or replacement parts required, only Evinrude/Johnson Genuine Parts. DR5703 IMPORTANT: Standard screws offered by local merchants may not provide the high strength required for outboard installations.

• Page 35: Transom Measuring And Drilling

  OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING TRANSOM MEASURING If the standard spacing does not allow full steering travel in a particular installation, it may be neces- AND DRILLING sary to increase the spacing. IMPORTANT: Some steering systems Hull Centerline require additional spacing. Refer to steering sys- Use the chines of the boat as reference points to tem manufacturer for recommendations.
• 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 25–30 HP, P OWER ODELS...
• Page 37 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING Before drilling any mounting holes: • Make sure the hole locations provide enough clearance for mounting bolts and washers. • Check the inside area of the transom for obstructions. • Check transom height(s) at centerlines. Drill four ½...
• 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 IMPORTANT: This is not a template. 2 in. 2 in. (50.8mm) (50.8mm) 6 7/16 in. 6 7/16 in.
• Page 39 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING IMPORTANT: This is not a template. 90°...
• Page 40 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING 40–65 HP, M ANUAL ODELS IMPORTANT: This is not a template. 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 IMPORTANT: This is not a template. 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 IMPORTANT: This is not a template. (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 IMPORTANT: This is not a template. (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 IMPORTANT: This is not a template. 1. Center of Transom 2. Top of Transom 3. 5/16” Bolt Hole Locations...
• Page 45 OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING IMPORTANT: This is not a template.

• Page 46: Lifting The Outboard

  OUTBOARD INSTALLATION LIFTING THE OUTBOARD LIFTING THE 60° V4 V6 M ODELS Position lifting tool on crankshaft and tighten the OUTBOARD center retaining 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 the weight of the outboard.
• Page 47 Use this tool for horizontal lifting of 30 HP and smaller Evinrude E-TEC models ONLY. DO NOT use this tool to lift outboards larger than 30 HP Evinrude E-TEC models. To avoid personal injury and boat or out- 007211 board damage, DO NOT use this tool to install or remove outboard from transom Remove chain from lifting tool.

• Page 48: Steering Systems

  WARNING Mechanical Cables If the chain snap hooks are too large, the All Evinrude outboards equipped with tilt tubes are cast in lift eye could break causing the out- compatible with mechanical steering systems that board to drop suddenly causing personal meet ABYC Standard P-17.
• Page 49 OUTBOARD INSTALLATION STEERING SYSTEMS Manual Hydraulic Steering Drag Links Manual hydraulic steering systems use hydraulic Use the correct drag link to allow full steering fluid to transfer motion and load from the helm to travel: the outboard. Model Drag Link Use only a hydraulic steering system designed for 90°...

• Page 50: Outboard Mounting

  OUTBOARD INSTALLATION OUTBOARD MOUNTING OUTBOARD MOUNTING 75–300 HP, A ODELS 40–60 HP, P OWER RIM MODELS 25–30 HP, P OWER ODELS IMPORTANT: Some rigging components, such Assemble transom mounting plates on mounting as steering cables, must be fitted to the outboard bolts.
• Page 51 OUTBOARD INSTALLATION OUTBOARD MOUNTING 40–65 HP, M Install the mounting bolts through the stern brack- ANUAL ODELS ets and transom. Install round backing plates and Manual tilt models require Transom Mounting Kit, locknuts onto bolts and tighten securely. P/N 394219. The kit includes a transom mounting plate and hardware for fastening outboard to tran- som.
• 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 control 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: IMPORTANT: Identify control cable function...

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

  OUTBOARD RIGGING EVINRUDE E-TEC 90° V MODELS 200–300 HP EVINRUDE E-TEC 90° V Refer to the following diagram to ensure proper 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: Control Cable Installation

  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 pull on the shift cable and observe the cable slack. Hold the casing guide in the center of the 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 If using an Evinrude ICON control system, the I- Command Engine Interface Cable, Power Supply Kit, and Ignition and Trim Harness are not required.
• Page 58 007883 ICON Network Connections 2. Small tabs If the outboard is equipped for an Evinrude ICON Do not rotate connectors until they align. This control system, connect the outboard to the net- could result in a mismatched connection. It is pos- work as follows.
• Page 59 To send water pressure data to the EMM, along remote control system. with an I-Command display, install a water pres- sure transducer kit. For more information, refer to the Evinrude ICON Remote Control System Installation Guide, Water pressure readings in excess of 40 psi (275 P/N 764952.

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

  OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP EVINRUDE E-TEC 60° V Refer to the following diagram to ensure proper 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.
• 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 If the outboard will be used with I-Command, or other NMEA 2000 compliant CANbus instruments, use the following connections to supply informa- tion to the network: If using an Evinrude ICON control system, the I- 1. Harness connections 004951 Command Engine Interface Cable, Power Supply...
• 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 powerhead. Secure do not use this connection. with tie straps.
• Page 65 2. Small tabs ICON Network Connections Do not rotate connectors until they align. This If the outboard is equipped for an Evinrude ICON could result in a mismatched connection. It is pos- control system, connect the outboard to the net- sible for each pin to enter a socket even if the tabs work as follows.
• Page 66 OUTBOARD RIGGING EVINRUDE E-TEC 60° V MODELS 115–200 HP Water Pressure Gauge To send water pressure data to the EMM, along with an I-Command display, install a water pres- To display engine water pressure, install a water sure transducer kit.

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

  OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP EVINRUDE E-TEC When grommet is in place and all cables have been installed, tighten a tie strap around the out- MODELS 40–90 HP side of the grommet to form a watertight seal 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 SystemCheck Harness Arrange connectors in flywheel cover. Connections Place the wiring harness through notch in lower motor cover and route to the recess in the fly- wheel cover. Secure the cable with a tie strap as...
• Page 70 OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP I-Command Network Connections Connect the I-Command Engine Interface Cable to the EMM CANbus connector. If the outboard will be used with I-Command, or other NMEA 2000 compliant CANbus instruments, use the following connections to supply 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 clipped to EMM the I-Command Ignition and Trim Harness and the cooling water hose. Remove clip from cap and I-Command Engine Interface Cable.
• Page 72 OUTBOARD RIGGING EVINRUDE E-TEC MODELS 40–90 HP Use Evinrude Diagnostics software to adjust net- Water Pressure Gauge work settings in the EMM. From the Settings To display engine water pressure, install a water screen, select Engine Options. pressure hose fitting in the cylinder block as shown.

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

  OUTBOARD RIGGING EVINRUDE E-TEC MODELS 15–30 HP EVINRUDE E-TEC When grommet is in place and all cables have been installed, tighten a tie strap around the out- MODELS 15–30 HP side of the grommet to form a watertight seal around the cables.
• Page 74 OUTBOARD RIGGING EVINRUDE E-TEC MODELS 15–30 HP Adjust the shift cable trunnion to align with the adjust the trunnion nut so the casing fits onto the center of the trunnion block. throttle lever pin. 1. Shift linkage 007215 1. Throttle lever pin 007217 2.
• Page 75 OUTBOARD RIGGING EVINRUDE E-TEC MODELS 15–30 HP SystemCheck Harness Route trim and tilt connector under air silencer. Use tie strap to secure connector as shown. Connections Before installing electrical connectors, check that the seal is in place. Clean 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

  Do not smoke, allow open flames or IMPORTANT: The only fuel additives approved sparks, or use electrical devices such as ® for use in Evinrude outboards are 2+4 fuel condi- cellular phones in the vicinity of a fuel leak tioner Evinrude/Johnson...

• Page 78: Fuel System Priming

  FUEL AND OIL PRIMING FUEL SYSTEM PRIMING FUEL SYSTEM PRIMING Priming the Fuel System WARNING Vent Line Clamp Federal Regulations require that all outboards 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 installed.

• Page 79: Oil Requirements

  XD30, XD50, or XD100. Evinrude/Johnson XD100, XD50, or XD30 out- • Applications requiring maximum lubrication. board oils are recommended for use in Evinrude • Extreme applications (commercial or harsh con- E-TEC outboards. If these oils are not available, ditions, racing or other high performance opera- you must use a TC-W3 certified oil.

• Page 80: Break-in Oiling

  EMM programming. Break-In Oiling IMPORTANT: DO NOT add oil in the fuel tank on Evinrude E-TEC models. 1. Evinrude/Johnson XD30 outboard lubricant (TC-W3) 004964 YELLOW label The Engine Management Module (EMM) will auto- 2. Evinrude/Johnson XD100 outboard lubricant (Premium)

• Page 81: Oil Supply Priming

  The pump assembly cannot prime itself until bution hoses, and to the crankcase fittings. it has been filled with oil. Use Evinrude Diagnostics software to make sure the EMM is programmed for the type of oil being used. Start the outboard. Use the oil priming functions in the software to make sure the system is com- pletely primed.
• Page 82 Continue to squeeze the oil primer bulb until oil flows through the oil pump, into the oil distribution hoses, and to the crankcase fittings. Use Evinrude Diagnostics software to make sure the EMM is programmed for the type of oil being used.
• 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 make sure the EMM is programmed for the type of oil being used. Start the outboard. Use the oil priming function in the software to make sure the system is com- pletely primed.

• Page 85: Predelivery

  PREDELIVERY BEFORE START-UP PREDELIVERY BEFORE START-UP Trim and Tilt Fluid CAUTION Gearcase Lubricant With outboard vertical, check the gearcase lubri- Correct fluid level must be maintained to cant level: ensure operation of the impact protection • Remove the lubricant level plug. Lubricant must built into the unit.

• Page 86: Running Checks

  PREDELIVERY RUNNING CHECKS • RUNNING CHECKS Single Ram System–Add Evinrude/Johnson Biodegradable TNT Fluid, as 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: Idle Speed

  (SystemCheck) Break-In Confirm accuracy of tachometer reading. Evinrude E-TEC outboards require no break in. • Adjust dial on back of tachometer to required When the outboard is delivered, refer the cus- setting (the outboard should not be running).

• Page 88: Propellers

  Water testing with various propeller designs and each situation. sizes is the best method of propeller selection. • Refer to the Evinrude/Johnson Genuine Parts and Accessories Catalog for propeller styles The correct propeller, under normal load condi- and sizes. tions, will allow the engine to run near the mid- •...

• Page 89: Propeller Hardware Installation

  120 to 144 in. lbs IMPORTANT: Depending on propeller style, dif- ferent thrust bushings, spacers, and cotter pin keepers are used. See the Evinrude/Johnson Genuine Parts and Accessories Catalog for cor- rect propeller hardware. Aluminum or stainless steel Large diameter hub...

• 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 sure the range outboard(s) and boat are rigged correctly, propel- •...

• 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 type, 2012 model outboards for boat speeds 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 Tilt Limit Switch Adjustment Place the outboard in normal operating position. (75 – 300 HP) Rotate the LOWER adjustment tab UP to reduce the maximum tilt. Rotate 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 Trim Sending Unit Adjustment Observe the trim gauge. If the needle does not show center position, tilt the outboard up and (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 adjusted 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 boat/motor combinations respond differ- Dual outboards must be connected with a tie bar ently to dual-outboard alignments. Each applica- and adjusted to align the outboards for correct tion must be thoroughly tested until the ideal 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

  Evinrude E-TEC outboards. If an Evinrude E-TEC outboard was pre-rigged by the boat builder, a complete predelivery inspection is still required. Refer to the current Evinrude E-TEC Installation and Predelivery Guide for detailed instructions. Dealer predelivery programs should include additional inspections related to boat accessories and trailers.

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Summary of Contents for Evinrude B10R4

• Page 1 Operator’s Guide 9.8 HORSEPOWER B10R4, B10RL4, B10TEL4, B10EL4, B10TPL4, B10PL4, B10TPX4, B10PX4 E10R4, E10RL4, E10TEL4, E10EL4, E10TPL4, E10PL4, E10TPX4, E10PX4 2012 and 'AA' Models *216182* 216182...
• Page 2 READ THIS MANUAL BEFORE USING THE OUTBOARD MOTOR. FAILURE TO FOLLOW THE INSTRUCTIONS AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE. Copyright 2012 BRP US Inc. All rights reserved. No part of this manual may be reproduced or transmitted in any from or by any means without the expressed written permission of BRP US Inc.
• Page 3 WILL NOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY, IF THIS PROCEDURE IS NOT FOLLOWED. PRE-DELIVERY CHECK Be sure that the product has been checked by an authorized Evinrude dealer before you take delivery. Limited Warranty Please refer to the BRP Limited warranty provided to you with this product, the terms and conditions of which, as amended from time to time, are incorporated by reference into the manual.
• Page 4 BRP offers technical literature specifically for your outboard. A service manual, a parts catalog, or an extra Operator’s Guide can be purchased from your selling Dealer. For the name and location of the nearest Evinrude Dealer in the United States and Canada visit www.evinrude.com.

• Page 5: Table Of Contents

  CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 GENERAL SAFETY INFORMATION .
• Page 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 2.
• Page 7 INDEX GENERAL SAFETY INFORMATION 1. SPECIFICATIONS 2. NAMES OF PARTS 3. LOCATIONS OF WARNING LABELS 4. INSTALLATION 5. PRE-OPERATING PREPARATIONS 6. ENGINE OPERATION 7. REMOVING AND CARRYING THE OUTBOARD MOTOR 8. TRAILERING 9. ADJUSTMENT 10. INSPECTION AND MAINTENANCE 11. TROUBLESHOOTING 12.

• Page 8: General Safety Information

  8 GENERAL SAFETY INFORMATION GENERAL SAFETY INFORMATION NOTICE : DANGER/WARNING/CAUTION/Note Before installing, operating or otherwise handling your outboard motor, be sure to thoroughly read and understand this Operator's Guide and carefully follow all of the instructions. Of particular importance is information preceded by the words 'DANGER,'...
• Page 9 GENERAL SAFETY INFORMATION SAFE OPERATION OF BOAT As the operator/driver of the boat, you are responsible for the safety of those aboard and those in other boat around yours, and for following local boating regulations. You should be thoroughly knowledgeable on how to correctly operate the boat, outboard motor, and accessories.

• Page 10: Specifications

  SPECIFICATIONS SPECIFICATIONS MODEL Item 975 (38.4) 590 (23.2) Overall Length mm (in) 354 (13.9) 320 (12.6) Overall Width mm (in) 1,035 (40.7) · 1,162 (45.7) · 1,289 (50.7) Overall Height S·L·XL mm (in) 435 (17.1) · 562 (22.1) · 689 (27.1) Transom Height S·L·XL mm (in) 37.0 (81.5)
• Page 11 NAMES OF PARTS MODEL Item 975 (38.4) 590 (23.2) Overall Length mm (in) 354 (13.9) 320 (12.6) Overall Width mm (in) 1,035 (40.7) · 1,162 (45.7) · 1,289 (50.7) Overall Height S·L·XL mm (in) 435 (17.1) · 562 (22.1) · 689 (27.1) Transom Height S·L·XL mm (in) 46.5 (102.5)

• Page 12: Names Of Parts

  NAMES OF PARTS NAMES OF PARTS R, TE, E ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ E type only ○ ○ ○...
• Page 13 NAMES OF PARTS TP, P ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ P type only ○ ○ ○ ○ ○ ○...

• Page 14: Locations Of Warning Labels

  14 LOCATIONS OF WARNING LABELS LOCATIONS OF WARNING LABELS Locations of warning labels Warning label regarding owner's manual, top cowl, engine stop switch, engine oil level and unleaded gasoline Warning label on position of outboard motor when setting down Warning label on engine stop switch C AU TI O N This fuel tank &...

• Page 15: Installation

  INSTALLATION INSTALLATION CAUTION 1. Mounting the outboard motor on boat ● Before beginning the running test, WARNING check that the boat with maximum capacity loading floats on the water in a proper attitude. Check the position Most boats are rated and certified of water surface on the driveshaft in terms of their maximum allowable housing.
• Page 16 16 INSTALLATION R, TE, E type Note ① To attach the outboard motor to the boat, tighten the clamp screws by It is recommended to install upper turning their handles. mounting bolts with bolt head at inside surface of transom. Bolts with Also, tighten the bolts.
• Page 17 INSTALLATION TP, P type (Power tilt model) Note It is recommended to install upper mounting bolts with bolt head at inside surface of transom. Bolts with threaded end at inside surface of transom can cause personal injury. Notes 1. Apply sealing agent such as silicone sealed between the bolts and transom board holes before tightening the bolts.

• Page 18: Installing The Remote Control Devices

  Lock nut 2. Installing the remote control devices Cable joint Remoto control cable WARNING When using other than Evinrude's genuine remote control box, DO NOT select the Approx. 10mm one without neutral safety switch that (0.39 inch) prevents in-gear start.
• Page 19 INSTALLATION ③ Connecting the Cord assembly WARNING (Wiring Harness) Do not disconnect cord ass'y when Pass the Cord assembly from the engine is in operation, or engine will go out of control. Remote control box through the hole in the Lower motor cover and cover the wire ends with the Sleeve (provided in a tool bag) and then c o n n e c t t h e e l e c t r i c t e r m i n a l s...
• Page 20 20 INSTALLATION P model Green Blue Blue Green Brown Blue Black Brown Yellow Brown Black Pink Sky blue Black Brown ② Connect the positive cord (+) to the CAUTION positive terminal (+) of the battery, ● Make sure that the battery cords do and then connect the negative not get stuck between the outboard cord (−).

• Page 21: Installing The Battery

  INSTALLATION WARNING 3. Installing the battery Battery electrolyte contains sulfuric acid ① Place the battery box in a con- and thus is hazardous, causing a burn venient position away from water if it comes in contact with your skin, or spray.

• Page 22: Pre-operating Preparations

  GASOLINES CONTAINING ALCOHOL The fuel system components on your After cleaning gasoline tank: Evinrude engine will withstand up to 10% ● Wipe off gasoline well immediately if alcohol content in the gasoline. But if spilt. ● If the fuel tank is disassembled...

• Page 23: Low Permeation Fuel Hose Requirement

  S tarting and operating difficulties ● CAUTION WARNING When operating a Evinrude engine on Fuel leakage can cause fire or explosion, gasoline containing alcohol, storage of potentially leading to severe injury or gasoline in the fuel tank for long periods loss of life.

• Page 24: Epa Pressurized Portable Fuel Tank Requirements

  EQUIPPED FOR UNITED STATES screw which should be closed for AND CANADA MODEL transportation and full open for Evinrude adopts Primer bulb/hose as- operation and cap removal. sembly approved by the Environment Protection Agency (EPA). Since sealed fuel tanks are not openly...

• Page 25: Recommended Engine Oil

  Be sure to use EPA approved tank outboard oil is recommended for use and EPA approved primer bulb hose in Evinrude 4-stroke outboards. assembly as a set. Confirm shapes of EPA approved tank and regular tank. If Evinrude/Johnson Ultra 4-stroke...

• Page 26: Break-in

  26 PRE-OPERATING PREPARATIONS 6. Break-in Your new outboard motor and lower CAUTION unit require break-in for the moving c o m p o n e n t s a c c o r d i n g t o t h e Operating the outboard motor without conditions described in the following break-in can shorten service life of the...

• Page 27: Engine Oil Warning Lamp

  PRE-OPERATING PREPARATIONS 7. Engine oil warning lamp 8. ESG (A device preventing over revolution) ESG is a device to prevent over revo- Oil pressure is required to lubricate internal engine parts. lution of the engine (more than ap- When the warning lamp (Red) is off, it proximately 6,250 rpm).

• Page 28: Engine Operation

  28 ENGINE OPERATION ENGINE OPERATION Before starting 1. Filling the fuel CAUTION DANGER The engine oil is drained for shipping Consult an authorized dealer for details on handling gasoline, if necessary. from the factory. Be sure to fill the en- gine to the proper level before starting Gasoline and its vapors are very flam- engine.
• Page 29 ENGINE OPERATION For USA and Canada model WARNING ① F ull open the air vent screw on the When opening fuel tank cap, be sure to tank cap and release internal pres- follow the procedure described below. sure. Fuel could blast out through the fuel Full open tank cap in case the cap is loosened by Air vent screw...

• Page 30: Feeding The Fuel

  30 ENGINE OPERATION pressure completely. After that, 2. Feeding the fuel close the tank cap. until two click sound is heaed. Except for USA and Canada model ① F ull open the air vent screw on the ③ Connect the fuel connector to the tank cap.

• Page 31: Starting

  ENGINE OPERATION 3. Starting CAUTION When using EPA approval fuel tank, only use a primer bulb/hose assembly that has a Fuel Demand Valve installed in the fuel hose or a sealing mechanism in the fuel connector as shown below. (FDV and fuel connector that has an sealing mechanism prevent pressurized fuel from entering the engine and caus- ing a fuel system overflow or possible...
• Page 32 32 ENGINE OPERATION ② Set the throttle grip to “START” po- you feel engagement, keep pulling sition. till you feel less resistance. Then pull it quickly. Repeat if necessary until started. ⑤ When starting the engine, push the choke knob back. Slowly Quickly ③...
• Page 33 ENGINE OPERATION E and P type Note ④ Insert the main switch key. ⑤ Set the control lever in the Neutral The free accel lever can not be raised position. when the control lever shift is in Forward or Reverse. ⑥ Raise the Free accel lever a little (both of cold engine and warm en- gine).
• Page 34 34 ENGINE OPERATION ② Loosen the screw for starter lock ◎ Confirm that the shift lever is at wire. neutral position. ◎ Wrap a rope around the starter pul- ley then pull quickly to start. ◎ Use a 10 mm socket wrench as a rope handle.

• Page 35: Warming Up The Engine

  ENGINE OPERATION If the choke solenoid fails to 4. Warming up the engine operate (E and P type only) War m the engine at low engine ① Remove the top cowl. speeds for about three minutes. This ② Close the choke plate by finger. allows the lubricating oil to circulate to ③...

• Page 36: Forward And Reverse

  36 ENGINE OPERATION Engine speeds 5. Forward and reverse Idling speed after warming up. Remark: In case of cold engine WARNING starting, idling speed is increased about 300 rpm for several minutes. Before shifting into forward or reverse, Clutch in (In gear) Clutch off (Out of gear) make sure that boat is properly moored and outboard motor can be steered...
• Page 37 ENGINE OPERATION R, TE and TP type CAUTION Be sure to warm up engine well before starting cruise. Operating cold engine may cause damage to your motor. Note Idle speed may be higher during warming up of engine. If shifted to Forward or Reverse during warming WARNING up, it may be difficult to shift back to...

• Page 38: Stopping

  38 ENGINE OPERATION ■ Forward 6. Stopping Quickly push the control lever to the Forward (F) position 32˚, where the R, TE and TP type gear is connected, while lifting up on the lock button located at the bottom of the control lever grip. Further shifting will open the throttle.

• Page 39: Trim Angle

  ENGINE OPERATION E and P type 7. Trim angle The trim angle of the outboard motor can be adjusted to suit the transom angle of the hull, and load conditions. Choose an appropriate trim angle START that will allow the anti-ventilation plate to run parallel to the water surface during operation.
• Page 40 40 ENGINE OPERATION WARNING TP and P type ■ Improper Trim Angle (bow rise too high) ● Do not put hand or finger in between If the trim angle is excessive, the outboard motor body and clamp bracket when adjusting trim angle to bow will rise out of the water and the prevent injury in case the outboard speed will decrease.
• Page 41 ENGINE OPERATION R, TE type ① Stop the engine. ② Shift the outboard into neutral. ③ Raise the engine to the tilt up posi- tion. ④ Change the thrust rod position. ⑤ Gentry lower the outboard. TP model P model Thrust Rod Higher ■...
• Page 42 42 ENGINE OPERATION P type ① O perate the Power Tilt switch and tilt the outboard motor up. (The Main Switch must be 'ON'.) The outboard motor can also be tilted up using the switch provided under the bottom cowl. (The Main Switch need not be turned 'ON'...
• Page 43 ENGINE OPERATION ② L ock the tilt with the Tilt stopper after the outboard motor has been tilted up. Tilt Stopper ③ Manual tilting If the battery is dead, and the Pow- er Tilt Switch inoperative, turn the manual valve to counter-clockwise. This will allow manual tilting of the outboard motor.
• Page 44 44 ENGINE OPERATION TP/P type CAUTION The provided Power tilt makes tilt- up/down electrically. It may be used The power Tilt can be set to any trim as a power trim and tilt when the angle, however, avoid cruising with the outboard motor tilted in the tilt range.

• Page 45: Tilt Up, Tilt Down And Shallow Water Operation

  ENGINE OPERATION ■ Tilt down 8. Tilt up, tilt down and shallow water operation Slightly tilt the motor up, and pull the tilt lever toward you to release the tilt- WARNING lock. Then lower the motor slowly. When tilting up or down, be careful not to place your hand between the swivel bracket and the stern bracket.
• Page 46 46 ENGINE OPERATION ■ Tilt down ① Move the tilt lock knob to the un- lock position. ② Raise the outboard to the tilt re- lease position. ③ Gently lower the outboard. Tilt lock knob in lock position Tilt lock knob in unlock position Tilt up position Tilt...

• Page 47: Shallow Water Operation

  ENGINE OPERATION R, TE type 9. Shallow water operation ■ Shallow water running position WARNING With the shift lever in Neutral or Forward, tilt the motor up slowly by During shallow water operation, be about 40˚ and then lower the tilt le- careful not to place your hand between ver for setting at the shallow water the swivel bracket and the stern bracket.
• Page 48 48 ENGINE OPERATION E type ■ Setting shallow water drive ■ Releasing shallow water drive ① Stop the engine. ① Stop the engine. ② Shift the outboard into forward. ② Tilt the outboard up to the tilt re- ③ Tilt the outboard up to one of the lease position.

• Page 49: Removing And Carrying The Outboard Motor

  REMOVING AND CARRYING THE OUTBOARD MOTOR REMOVING AND CARRYING THE OUTBOARD MOTOR WARNING 1. Removing the outboard motor ● Close air vent screw of fuel tank and ① Stop the engine. ② Disconnect the fuel connector, fuel cock before carrying or storing outboard motor and fuel tank, or fuel the remote control cables and the may leak, potentially catching fire.

• Page 50: Trailering

  50 TRAILERING TRAILERING WARNING Do not go under outboard motor tilted up even if it is supported by support bar, or accidental fall of outboard motor could lead to severe personal injury. WARNING Close air vent screw of fuel tank and fuel cock before carrying or storing outboard motor and fuel tank, or fuel may leak, potentially catching fire.

• Page 51: Adjustment

  ADJUSTMENT ADJUSTMENT 1. Steering friction 2. Throttle grip R, TE type R, TE and TP type The steering friction can be adjusted The turning force of the throttle grip in accordance with your preference can be adjusted with a throttle adjust by turning the steering adjust bolt.

• Page 52: Remote Control Lever Load

  52 ADJUSTMENT 3. Remote Control Lever Load Notes ● The trim tab also acts as an anode E and P type (Throttle friction adjustment screw) to prevent electrolytic corrosion. Therefore do not paint or grease To adjust the load of the remote this part.

• Page 53: Inspection And Maintenance

  INSPECTION AND MAINTENANCE INSPECTION AND MAINTENANCE Care of your outboard motor EPA Emissions Regulations To keep your outboard motor in the EPA (United States Environmental best operating condition, it is very Protection Agency) has emission important that you perform daily and regulations regulating air pollution periodic maintenance as suggested from new outboard motors.

• Page 54: Daily Inspection

  54 INSPECTION AND MAINTENANCE 1. Daily inspection WARNING Perform the following checks before and after use. Do not use outboard motor if any abnormality is found during pre-operation check or it could result in severe damage to the motor or severe personal injury. Item Points to Check Remedy...
• Page 55 INSPECTION AND MAINTENANCE Maintaining engine oil Notes If the engine oil is low, the life of the engine will be shortened significantly. Consult with an authorized dealer if the engine oil is milky color, or appears contaminated. ■ Checking oil level ①...
• Page 56 56 INSPECTION AND MAINTENANCE ■ Use flushing attachment. Washing outboard motor ① Remove propeller (refer to Propeller If outboard motor is used in salt water, brackish water or water with a Replacement). Remove the water high acidic level, use fresh water to plug from the motor, and screw in remove salt, chemicals or mud from the flushing attachment.
• Page 57 INSPECTION AND MAINTENANCE Replacing the propeller WARNING A worn-out or bent propeller will lower the motor's performance, and cause Do not hold propeller with hand(s) engine trouble. when loosening or tightening propeller nut. Put a piece of wood block between Before removing the propeller, remove propeller blade and anti-ventilation the spark plug caps from the spark...
• Page 58 58 INSPECTION AND MAINTENANCE ⑤ Attach spark plug and tighten to Replacing the spark plugs specified torque. WARNING Notes ● Do not reuse spark plug with damaged insulation, or sparks ◎ Spark plug torque : can leak through crack, potentially 18.0Nm(13.3ft-lb)(1.84kgf-m) leading to electric shock, explosion If a torque-wrench is not available...
• Page 59 INSPECTION AND MAINTENANCE ② Recommended oil Checking and Refilling Oil in the Use an automatic transmission Power Tilt. ① Check the oil level of the reservoir fluid or equivalent. tank as shown on the right while the Recommended oils are as shown tank is kept in a vertical position.

• Page 60: Periodic Inspection

  60 INSPECTION AND MAINTENANCE 2. Periodic inspection It is important to inspect and maintain your outboard motor regularly. At each interval on the chart below, be sure to perform the indicated servicing. Maintenance intervals should be determined according to the number of hours or number of months, whichever comes first.
• Page 61 INSPECTION AND MAINTENANCE Drain hole Notes Your outboard motor should receive careful, and complete inspection at 300 hours. This is the best time for major maintenance procedures to be carried out. Replacing engine oil Engine oil mixed with dust or water Use only high quality 4-stroke engine will dramatically shorten the life of the oil to insure performance and pro-...
• Page 62 62 INSPECTION AND MAINTENANCE Cleaning the fuel filters and the CAUTION fuel tank Fuel filters are located inside the fuel You may be injured due to high engine tank and engine. temperatures if you fill engine oil just after stopping. Changing engine oil should be done after the engine has WARNING been cooled.
• Page 63 INSPECTION AND MAINTENANCE ■ Fuel filter (for fuel tank) Loosen the fuel pickup elbow shown at left, remove it and clean the fuel filter. Fuel Filter pick up elbow ■ Fuel tank Water or dirt in the fuel tank will cause engine performance problems.
• Page 64 64 INSPECTION AND MAINTENANCE until oil flows out from upper plug Replacing gear oil hole. Oil plug (Upper) WARNING ● Be sure that outboard motor is secured to transom or service stand, or acciden- tal drop or fall of outboard motor could lead to severe personal injury.

• Page 65: Off-season Storage

  INSPECTION AND MAINTENANCE 3. Off-season storage ⑥ Change the gear oil in the gear case. Before you put your outboard motor ⑦ Apply grease to the propeller shaft. in storage, it is a good opportunity to ⑧ Apply grease to all sliding parts, have it serviced and prepared by your dealer.

• Page 66: Pre-season Check

  66 INSPECTION AND MAINTENANCE 4. Pre-season check 5. Motor submerged in water ① Check that the shift and throttle After taking your outboard motor out function properly. of the water, immediately take it to (Be sure to turn the propeller shaft your dealer.

• Page 67: Cold Weather Precautions

  INSPECTION AND MAINTENANCE 6. Cold weather precautions 7. Checking after striking underwater object If you moor your boat in cold weather Striking the sea bottom or an under- at temperatures below 0˚C (32˚F), water object may severely damage there is the danger of water freezing the outboard motor.

• Page 68: Troubleshooting

  TROUBLESHOOTING TROUBLESHOOTING If you encounter a problem, consult the check list below to determine the cause and to take the proper action. An authorized dealer will always be happy to provide any assistance and informa- tion. Possible cause ● ● Empty fuel tank ●...
• Page 69 TROUBLESHOOTING Possible cause ● ● ● ● ● ● ● Spark plug other than specified ● ● ● ● ● ● Dirt, soot, etc. on spark plug ● ● Faulty oil pressure switch ● ● ● ● ● ● No Spark or weak spark ●...
• Page 70 TROUBLESHOOTING Possible cause ● ● ● ● ● Low compression ● ● Carbon deposits in the combustion chamber ● ● Incorrect valve clearance ● Low oil pressure/level ● ● ● Low oil level ● ● Use of improper oil ● ●...

• Page 71: Tool Kit And Spare Parts

  TOOL KIT AND SPARE PARTS TOOL KIT AND SPARE PARTS The following a list of the tools and spare parts provided with the motor. Items Quantity Remark Tool bag Pliers 10 × 13 mm Socket wrench Socket wrench 16 mm (spark plug) Service tools Socket wrench handle Screwdrivers...

• Page 72: Optional Accessories

  72 OPTIONAL ACCESSORIES OPTIONAL ACCESSORIES Selector Tachometer Flushing attachment Tachometer with oil lamp (for P) Propeller High thrst propeller...

• Page 73: Propeller Table

  PROPELLER TABLE PROPELLER TABLE Use a genuine propeller. Select a propeller that will allow the engine to reach the recommended with open throttle operating range when cruising at wide-open throttle. Wide open throttle operating range is : • 9.8HP : 5000 to 6000 rpm Propeller Size (Diameter ×...

• Page 74: Product Warranty Information

  1. SCOPE OF THE LIMITED WARRANTY Bombardier Recreational Products* (“BRP”) warrants its 2012 Evinrude® outboard engines sold by au- thorized Evinrude dealers in the fifty United States and Canada (“Product”) from defects in material or workmanship for the period and under the conditions described below.
• Page 75 This warranty coverage is available only on Evinrude outboard engines purchased as new and unused from a dealer authorized to distribute Evinrude products in the country in which the sale occurred (“Dealer”), and then only after the BRP specified pre-delivery inspection process has been completed and documented by the purchaser and Dealer.
• Page 76 For a copy of the Limited Warranty, see your Bombardier Recreational Products (“BRP”) distributor/dealer authorized to distribute Evinrude products in the country in which the sale occurs. If further assistance is required, please contact BRP US Inc. / Outboard Engines Division, After Sales Sup- port, P.O Box 597, Sturtevant, WI 53177, or the affiliate of BRP where the Product was registered for war-...

• Page 77: California Emission Control Warranty Statement

  California Emission Control Warranty Statement Your Evinrude 4-Stroke outboard has a special environmental label required by the California Air Resources Board. The label has one, two, three, or four stars. A hangtag, provided with your outboard, describes the meaning of the star rating system.
• Page 78 BRP dealer. Manufacturer’s Limited Warranty Coverage This emission limited warranty covers Evinrude outboards certified and produced by BRP for sale in Cali- fornia, that are originally sold in California to a California resident, or subsequently warranty-registered to a California resident.

• Page 79: Product Warranty Information

  This warranty coverage is available only if each of the following conditions has been fulfilled: a. Evinrude outboard engines must be purchased as new and unused by its first owner from a BRP distribu- tor / dealer authorized to distribute Evinrude products in the country in which the sale occurred (hereinafter “Distributor / Dealer”),...
• Page 80 4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE Registered owner (“Owner”) must notify within 2 months an authorized Distributor / Dealer of the appear- ance of a defect. Owner must bring Product, including any defective part therein, to Distributor / Dealer promptly after the appearance of the defect, and in any event, within the warranty period, and must provide Distributor / Dealer with reasonable opportunity to repair the defect.
• Page 81 7. LIMITATIONS OF LIABILITY ALL WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS LIMITED WARRANTY. ALL INCIDENTAL, CONSEQUENTIAL, DIRECT, INDIRECT OR OTHER DAMAGES OF ANY KIND ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY INCLUDING, BUT NOT LIMITED TO: expense for gasoline, expense for transporting Product to and from Distributor / Dealer, removal of Prod- uct from a boat and reinstallation, mechanic’s travel time, in-and-out of water charges, slip or dock fees,...

• Page 82: Product Warranty Information

  Bombardier Recreational Products Inc. (“BRP”) warrants its Evinrude® outboard engines (“Product”) from defects in material or workmanship for the period and under the conditions described below, when they are sold by authorized Evinrude distributors / dealers and used, at any point during the warranty period, in the following territories: •...
• Page 83 This warranty coverage is available only if each of the following conditions has been fulfilled: a. The Evinrude outboard engines must be purchased as new and unused by its first owner from a BRP distributor / dealer authorized to distribute Evinrude products in the country in which the sale occurred (“Dis- tributor /Dealer”),...
• Page 84 6. WHAT TO DO TO OBTAIN WARRANTY COVERAGE Registered owner (“Owner”) must notify a servicing BRP authorized Distributor / Dealer within two (2) days of the appearance of a defect. Owner must bring Product, including any defective part therein, to the au- thorized BRP Distributor / Dealer promptly after the appearance of the defect, and in any event, within the warranty period, and must provide BRP Distributor / Dealer with reasonable opportunity to repair the defect.

• Page 85: Readiness Test

  Readiness Test The Operator’s Readiness Test..1. Did you read this Guide from front cover to rear cover? 2. Are you ready to take responsibility for the safe operation of your boat and out- board? 3. Do you understand all the safety precautions and instructions contained in this Guide? 4.

• Page 86: Frequently Asked Questions

  Your dealer can order the parts and accessories you desire. Do I need to complete any paperwork when I move or sell my Evinrude 4-Stroke outboard? Yes. In order to maintain contact with you or the new Evinrude 4-Stroke owner, BRP requests you complete the form outlining Change of Address / Change of Ownership.

• Page 88: Change Of Address / Change Of Ownership

  Change of Address / Change of Ownership If your address has changed or if there has been a change of ownership, be sure to fill out and mail the form provided on this page. This notification is necessary for your own safety even after expiration of the original warranty, since BRP will be in a position to contact you if correction to your outboard is required.

• Page 90: Confirmation Of Receipt

  I understand and agree to be bound with. I am also satis ed with the predelivery set-up and inspection of my Evinrude /Johnson outboard. I have also received a copy of the Operator’s Guide. Signature:...
• Page 92 003-16231-0 1112NB Printed in Japan...