2007 Evinrude E-TEC Repair Manual 115 to 200 HP

Printed in the United States. © 2006 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 † Frahm is a registered trademark of James G. Biddle Co. † Gasoila is a registered trademark of The Federal Process 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. † NGK is a registered trademark of NGK Spark Plugs (U.S.A.) Inc. † 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. † Plastigage is a registered trademark of The Dana Corporation. † STP is a registered trademark of STP Products Company. † Snap-on is a registered trademark of Snap-on Technologies, Inc. † ThreeBond is a registered trademark of Three Bond Co., Ltd. Bombardier logo is a registered trademark of Bombardier, Inc., used under license. The following trademarks are the property of BRP US Inc. or its affiliates: Carbon Guard™ Nut Lock™ DPL™ Lubricant QuikStart™ Evinrude ® S.A.F.E.™ Evinrude ® E-TEC ® S.L.O.W.™ Evinrude ® / Johnson ® XD30™ Outboard Oil Screw Lock™ Evinrude ® / Johnson ® XD50™ Outboard Oil SystemCheck™ Evinrude ® / Johnson ® XD100™ Outboard Oil Triple-Guard ® Grease FasTrak™ Twist-Grip™ Gel-Seal II™ 2+4 ® Fuel Conditioner Hi-Vis™ Gearcase Lubricant Ultra™ 4-Stroke Outboard Oil I-Command™ HPF XR™ Gearcase Lubricant Johnson ® Ultra Lock™ Moly Lube™

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 alert signal words 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 pro- cedure. 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.

4 T ABLE OF CONTENTS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 SERVICE SPECIFICATIONS AND SPECIAL TOOLS . . 17 2 INSTALLATION AND PREDELIVERY . . . . . . . . . . . . . . 33 3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 4 ENGINE MANAGEMENT MODULE (EMM) . . . . . . . . . . 95 5 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 6 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . 135 7 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 8 OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 9 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 10 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 11 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 12 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 13 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–1 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index–1 TROUBLE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . T–1 DIAGRAMS EMM SERVICE CODE CHART

INTRODUCTION 5 INTRODUCTION CONTENTS MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 IDENTIFYING MODEL AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TYPICAL PAGE – A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TYPICAL PAGE – B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 TYPICAL PAGE – C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TYPICAL PAGE – D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ENGINE EMISSIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 MANUFACTURER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 DEALER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 OWNER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 EPA EMISSION REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6 INTRODUCTION MODELS COVERED IN THIS MANUAL MODELS COVERED IN THIS MANUAL This manual covers service information on all 60° Evinrude E-TEC ® models. Identifying Model and Serial Numbers Outboard model and serial numbers are located on the swivel bracket and on the powerhead. Model Number Shaft Paint HP E115DPLSUC 20” BL 115 E115DPXSUC 25” WH 115 E115DBXSUC 25” BL 115 E115DSLSUC 20” WH 115 E150DPLSUC 20” BL 150 E150DPLSUF 20” BL 150 E150DPXSUC 25” WH 150 E150DPXSUF 25” WH 150 E150DBXSUF 25” BL 150 E150DSLSUC 20” WH 150 E150DSLSUF 20” WH 150 E150DHLSUC 20” BL 150 E150DHLSUF 20” BL 150 E150DCXSUC 25” WH 150 E150DCXSUF 25” WH 150 E175DPLSUF 20” BL 175 E175DPXSUF 25” WH 175 E175DSLSUF 20” WH 175 E175DCXSUF 25” WH 175 E200DPLSUR 20” BL 200 E200DPLSUF 20” BL 200 E200DPXSUR 25” WH 200 E200DPXSUF 25” WH 200 E200DSLSUR 20” WH 200 E200DSLSUF 20” WH 200 E200DCXSUR 25” WH 200 E200DCXSUF 25” WH 200 Swivel Bracket 1. Model and serial number 005231 1. Serial number 005232 1 1

7 INTRODUCTION MODEL DESIGNATION MODEL DESIGNATION B E 200 DP X SU F 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: SU = 2007 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

8 INTRODUCTION TYPICAL PAGE – A TYPICAL PAGE – A Page Number Bold letter indicates liquid product to be applied to a surface Pay attention to torque specifications. Some units appear as in. lbs. Use appropriate torque. Tightening torque for a fastener. Subsection title indicates beginning of the subsection. Italic subheading above Service Chart indicates pertaining models. Indicates list corresponding to applicable letter in exploded view of the Service Chart. Exploded view of Service Chart assists in identifying parts and positions

2007 Evinrude E-TEC Repair Manual 115 to 200 HP

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