2004 Johnson Evinrude 75HP, 90HP E-TEC Parts Catalog Manual
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™
75,90HP (1296cc)
E-TEC MODELS
E75DPLSRC
E90DPLSRC
E90DPXSRC
E90DSLSRS
75,90 E-TEC
ABOUT THIS CATALOG
Bombardier Motor Corporation of America reserves the right to make changes at any time, without
notice, to features, specifications, and model availability. The right is also reserved to change any speci-
fication or part, at any time, without incurring any obligation to update older models. The information in
this catalog is based on the latest specifications available at the time of publication.
Illustrations used in this catalog may not depict actual models or equipment, but are intended as repre-
sentative views for reference only. Certain features or equipment shown in this catalog might not be
found on all models in all marketing areas.
IMPORTANT: This catalog is a part reference. Refer to the appropriate Evinrude/Johnson Service Man-
ual for exact service and maintenance information.
The continuing accuracy of this catalog cannot be guaranteed.
FEATURES
Use exact engine model number, including suffix or prefix letter, when indentifying parts in this catalog.
WARNING
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.
For the latest service part number information visit
www.dealerport.com
EPC (Electronic Parts Catalogs) on the DealerPort™ website.
Indented part names indicate that
the parts are included in the preced-
ing assembly.
1 582365 LEAD Assy., Spark Plug
2 581027 *COVER & TERMINAL Ass y
3 510231 **TERMINAL, Spring
4 580339 *COVER & TERMINAL Ass y
5 510231 **TERMINAL, Spring
6 328701 LOCK WASHER, COIL & stop sw. grd
1
75,90 E-TEC
TABLE OF CONTENTS
DECALS-BLUE MODELS ...................................................................................................................................... 2
DECALS-WHITE MODELS ................................................................................................................................... 2
ENGINE COVER ................................................................................................................................................... 3
LOWER ENGINE COVER ..................................................................................................................................... 3
FUEL INJECTOR & IGNITION COIL ..................................................................................................................... 4
FUEL VAPOR SEPARATOR & PUMP .................................................................................................................. 4
FUEL LIFT PUMP .................................................................................................................................................. 5
OIL TANK & PUMP ................................................................................................................................................ 5
COOLING HOSES ................................................................................................................................................. 6
EMM, STATOR, & FLYWHEEL ............................................................................................................................. 6
THROTTLE BODY & INTAKE MANIFOLD ............................................................................................................ 7
THROTTLE & SHIFT LINKAGE ............................................................................................................................ 8
CYLINDER HEAD & THERMOSTAT .................................................................................................................... 9
CYLINDER/CRANKCASE ..................................................................................................................................... 9
CYLINDER/CRANKCASE FITTINGS & OIL RECIRCULATION HOSES ............................................................ 10
CYLINDER/CRANKCASE GASKET KIT ............................................................................................................. 10
CRANKSHAFT & PISTONS ................................................................................................................................ 11
STARTER & SOLENOID ..................................................................................................................................... 11
ENGINE ELECTRICAL HARNESS ................................................................................................................ 12-13
UPPER ENGINE MOUNTS ................................................................................................................................. 14
REMOTE STEERING LINK ................................................................................................................................. 14
EXHAUST ADAPTER & INNER HOUSING ........................................................................................................ 14
EXHAUST HOUSING .......................................................................................................................................... 15
TRIM & TILT RELAY ........................................................................................................................................... 15
STERN & SWIVEL BRACKET ........................................................................................................................ 16-17
GEARCASE - PL & SL MODELS ................................................................................................................... 18-19
GEARCASE - PX MODEL .............................................................................................................................. 20-21
TRIM & TILT HYDRAULIC ASSEMBLY .............................................................................................................. 22
TILLER UPGRADE SystemCheck™ HARNESS KIT .......................................................................................... 23
TILLER UPGRADE KIT .................................................................................................................................. 24-25
ALUMINUM PROPELLERS & HARDWARE PL & SL MODELS .......................................................................... 26
STAINLESS STEEL 3 BLADE PROPELLERS & HARDWARE PL & SL MODELS ............................................. 27
STAINLESS STEEL 4 BLADE PROPELLERS & HARDWARE PL & SL MODELS ............................................. 28
ALUMINUM PROPELLERS & HARDWARE PX MODEL..................................................................................... 29
STAINLESS STEEL 3 BLADE PROPELLERS & HARDWARE PX MODEL ........................................................ 30
STAINLESS STEEL 4 BLADE PROPELLERS & HARDWARE PX MODEL ........................................................ 31
QUICK REFERENCE - SERVICE PARTS & ACCESSORIES ............................................................................ 32
LITERATURE & SOFTWARE
PAINT
COLOR
NAME
SPRAY CAN
PPG #
1
1. ONE COAT FINISH FOR MIDSECTION & GEARCASE
PPG #
2
2. BASE COAT PLUS CLEARCOAT FOR UPPER & LOWER ENGINE
COVERS
PRIMER 771227 DP40401 –
BLACK
3
3. USED ON ENGINE CRANKCASE ASSEMBLY.
771234 9696 –
BLUE 771230 18319 18320
WHITE 771226 90538 –
CLEARCOAT 772414 – –
5005644 SERVICE MANUAL – ENGLISH
5005645 SERVICE MANUAL – FRENCH
777231 DIAGNOSTIC SOFTWARE - PC Version
777230 DIAGNOSTIC SOFTWARE - PDA Version
215408 OPERATOR’S GUIDE – ENGLISH
215409 OPERATOR’S GUIDE – FRENCH
215410 OPERATOR’S GUIDE – SPANISH
215411 OPERATOR’S GUIDE – PORTUGUESE
2
DECALS-BLUE MODELS
DECALS-WHITE MODELS
EPC3668
Ref P/N Name of Part Qty
1 215536 EVINRUDE - Front/Rear A 2
2 215331 LENS, BOMBARDIER logo A 2
3 215542 EVINRUDE E-TEC - Port A 1
4 215541 EVINRUDE E-TEC - Starboard A 1
5 215559 STRIPE, Port A 1
6 215560 STRIPE, Starboard A 1
7 215540 "90" HP Front/Rear 2
8 215539 "75" HP Front/Rear 2
9 215558 EVINRUDE "EU" 2006 1
10 334435 DECAL, Owner Attn, Air Silencer 1
A Included with
"ENGINE COVER Assy"
1
2
3
4
5
6
7 8
9
10
5
4
3
2
1
6
7
8
9
11
10
EPC3693
Ref P/N Name of Part Qty
1 215545 EVINRUDE - Front/Rear A 2
2 215331 LENS, "BOMBARDIER" logo A 2
3 215547 EVINRUDE E-TEC - Port A 1
4 215546 EVINRUDE E-TEC - Starboard A 1
5 215559 STRIPE, Port A 1
6 215560 STRIPE, Starboard A 1
7 215544 90 HP Front/Rear 2
8 351222 "SALTWATER EDITION" - Port 1
9 351237 "SALTWATER EDITION" - Starboard 1
10 215558 EVINRUDE "EU" 2006 1
11 334435 DECAL, Owner Attn, Air Silencer 1
A Included with
"ENGINE COVER Assy"
3
75,90 E-TEC
ENGINE COVER
LOWER ENGINE COVER
EPC3669
Ref P/N Name of Part Qty
1 285602 ENGINE COVER Assy - BLUE A 1
1 285606 ENGINE COVER Assy - WHITE A 1
2 350664 HOOK, Latch-Starboard 1
3 350665 HOOK, Latch-Port 1
4 350667 SEAL 1
5 350955 INSULATION, Sound 1
6 350966 BRACKET, Latch 2
7 351033 SCREW, Bracket 4
A
IMPORTANT:
When ordering
"ENGINE COVER Assy"
also order appropriate
"HP"
decals.
1
5
7
6
4
3
2
12
4
5
6
20
17
18
11
10
14
15
13
13
13
13
9
8
7
2
3
22
26
1
19
17
21
23,24,25
21
21
27
EPC3670
Ref P/N Name of Part Qty
1 5005365 LOWER COVER Assy, Port - BLUE
1
1 5005285 LOWER COVER Assy, Port - WHITE
1
2 330234 *WASHER, Spring 1
3 342191 *SCREW, Latch 1
4 350979 *INSULATION, Sound-Port 1
5 351029 *PLATE, Valve 1
6 5004576 *VALVE, Drain 1
7 5005290 *LATCH 1
8 5005291 *LATCH HANDLE 1
9 5005366 LOWER COVER Assy, Stbd - BLUE
1
9 5005286 LOWER COVER Assy, Stbd - WHITE
1
10 330234 *WASHER, Spring 1
11 342191 *SCREW, Latch 1
12 350980 *INSULATION, Sound-Starboard 1
13 351195 *INSERT, Nut 8
14 5005290 *LATCH 1
15 5005291 *LATCH HANDLE 1
17 332413 MOUNT, Lower cover 4
18 350500 GROMMET, Control cable 1
19 350771 GROMMET, Trim and tilt lead 1
20 350852 GROMMET, Steering arm 1
21 351152 SCREW, Port to Starboard cover 8
22 586789 SWITCH, Trim and tilt lower cover 1
23 3011148 *CONTACT, Tab 3
24 3011149 *SEAL, Wire 3
25 3011156 CONNECTOR, 3 Terminal 1
26 334656 NUT, Switch 1
27 351232 GROMMET 1
4
FUEL INJECTOR & IGNITION COIL
FUEL VAPOR SEPARATOR & PUMP
11
2,3,4
1
7
8
6
10
14
13
12
16
15
9
19
18
17
23
22
20
21
24
20
EPC3671
Ref P/N Name of Part Qty
1 5005340 FUEL INJECTOR Assy 3
2 3011156 *HOUSING, 3 pin terminal 1
3 3011148 *CONTACT, Tab 2
4 3011149 *SEAL, Lead 2
6 5005803 *INJECTOR SEAL KIT 1
7 350361 **RING, Crush 1
8 349291 **O-RING, Outer injector 1
9 349292 **O-RING, Inner injector 1
10 350779 **O-RING, Fuel rail 2
11 351125 INSULATOR, Fuel injector to cyl head 3
12 350775 BRACKET, Fuel rail to housing 3
13 315287 SCREW, Bracket to housing 3
14 3011292 ANCHOR, Electrical connector 3
15 350995 SCREW, Injector to cylinder head 6
16 328708 WASHER, Injector screw 6
17 586817 IGNITION COIL 3
18 3011149 *SEAL, Lead 1
19 3011148 *CONTACT, Tab 1
20 328703 WASHER, Ignition coil screw 12
21 328701 LOCK WASHER, Ignition coil screw 3
22 331025 SCREW, Ignition coil 6
23 5005783 HIGH TENSION LEAD Assy 3
24 3011345 RETAINER, High tension lead to hose 2
11
12
13 14
12
10
9
8
7
1
5 6
5
2
4
25
22
23
24
26
17
26
27
18
19
30
26
20
26
28
26
21
26
29
16
26
15
3
26
31
EPC3672
Ref P/N Name of Part Qty
1 5005177 FUEL VAPOR SEPARATOR/PUMP Assy 1
2 329518 *GROMMET , Vapor separator mount 1
3 510487 RING RETAINING, Stud 1
4 344848 STUD MOUNT, Vapor separator to C/C 1
5 317893 TIE STRAP, Vapor separator vent hose 2
6 348562 HOSE, Vapor separator to reed plate vent 1
7 5005348 FUEL RAIL Assy, Suppl y 1
8 350779 *O-RING, Fuel rail 3
9 5005347 FUEL RAIL Assy, Return 1
10 350779 *O-RING, Fuel rail 3
11 302325 SCREW, Vapor separator to C/C 2
12 328700 WASHER, Vapor separator to C/C 4
13 329518 GROMMET, Vapor separator to C/C 2
14 335328 SPACER, Vapor separator grommet 2
15 320107 TIE STRAP, Fuel rail 1
16 320107 TIE STRAP, Fuel pump pulse hose 1
17 350792 HOSE, Fuel pump to fuel filter 1
18 348561 HOSE, Fuel filter to vapor separator 1
19 772572 HOSE, Fuel pulse (
1/4in. - Bulk Roll 25 ft.) AR
(Qty 1) - length 4.0in.(101.6mm)
20 350998 HOSE, Oil tee to fuel pump 1
21 351226 HOSE, Fuel inlet to tee
22 5005266 FILTER, Fuel 1
23 351009 CLAMP, Fuel filter to C/C 1
24 312455 SCREW, Fuel filter clamp to C/C 1
25 907833 TIE STRAP, Fuel filter to clamp 1
26 346150 HOSE CLAMP, Tee to fuel Inlet (18.5mm) 2
26 346150 HOSE CLAMP, Filter (18.5mm) 2
26 346150 HOSE CLAMP, Pump to fitler (18.5mm) 2
26 346150 HOSE CLAMP, Inlet hose to tee (18.5mm) 2
27 346785 HOSE CLAMP, Pump pulse (14.5mm) 1
28 345701 FITTING. Oil check valve to fuel inlet tee 1
29 348939 CONNECTOR, Fuel inlet to hose 1
30 5005459 CONNECTOR, Hose to vapor separator 1
31 331649 CAP, Fuel connector storage 1
5
75,90 E-TEC
FUEL LIFT PUMP
OIL TANK & PUMP
Fuel Pump
Repair Kit
1
12
11
10
13
14
15
16
17
18
19
20
21
2
3
4
5
6
7
9
8
22
23
16
EPC3673
Ref P/N Name of Part Qty
1 5005462 FUEL LIFT PUMP Assy 1
2 330061 *SCREW, Inlet cap 1
3 335335 *CAP, Inlet 1
4 324660 *O-RING, Inlet screw A 1
5 319528 *O-RING, Cap A 1
6 312675 *SCREEN, Filter 1
7 329892 *SCREW, Housing 4
8 N/A *COVER, Fuel pump 1
9 N/A *GASKET, Cover A 1
10 N/A *HOUSING, Valve 1
11 305739 *O-RING, Outlet fitting 1
12 350971 *FITTING, Outlet 1
13 332678 *DIAPHRAGM A 1
14 N/A *GASKET, Diaphragm to outer hsg A 1
15 N/A *HOUSING & FITTING Assy 1
16 335334 *VALVE, Check A 2
17 312676 *NUT, Tee 1
18 315255 *SPRING, Diaphragm 1
19 304094 *SUPPORT, Diaphragm spring 1
20 N/A *SUPPORT, Air dome spring A 1
21 N/A *SPRING, Air dome 1
22 314417 SCREW, Pump to C/C 2
23 438616 REPAIR KIT, Fuel lift pump 1
A Included in "FUEL PUMP REPAIR KIT" P/N 438616
EPC3674
Ref P/N Name of Part Qty
1 5005804 OIL TANK & PUMP Assy 1
2 351416 *SEAL, Pump to tank 1
3 351159 *CLAMP, Pump to tank - 60.5mm 1
4 5005179 **OIL CAP Assy 1
5 351037 ***O-Ring 1
6 512937 *SLEEVE, Braided oil to manifold 3
7 350323 *SLEEVE, Braided oil to check valve 1
8 776892 *HOSE, Oil (.093in. - Bulk Roll 25 ft.) AR
(Qty 1) - length 23.0in. (584mm)
9 776892 *HOSE, Oil (.093in. - Bulk Roll 25 ft.) AR
(Qty 3) - length 20.0in. (508mm)
10 349898 *HOSE, Support 5
11 5001110 *VALVE, Oil check 1
12 349516 *CLAMP, Hose to check valve - (11.3mm) 1
13 772571 *HOSE, Oil (5/32in. - Bulk Roll 25 ft.) AR
(Qty 1) - length 3.0in. (76mm)
14 351412 *RETAINER, Oil hose 1
15 343245 *SCREW, Retainer 3
16 348838 CLAMP, Hose to fuel tee - (10.5mm) 1
17 341512 STUD, Oil tank to exhaust cover mount 1
18 338558 SPACER, Flanged 4
19 333040 GROMMET 4
20 328703 WASHER, Oil tank mount 4
21 313022 NUT, Upper oil tank mount 1
22 325115 SCREW, Oil tank/EMM mount 2
23 328725 SCREW, Oil tank to inj ector bracket 1
24 350990 BRACKET, Oil tank mount to inj ector 1
25 3011347 CLIP, Oil tank conn to fl ywheel cover 1
26 317893 TIE STRAP, Oil hose to manifold 3
27 351520 EMM Oil program tag, XD100 oil 1
28 351519 EMM Oil program tag, TCW3RL oils 1
19
18
21
22
20
24
20
19
18
23
1
17
10
26
9
3
11
12
7
9
9
6
2
13
26
16
25
8
5
4
14
15
*IMPORTANT*
Th
is outboard has
been programmed
for use of
Evi
n
rude/Johnson
XD100™ oil.
See your Dealer if
you decide to
discontinue using
Evinrude/Johnson
XD100 oil.
Refer to the
Operator’s Guide for
Oil Requirements.
P/N 351520
*IMPORTANT*
This outboard has
been programmed
for use of
Evinrude/Johnson
TCW3RL OIL
See your Dealer if
you decide to
discontinue using
Evinrude/Johnson
Refer to the
Operator’s Guide for
Oil Requirements.
P/N 351520
TCW3RL OIL
28 27
6
COOLING HOSES
EMM, STATOR, & FLYWHEEL
6
8
9
9
7
9
4
9
9
9
9
9
9
1
2
1
5
9
9
9
3
EPC3676
Ref P/N Name of Part Qty
1 338896 FITTING, Water hose tee 2
2 333390 HOSE, Tee to tee water exi t 1
3 350531 HOSE, C/C water to EMM 1
4 351265 HOSE, EMM water outlet to tee 1
5 351266 HOSE, Tee to separator water inlet 1
6 351267 HOSE, Separator water outlet to tee 1
7 351268 HOSE, Tee to water exit fitting 1
8 350819 FITTING, Water exit 1
9 320107 TIE STRAP 12
10
11
10
12
14
13
8
9
7
6
1
4
5
2
3
2
16
15
3
17,18,19
EPC3679
Ref P/N Name of Part Qty
1 586759 EMM Unprogrammed 1
2 333040 ISOLATOR, EMM to water cover 3
3 338558 SPACER, Isolator-EMM mounting 3
4 333710 SCREW, Lower-EMM to cover 1
5 328703 WASHER, EMM mounting 1
6 514022 PLUG, Spare fuse to fl ywheel cover 1
7 350992 SCREW, Stator to C/C 3
8 329267 NUT, Fl ywheel 1
9 586765 FLYWHEEL 1
10 315656 SCREW, Electrical components to cover 4
11 350854 COVER , Electrical components 1
12 350556 FLYWHEEL COVER 1
13 350973 GROMMET, Fl ywheel cover mounting 3
14 351002 SCREW, Fl ywheel cover mount 3
15 967545 FUSE, Spare 10 AMP 1
16 586766 STATOR Assy 1
17 3011148 *CONTACT, Tab 6
18 3011149 *SEAL , Lead 6
19 3011158 *CONNECTOR, 6 position 1
7
75,90 E-TEC
THROTTLE BODY & INTAKE MANIFOLD
19
41
18
17
23
32
20
16
40
39
36
37
35
34
33
21
9
14
13
8
6
1
25 24
26
27
22
28
38
30
29
2
15
31
3,4,5
7
10,11,12
EPC3677
Ref P/N Name of Part Qty
1 5005182 THROTTLE BODY Assy 1
2 586785 *SENSOR, Crankshaft position (CPS) 1
3 3011148 **CONTACT TAB 1
4 3011149 **SEAL WIRE 2
5 3011156 **CONNECTOR, 3 position 1
6 3010673 *SENSOR, Air temperature 1
7 310442 *CLAMP, TPS lead 1
8 350805 *GASKET, Air temperature sensor 1
9 350649 *POINTER, Timing 1
10 351752 *SPRING, Throttle return 1
11 328765 *CLIP, Throttle shaft 1
12 332226 *SCREW, Throttle shaft cli p 1
13 332226 *SCREW, Air temperature sensor 2
14 332226 *SCREW, Timing pointer 1
15 332226 *SCREW, CPS 1
16 350496 GASKET, Throttle body to reed plate 1
17 908045 SCREW, Throttle position sensor 2
18 586671 SENSOR, Throttle position (TPS) 1
19 5005188 THROTTLE LEVER 1
20 350970 THROTTLE LEVER BUSHING 1
21 310441 CLAMP, CPS lead 2
22 329110 SCREW, Throttle body/reed plate to C/C 14
23 350548 SEAL, Air silencer to throttle body 2
24 314021 BUMPER, Air silencer 3
25 5005183 AIR SILENCER Assy 1
26 340840 SEAL, Air silencer fastener 1
27 439922 FASTNER, Air silencer 1
28 328701 LOCK WASHER, Clamp 2
29 350657 RETAINER, Trunnion 1
30 328724 SCREW, Trunnion retainer 1
31 317893 TIE STRAP 1
32 309776 LOCK WASHER, TPS screw 2
33 397336 REED VALVE Assy 3
34 333677 SCREW, Reed valve to reed plate 6
35 350553 GASKET, Reed valve to C/C 3
36 5005282 REED PLATE Assy 1
37 348471 FITTING, Upper C/C vent to reed plate 1
38 349181 FITTING, Reed vent to vapor separator 1
39 351216 FITTING, Reed plate-idle air inlet 2
40 324334 SCREW, Reed plate to C/C 4
41 351708 TPS, Gasket 1
8
THROTTLE & SHIFT LINKAGE
32
34
33
31
30
28
27
26
24
25
14
23
22
21
18
36
35
14
17
15
16
20
19
14
1
2
3
4
7
5
6
10
9
8
11
12
13
37
EPC3681
Ref P/N Name of Part Qty
1 347338 SCREW, Throttle cam to C/C 1
2 127386 WASHER, Screw to throttle cam 1
3 5005186 THROTTLE CAM 1
4 908398 WASHER, Screw throttle cam to C/C 1
5 5005626 THROTTLE LINK, Lever to T-shaft lever 1
6 334153 *SHELL, Throttle cam link 1
7 347338 SCREW, Throttle lever to C/C 1
8 127386 WASHER, Screw to T-lever 1
9 324678 O-RING , Roller & Sleeve 1
10 432639 ROLLER & SLEEVE Assy, Cam follower 1
11 5005187 THROTTLE LEVER 1
12 908398 WASHER, Screw-lever & pin to C/C 1
13 350908 SPRING , Throttle lever return 1
14 333774 CLIP, Pin-throttle cable to throttle cam 1
14 333774 CLIP, Pin-link-shift lever to shift arm 2
14 333774 CLIP, Pin-shift cable to shift lever 1
15 350895 SCREW, Shift arm to C/C 1
16 553766 SPRING WASHER, Screw to shift lever C/C 1
17 5005230 LEVER, Shift 1
18 331224 LINK, Shift lever to shift arm 1
19 202026 WASHER , Shift rod lever to C/C 3
20 315081 BUSHING , Shift lever 1
21 332226 SCREW, Safety switch bracket to C/C 2
22 350611 BRACKET, Safety switch 1
23 328724 SCREW, Detent to shift lever 2
24 5005238 SHIFT LEVER & SHAFT, Crankcase 1
25 340955 DETENT SHIFT LEVER 1
26 315164 BALL , Shift detent 1
27 334241 GUIDE, Shift detent ball 1
28 334338 SPRING , Shift detent 1
30 312708 BUSHING, Shift shaft lever 2
31 350592 LEVER , Shift rod 1
32 328695 SCREW , Shift rod lever 1
33 302290 LOCK WASHER, Pin-shift lever to shift rod 1
34 327590 PIN, Shift lever to shift rod 1
35 586780 SWITCH, Neutral start safety 1
36 334192 SCREW, Switch to bracket 2
37 303851 WASHER, Screw-safety switch to bracket 2
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Full Search Facility
Print one or all pages of your manual
$27.99
$36.99
This manual provides comprehensive information for performing procedures correctly, catering to both first-time owners and professional technicians. Regular reference to this service manual is essential for conducting routine and preventive maintenance, ultimately saving time and money by preventing premature failure and unnecessary repairs.
- Models Covered:
- E75DPLSRC
- E90DPLSRC
- E90DPXSRC
- E90DSLSRS
Manual Contents:
- Decals
- Motor Cover
- Recoil Starter Assembly
- Ignition
- Electrical
- Carburetor
- Piston & Crankshaft
- Cylinder & Crankcase
- Stern & Swivel Bracket
- Midsection
- Gearcase
- Exhaust Housing
- Rewind Starter
- Fuel Tank
File Format: PDF
Compatibility: All Versions of Windows & Mac
Language: English
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