2009 Evinrude E-Tec 115-200HP V4/V6 Outboards Service & Repair Manual

Printed in the United States. © 2008 BRP US Inc. All rights reserved. TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates. BRP US Inc. Technical Publications 250 Sea Horse Drive Waukegan, Illinois 60085 United States † AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II are registered trademarks of Tyco International, Ltd. † Amphenol is a registered trademark of The Amphenol Corporation. † Champion is a registered trademark of Federal-Mogul Corporation. † Deutsch is a registered trademark of The Deutsch Company. † Dexron is a registered trademark of The General Motors Corporation. † Fluke is a registered trademark of The Fluke Corporation † GE is a registered trademark of The General Electric Company. † GM is a registered trademark of The General Motors Corporation. † Locquic and Loctite are registered trademarks of The Henkel Group. † Lubriplate is a registered trademark of Fiske Brothers Refining Company. † NMEA is a registered trademark of the National Marine Electronics Association. † Oetiker is a registered trademark of Hans Oetiker AG Maschinen. † Packard is a registered trademark of Delphi Automotive Systems. † Permatex is a registered trademark of Permatex. † STP is a registered trademark of STP Products Company. † Snap-on is a registered trademark of Snap-on Technologies, Inc. The following trademarks are the property of BRP US Inc. or its affiliates: Evinrude ® Nut Lock™ Johnson ® Screw Lock™ Evinrude ® E-TEC ® Ultra Lock™ FasTrak™ Gel-Seal II™ S.A.F.E.™ Moly Lube™ SystemCheck™ Triple-Guard ® Grease I-Command™ DPL™ Lubricant Evinrude ® / Johnson ® XD30™ Outboard Oil 2+4 ® Fuel Conditioner Evinrude ® / Johnson ® XD50™ Outboard Oil Carbon Guard™ Evinrude ® / Johnson ® XD100™ Outboard Oil HPF XR™ Gearcase Lubricant Twist Grip™

2 T ABLE OF CONTENTS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2 INSTALLATION AND PREDELIVERY . . . . . . . . . . . . . . 27 3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 4 ENGINE COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . 89 5 ENGINE MANAGEMENT MODULE (EMM) . . . . . . . . . . 93 6 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 7 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . 127 8 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 9 OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 10 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 11 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 12 -MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 13 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 GEARCASE – STANDARD ROTATION . . . . . . . . . . . . 311 GEARCASE – COUNTER ROTATION . . . . . . . . . . . . . 342 14 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–1 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I–1 TROUBLE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . T–1 DIAGRAMS EMM SERVICE CODE CHART

INTRODUCTION 3 INTRODUCTION CONTENTS ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ENGINE EMISSIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 MANUFACTURER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DEALER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 OWNER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 EPA EMISSION REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 IDENTIFYING MODEL AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SAFETY INFORMATION Before working on any part of the outboard, read the SAFETY section at the end of this manual. This manual is written for qualified, factory-trained technicians who are already familiar with the use of Evinrude ® /Johnson ® Special Tools. This manual is not a substitute for work experience. It is an organized guide for reference, repair, and maintenance of the outboard(s). This manual uses the following signal words identifying important safety messages. IMPORTANT: Identifies information that will help prevent damage to machinery and appears next to information that controls correct assembly and operation of the product. These safety notices mean: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so to protect your- self, as well as the people around you. It is understood that this manual may be trans- lated into other languages. In the event of any dis- crepancy, the English version shall prevail. To reduce the risk of personal injury, safety warn- ings are provided at appropriate times throughout the manual. DO NOT make any repairs until you have read the instructions and checked the pictures relating to the repairs. Be careful, and never rush or guess a service procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alco- hol use, to name a few. Damage to a boat and outboard can be fixed in a short period of time, but injury or death has a lasting effect. When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Using substandard parts could result in injury or product malfunction. Torque wrench tightening specifications must be strictly followed. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts. If you use procedures or service tools that are not recommended in this manual, YOU ALONE must decide if your actions might injure people or damage the outboard. DANGER Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING Indicates a potentially hazardous situation which, if not avoided, CAN result in severe injury or death. CAUTION Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate personal injury or property damage. It also may be used to alert against unsafe practices.

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. Remove propeller before servicing and when running the outboard on a flushing device. DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death. WARNING Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa). The motor cover and flywheel cover are machinery guards. Use caution when conducting tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and clothing away from rotating parts. During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service. To prevent accidental starting while servicing, disconnect the battery cables at the battery. Twist and remove all spark plug leads. The electrical system presents a serious shock hazard. DO NOT handle primary or secondary ignition components while outboard is running or flywheel is turning. Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system. Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling. Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and causing an explosion. Always work in a well ventilated area. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to tightening must be felt when reusing a locking fastener. If replacement is indicated, use only authorized replacement or equivalent.

6 INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Units of Measurement List of Abbreviations A Amperes amp-hr Ampere hour fl. oz. fluid ounce ft. lbs. foot pounds HP horsepower in. inch in. Hg inches of mercury in. lbs. inch pounds kPa kilopascals ml milliliter mm millimeter N·m Newton meter P/N part number psi pounds per square inch RPM revolutions per minute °C degrees Celsius °F degrees Fahrenheit ms milliseconds μs microseconds Ω Ohms V Volts VAC Volts Alternating Current VDC Volts Direct Current ABYC American Boat & Yacht Council ATDC after top dead center AT air temperature sensor BPS barometric pressure sensor BTDC before top dead center CCA cold cranking amps CPS crankshaft position sensor EMM Engine Management Module ICOMIA International Council of Marine Industry Associations MCA marine cranking amps MWS modular wiring system NMEA National Marine Electronics Assoc. NTC negative temperature coefficient PTC positive temperature coefficient ROM read only memory S.A.F.E.™ speed adjusting failsafe electronics SAC start assist circuit SAE Society of Automotive Engineers SYNC synchronization TDC top dead center TPS throttle position sensor WOT wide open throttle WTS water temperature sensor

7 INTRODUCTION ENGINE EMISSIONS INFORMATION ENGINE EMISSIONS INFORMATION Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine SI (spark ignition) engine repair establishment or individual. Manufacturer’s Responsibility Beginning with 1999 model year outboards, man- ufacturers of marine outboards must determine the exhaust emission levels for each outboard horsepower family and certify these outboards with the United States of America Environmental Protection Agency (EPA). An emissions control information label, showing emission levels and outboard specifications, must be placed on each outboard at the time of manufacture. Dealer’s Responsibility When performing service on all 1999 and more recent Evinrude/Johnson outboards that carry an emissions control information label, adjustments must be kept within published factory specifications. Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed certification standards. Dealers are not to modify the outboard in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications. Exceptions include manufacturer’s prescribed changes, such as altitude adjustments, for exam- ple. Owner’s Responsibility The owner/operator is required to have outboard maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to, and should not allow anyone to, modify the outboard in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. Tampering with the fuel system to change horsepower or modify emission levels beyond factory settings or specifications will void the product war- ranty. EPA Emission Regulations All new 1999 and more recent Evinrude/Johnson outboards are certified to the EPA as conforming to the requirements of the regulations for the control of air pollution from new watercraft marine spark ignition outboards. This certification is con- tingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, whenever practical, returned to the original intent of the design. The responsibilities listed above are general and in no way a complete list- ing of the rules and regulations pertaining to the EPA requirements on exhaust emissions for marine products. For more detailed information on this subject, you may contact the following loca- tions: VIA U.S. POSTAL SERVICE: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 401 M St. NW Washington, DC 20460 VIA EXPRESS or COURIER MAIL: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 501 3rd St. NW Washington, DC 20001 EPA INTERNET WEB SITE: www.epa.gov

8 INTRODUCTION MODEL DESIGNATION MODEL DESIGNATION B E 200 DP X SE A PREFIX STYLE: J = Johnson E = Evinrude HORSEPOWER LENGTH: = 15” Std. L = 20” Long Y = 22.5” Special X = 25” X-long Z = 30” XX-long MODEL YR: I = 1 N = 2 T = 3 R = 4 O = 5 D = 6 U = 7 C = 8 E = 9 S = 0 Ex: SE = 2009 MODEL RUN or SUFFIX DESIGN FEATURES: AP = Advanced Propulsion B = Blue Paint C = Counter Rotation D = Evinrude E-TEC™ E = Electric Start w/Remote Steering F = Direct-Injection G = Graphite Paint H = High Output J = Jet Drive M = Military P = Power Trim and Tilt R = Rope Start w/Tiller Steering S = Saltwater Edition T = Tiller Steering TE = Tiller Electric V = White Paint W = Commercial Model

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2009 Evinrude E-Tec 115-200HP V4/V6 Outboards Service & Repair Manual

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