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 . . . . . . . . . . . . . . 25
3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4 ENGINE COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . 81
5 ENGINE MANAGEMENT MODULE (EMM) . . . . . . . . . . 85
6 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . 117
8 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
9 OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
10 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
11 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
12 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
13 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
14 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
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 man-
ual is not a substitute for work experience. It is an
organized guide for reference, repair, and mainte-
nance of the outboard(s).
This manual uses the following signal words iden-
tifying 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 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 dam-
age the outboard.
DANGER
Indicates an imminently hazardous situa-
tion 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 ser-
vicing 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 specifica-
tions.
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 lev-
els 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 emis-
sions levels to exceed their predetermined factory
specifications.
Tampering with the fuel system to change horse-
power 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 con-
trol 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 75HP, 90HP E-TEC Outboards OEM Service & Repair Manual
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Description
2009 Evinrude 75HP, 90HP E-TEC Outboards OEM Service & Repair Manual
Models covered:
- E75DPLSEE
- E75DSLSEC
- E90DPLSEE
- E90DSLSEB
- E90DPXSEE
- E9OWDELSEC
- E90WDEXSEC
The 2009 Evinrude 75HP, 90HP E-TEC Outboards OEM Service & Repair Manual covers official factory service procedures for maintaining and repairing mid-range direct-injected two-stroke models. This manual includes support for all listed models in the E75 and E90 families, including long, short, and extra-long shaft variants. It’s the same manual used by certified Evinrude technicians, laid out clearly for practical, real-world use by mechanics and DIY owners alike.
Whether you’re keeping a commercial fishing boat running or dialing in a recreational setup, this manual delivers the core service data and test procedures needed to do the job right — from trim motor testing to full powerhead teardown.
What’s Inside the 2009 Evinrude 75HP, 90HP E-TEC Service Manual
Introduction
Includes model identification, serial number decoding, service documentation layout, and how to use the manual effectively for maintenance and repairs.
Special Tools
Factory-approved tool list for precision servicing and calibration. Includes adapters, pullers, and diagnostic interfaces required for E-TEC systems.
Installation and Predelivery
Step-by-step procedures for new unit installation, engine mounting, system connections, and final inspection prior to customer delivery.
Maintenance
Service intervals, lubrication charts, and routine maintenance guidelines — including oil changes, filter inspections, and cooling system flushes.
Engine Cover Service
Removal and inspection procedures for the cowl assembly and related fasteners, seals, and access covers.
Engine Management Module (EMM)
EMM diagnostics, fault code interpretation, firmware service steps, and related sensor testing. Includes service code chart for efficient troubleshooting.
System Analysis
General troubleshooting techniques and engine operation testing for identifying faults across ignition, fuel, and mechanical systems.
Electrical and Ignition
Coverage includes battery service, ignition timing checks, spark plug specs, and power supply diagnostics.
Fuel System
Servicing procedures for fuel pumps, vapor separators, fuel lines, and injectors — including testing and calibration steps.
Oiling System
Includes oil pump operation, line priming, oil tank service, and lubrication fault diagnostics.
Cooling System
Procedures for inspecting and replacing the water pump impeller, thermostat service, and coolant flow checks.
Powerhead
Full teardown and rebuild of the engine block, including crankcase service, piston inspection, and torque specs.
Midsection
Inspection and maintenance for the exhaust housing, steering pivot bracket, and corrosion-prone components.
Gearcase
Lower unit service, including oil replacement, bearing checks, shift rod adjustment, and prop shaft repairs.
Trim and Tilt
Hydraulic tilt motor diagnostics, fluid checks, trim sender calibration, and troubleshooting leaks or uneven lift.
Safety Information
Outlines safety procedures for engine handling, fuel system service, and rotating part precautions. Emphasizes proper shop protocol.
Trouble Check Chart
Quick reference diagnostic flowchart for common issues like hard starting, performance loss, or overheat conditions.
Wiring Diagrams & EMM Code Charts
Factory electrical schematics and EMM fault code lookups for advanced diagnostic troubleshooting (diagrams typically provided separately).
Why Choose the Evinrude E-TEC Service Manual?
If you’re working on a modern two-stroke E-TEC, this manual is as close as it gets to having a BRP technician looking over your shoulder. Every procedure follows factory workflow, with the specs and testing logic built right in. It’s perfect for professional outboard shops or owners looking to handle more than just the basics.
Built for those who appreciate correct torque values, proper test points, and avoiding costly mistakes when servicing a direct-injection motor.
Format & Compatibility
Provided as high-resolution, searchable repair manual software in PDF format. Compatible with Windows, macOS, Android, iOS, and Linux — ideal for use on laptops, tablets, or printed at the dock.
Download the Evinrude 75HP, 90HP E-TEC Manual Now
From midsection rebuilds to EMM diagnostics, this OEM service manual gives you factory-authorized guidance to keep your Evinrude running clean, smooth, and reliable.
Language: English
Compatibility: Windows, macOS, Linux, iOS, Android
Requirements: PDF Reader (e.g., Adobe Reader)
