Routine Service

Routine Service
Table of Contents
2
Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oetiker Clamp Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oetiker Clamp Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Gearcase Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fuel and Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Exhaust Pressure Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Anti-corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pre-Season Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Lifting The Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Rigging Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Filling and Bleeding the Hydraulic Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Hydraulic Steering Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Single Station / Single Engine Steering Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Single Station / Multiple Engine Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Steering System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Before Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Engine Mounting Height and Jack Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Fuel System Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Engine Water Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Trim & Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Tilt Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Trim Gauge Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
i-Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Dynamic Power Steering (DPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Multiple-Outboard Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Submerged Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

15
Routine Service
Inspection and Maintenance Schedule

Inspection and Maintenance Schedule

Routine inspection and maintenance is necessary to prolong outboard life. The following chart provides
guidelines for inspection and maintenance to be performed by an authorized Dealer.
IMPORTANT: Outboards used in rental, commercial, or other high hour applications require more fre-
quent inspections and maintenance. Adjust schedule for operating and environmental conditions.

Every 500 hours or every 5 years(1)

Routine Inspection
Description of Service Engine Care Product
Anodes (anti–corrosion), check condition  
Back pressure probe, replace 
Batteries, check connections and condition  
Cooling system; check water pump indicator / water pressure  
Displays & gauges, self-test/warning horn, check operation  
Emergency cut–off switch(es) and tether cord, check operation  
Engine to transom mounting hardware, re-tighten (40 ft. lbs.) 
Fuel and oil systems, inspect and repair leaks (2)  
Fuel filters, replace 
Gearcase and water inlet screens, check condition  
Gearcase lubricant, inspect level A 
Gearcase lubricant, replace A 
Grease fittings, lubricate (3) C 
Oil filter, replace 
Power trim and tilt system, check operation B 
Propeller, check condition  
Propeller shaft splines, inspect and lubricate (3) C 
Remote control system and switches (START/STOP, Trim etc.) check operation
Service codes, access EMM information, resolve any service codes 
Spark plugs, replace (2) 
Steering system, inspect fluid level, check hydraulic hose condition, check operation D 
Thermostats, inspect and check operation (2) 
Water pump, replace (more frequent if water pressure loss or overheating occurs) 

(1) Commercial use, heavy use, or use in salt or polluted water requires more frequent inspection and maintenance.
(2) Emission-related component
(3) Annually in salt water applications

Engine Care Products

The engine care products listed in the table below are referenced in this service manual, and are recom-
mended for use with Evinrude E-TEC G2 outboards.
A HPF Pro Gearcase Lubricant D Hydraulic Fluid, P/N 770891.
B Power Trim/Tilt and RAVE Fluid, P/N 767969 Anti-Corrosion Spray
C Triple-Guard Grease “6 in 1” Multi-Purpose Lubricant

16
 Routine Service
Maintenance

Maintenance Check battery connections frequently. Periodically

remove battery to clean and service connections.
Batteries • Confirm that battery meets the minimum engine
requirements.
 WARNING • Connections must be clean and tight.
Battery electrolyte is acidic—handle with
care. If electrolyte contacts any part of the
• Observe all wiring connections prior to disas-
sembly.
2
body, immediately flush with water and seek Disconnecting the Battery
medical attention.
Disconnect battery negative (–) cable first and the
Each outboard requires its own starting battery. battery positive (+) cable last.
Select a battery that meets or exceeds the mini-
Clean all terminals, battery posts, and connectors
mum requirements.
with a solution of baking soda and water. Use a
wire brush or battery terminal tool to remove cor-
Battery Recommendations
rosion buildup. Rinse and clean all surfaces.
Outboard Battery Rating
Connecting the Battery
Model
200–300 HP 675 CCA (845 MCA), or NOTICE
800 CCA (1000 MCA) below Do not use wing nuts to fasten ANY battery
32°F (0°C) 107 amp-hr in extreme cables. Wing nuts can loosen and cause elec-
applications trical system damage not covered under war-
ranty.
Battery Location
IMPORTANT: Connect the battery positive (+)
Proper installation will prevent battery movement cable to the battery positive (+) post FIRST. Con-
while underway. nect the battery negative (–) cable to the battery
• Secure all batteries in protected locations negative (–) post LAST.
• Place battery as close to the outboard as possi-
ble Install a starwasher on the threaded battery post.
• Battery location must provide access for peri- Stack cables from the outboard, then cables from
odic maintenance accessories. Finish this connection with a hex nut.
• Use battery mounting trays or battery boxes on
all battery installations
• Connections and terminals must be covered
with an insulator
• Battery connections must be clean and free
from corrosion
• Read and understand the safety information 3
supplied with the battery before installation.

Battery Connections 1 2
 WARNING
Keep the battery connections clean, tight, and
insulated to prevent their shorting or arcing Marine Style Battery Post 009166
1. Starwasher
and causing an explosion. If the battery 2. Hex nut
mounting system does not cover the connec- 3. Terminal Insulator
tions, install protective covers. Check often to
see that connections stay clean and tight.

17
Routine Service
Maintenance

Tighten all connections securely. Apply Triple- Clamp Installation

Guard grease to prevent corrosion. A constant stress should be applied to close the
ear clamps. This method ensures a positive stress
Oetiker Clamp Servicing on the hose and does not result in excessive com-
pression or expansion of the band material.
 WARNING IMPORTANT: Use only Oetiker recommended
DO NOT re-use Oetiker clamps. Fuel leakage tools to close Oetiker stepless clamps.
could contribute to a fire or explosion.
Oetiker pincers are available in the Evinrude Gen-
uine Parts and Accessories Catalog.
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.
The clamp identification numbers appear on the
side of the clamp, near the top of the ear. Refer to
Oetiker Clamp Chart on p. 20 chart for clamp
DP0886
dimensions.
• Position correct size clamp over hose.
• Install hose on fitting.
1 Larger size Oetiker clamps may come apart
during handling. To reassemble the clamp, con-
nect the end loop to the end hook. Make sure the
alignment tab is installed into the alignment slot.

3
4
4
3 1
1. Clamp identification numbers 000093 5
2
Clamp Selection
To select the correct size Oetiker clamp, measure
the outside diameter of the hose when installed on
the fitting.
1. End loop 009095
Chose a clamp so that the outside diameter of the 2. End hook
hose is approximately in the middle of the clamp- 3. Alignment tab
4. Alignment slot
ing range of the clamp. 5. Correctly assembled clamp

Refer to Oetiker Clamp Chart on p. 20.

• Close clamp ear fully with Oetiker pincers (pli-
ers).

18
 Routine Service
Maintenance

1. Open clamp 000092

2. Closed clamp

Clamp Removal
Method 1: Position Oetiker pincers across clamp
ear and cut clamp.

000108

Method 2: Lift end of stepless clamp with screw-

driver.

000090

Use Oetiker pincers (pliers) to grip clamp. Pull

clamp off of connection and discard.

19
20
Oetiker Clamp Chart Maintenance

I.D. P/N Clamping Range

Routine Service

560 356360
515 357516
455 358005
440 352110
410 349729
346 351685
331 352335
316 349759
301 346153
256 346152
241 352703
226 353516
210 346151
185 346150
170 348839
157 346786
145 346785
140 346931
138 347108
133 347107
113 349516
105 348838
95 346930
Hose 0 mm 5 10 15 20 25 30 35 40 45 50 55 60
Diameter 0 in. 1/8 1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 1-3/4 2 2-1/4

Extra–Large Clamps
I.D. P/N Clamping Range
995 356019 96.3 to 99.5 mm (3.79 to 3.92 in.)
695 352868 66.3 to 69.5 mm (2.61 to 2.73 in.)
605 351159 57.3 to 60.5 mm (2.25 to 2.38 in.)
 Routine Service
Maintenance

Cooling System Flushing — Outboard Running

Check the condition of cooling system compo-  WARNING

nents regularly: To prevent injury from contact with rotating
• water intake screens propeller, remove the propeller before flush-
• water pump
• all internal water passages
ing. 2
• thermostats Place outboard in VERTICAL (DOWN) position in
• all external water hoses and fittings a well ventilated area.
• vapor separator cooling passages and fittings
• EMM cooling passages and fittings Thread garden hose into flushing port.
• overboard water pressure indicator.

Water Intake Screens

Inspect condition of water intake screens. Clean
or replace as needed.

Confirm function of overboard water pressure indi-

cator.

009071

Turn water supply on.

1
1 Run outboard at IDLE only until full operating tem-
perature is reached.

Leave the outboard in VERTICAL (DOWN) posi-

tion long enough for the powerhead to drain com-
1. Water intake screens 009041 pletely.

Engine Flushing Reinstall propeller.

Flush the outboard with fresh water following each Flushing — Outboard Not Running
use in brackish, salt, or polluted water to minimize Outboard can be in VERTICAL (DOWN) or
the accumulation of scale and silt deposits in cool- TILTED (UP) position.
ing system passages.
Thread garden hose into flushing port.
The outboard can be flushed on the trailer or at
dockside; running or not running. Turn water supply ON.

IMPORTANT: The outboard must be located in a Flush outboard for at least five minutes.
well ventilated area with appropriate ground drain-
age during the flushing procedures. Turn off water supply and remove garden hose.

Keep water inlet pressure between 20 to 40 psi Leave the outboard in VERTICAL (DOWN) posi-
(140 to 275 kPa). tion long enough for the powerhead to drain com-
pletely.

21
Routine Service
Maintenance

Propeller Shaft • Lubricant level should be between the marks as

shown.
Debris from the water can become lodged around
propeller shaft. Frequent inspection can minimize
potential gearcase damage.
 WARNING
When servicing the propeller, always shift the
outboard to NEUTRAL position, turn the key
switch OFF and remove the key, so the out- 1
board cannot be started accidentally.
1.5 in.
(38 mm) { 2
Remove propeller. Refer to Propeller Hardware
Installation on p. 292.
Lubricant Level 009141
1. Maximum
Inspect bushing and blade surfaces. Replace 2. Minimum
damaged or worn propellers.
If lubricant level is low, refer to Gearcase Leak
Clean propeller shaft. Inspect propeller shaft Test on p. 293.
seals. Replace damaged or worn seals.
Draining
Apply Triple-Guard grease to entire length of pro-
peller shaft prior to installing propeller.  CAUTION
Reinstall propeller hardware and propeller. Gearcase lubricant may be under pressure
and/or hot if outboard was recently operated
or if gearcase lubricant is above the Maxi-
Gearcase Lubricant mum level.
Refer to the Inspection and Maintenance Wear safety glasses and take precautions to
Schedule on p. 16 for service frequency. avoid injury when removing vent hose from
reservoir upper fitting.
Lubricant Level
Carefully remove vent hose from the reservoir
Remove the starboard side panel.
upper fitting.
IMPORTANT: ALWAYS check the fill level of the
gearcase lubricant at the oil reservoir before re-
moving the drain/fill plug.
1

1
1. Vent hose upper fitting 009141

1. Lubricant reservoir 009140

22
 Routine Service
Maintenance

Remove the low water intake screens. Then IMPORTANT: The recommended gear lubricant
remove the lubricant drain/fill plug. Drain the lubri- is formulated for marine applications. Do not use
cant from the gearcase into a suitable container. automotive gear lubricants, engine oils, or any oth-
er oil or grease.

Secure the gearcase in a vertical position.

2

1
1

1. Lubricant drain/fill plug 009165

Trim the engine up slightly to completely drain

lubricant from the gearcase. 1. Vent hose upper fitting 009141

Use Gearcase Filler, P/N 501882, to slowly fill the

Inspection gearcase with HPF PRO lubricant until lubricant
Inspect the lubricant for metal chips. The pres- level in the reservoir is between the marks as
ence of metal fuzz can indicate normal wear of shown in Lubricant Level on p. 22.
the gears, bearings, or shafts within the gearcase.
Metal chips can indicate extensive internal dam- IMPORTANT: Filling the gearcase too quickly
age. can cause air pockets and the gearcase may not fill
completely.
Inspect the lubricant for water contamination.
Water can make the lubricant milky in appear- Clean plug seal area and install the lubricant
ance. However, normal aeration can also cause drain/fill plug and a new seal. Tighten the plug to a
the same appearance. torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

To check for water contamination, put lubricant Install the water screens. Tighten the screw to a
into a clear container. Allow the oil to settle for a torque of 10 to 14 in. lbs. (1.2 to 1.6 N·m).
minimum of one hour to determine if there is an
abnormal amount of water in the oil.

If water is present, refer to Gearcase Leak Test

on p. 293.

Overheated lubricant will have a black color and

burned odor. 1

Internal gearcase inspection is recommended

when lubricant is contaminated or shows signs of
failure.
1. Lubricant drain/fill plug 009165

Filling
Refer to Service Specifications on p. 11 for lubri-
cant capacities.

23
Routine Service
Maintenance

Install the vent hose on the reservoir upper fitting. Move the ignition coil and bracket assemblies to
the side as shown.

1. Vent hose upper fitting 009141

1. 00
Install the starboard side panel.
Remove the spark plug leads from the spark
Spark Plugs plugs.

Spark plugs should be removed and examined Use the spark plug socket and a combination
periodically. Replace worn, fouled or damaged wrench to remove the spark plugs.
spark plugs.
Installation
Use only recommended spark plugs with the cor-
The cylinder heads of Evinrude E-TEC G2 models
rect gap setting.
are manufactured with indexed spark plug
Spark Plug, Champion threads. Q C 8 W E P I s p a r k p l u g s do NOT
Q C 8 W E P I @ 0.028 ± 0.003 in. (0.76 mm) require indexing of the spark plug.

Set spark plug gap on new, replacement spark

Removal
plugs.
Remove the engine cover panels. Remove spark
plugs and inspect condition. Apply Triple-Guard grease to the gasket surface
of the spark plug.
Starboard Spark Plugs
Remove the spark plug leads from the spark Use a spark plug socket to install spark plug hand
plugs. tight. Make sure the gasket of the spark plug is
contacting the cylinder head.
Use a spark plug socket, extension and wrench to
remove the spark plugs. Install a wrench on the spark plug socket and con-
tinue to tighten a new spark plug approximately
Port Spark Plugs 180 degrees, or a re-used spark plug approxi-
Remove the spark plug leads from the ignition mately 45 degrees.
coils.
Apply Electrical Grease to the ribbed portion of
Use an 8 mm socket to remove the screw and the spark plug ceramic and to the opening of the
washer from the ignition coil mounting brackets. spark plug cover to prevent corrosion.
Install the spark plug leads onto the spark plugs.

Additional Steps for Port Spark Plugs

Clean all old Ultra Lock from the threads of the
coil mounting bracket screws.

24
 Routine Service
Maintenance

Starting with the bottom, move the ignition coil and Oil Filters and Oil Reservoir
brackets into place. Make sure the spark plug lead Perform visual inspections to identify oiling system
is accessible. leaks. Make certain the oil tank is filled and oil
supply is not contaminated.
Apply Ultra Lock to the threads of the coil mount-
ing bracket screw. A serviceable oil filter is located in the oil supply
line between the on-engine oil tank and rear oil
2
Install the washer and screw. Tighten the screw to
pump.
a torque of 84 to 106 in. lbs. (9.5 to 12 N·m).

Apply Electrical Grease to the ignition coil cover.

Install the spark plug lead onto the ignition coil.

Repeat the previous steps to install the middle

and then the upper ignition coil and bracket
assemblies.
1
Install the port and starboard engine cover panels.

Fuel and Oil Systems

1. Inline oil filter 009238
 WARNING
Failure to check for fuel leakage could allow a Hoses and Connections
leak to go undetected, resulting in fire or Check condition of all hoses and connections in
explosion. both the fuel and oil systems:
Routine replacement of filters reduces the possi- • Visually inspect all components.
bility of foreign material restricting the incoming • Observe all clamps, hoses, and connections
fuel or oil supplies. while outboard is running.
• Replace all damaged components.
Replacement filter elements are available through • Repair all leaks.
Evinrude Genuine Parts.
Exhaust Pressure Fitting
Fuel Filter
Evinrude E-TEC G2 model outboards are The exhaust pressure fitting is threaded into the
equipped with inline fuel filter and a water-sens- adapter housing and protrudes into the exhaust
ing, water-separating fuel filter. Refer to Fuel adapter.
Component Servicing on p. 170.

1
1

2
1. Exhaust pressure fitting 005026

1. Inline fuel filter 009186

2. Water-separating fuel filter

25
Routine Service
Maintenance

A hose is routed from this fitting to the EMM. Due Cleaning

to carbon accumulation in the exhaust, this fitting
must be periodically de-carbonized or replaced.  WARNING
Wear safety glasses to avoid personal injury,
Operation Test and set compressed air pressure to less than
Use the Evinrude Diagnostics software Monitor 25 psi (172 kPa).
screen to confirm:
• barometric pressure reading; and Cleaning with Engine Tuner maintenance product
• changes in exhaust pressure reading. can dissolve carbon build-up.

With key ON, outboard NOT running, make sure Spray Engine Tuner through the fitting and allow it
the barometric pressure reading reflects actual to soak for four to six hours.
atmospheric conditions. Use compressed air to blow through the fitting.
If barometric pressure reading is inaccurate, Limit the air pressure to 25 psi (170 kPa). Confirm
remove exhaust/barometric pressure hose from movement of air through fitting.
EMM. Retest and observe engine Monitor screen. IMPORTANT: Fitting does restrict air movement.
If barometric pressure reading is accurate with
hose removed, replace hose and diaphragm Replace exhaust pressure fittings that are
assembly. and inspect exhaust fitting for restric- blocked and cannot be de-carbonized.
tion.
With key ON, outboard NOT running, the exhaust Anti-corrosion Protection
pressure sensor reading should be close to zero.
With the outboard running, make sure the exhaust Sacrificial Anodes
pressure reading changes with throttle setting. Galvanic corrosion occurs in fresh or salt water.
This reading will vary, based on actual outboard Salt, brackish, and polluted water can accelerate
exhaust pressure conditions. corrosion. “Sacrificial” anodes are intended to pro-
tect the underwater metal components of the out-
If the exhaust pressure readings are not as board from galvanic corrosion.
described, clean or replace exhaust pressure fit-
tings. Outboards are equipped with five sacrificial
anodes.

3
1 2

1. Propeller shaft 009240

2. Bearing housing
3. Gearcase housing
Engine Monitor Screen 009242
1. Barometric and Exhaust pressure readings

26
 Routine Service
Maintenance

Exterior Finishes
Maintain the outboard’s exterior finish to prevent
4 corrosion and reduce oxidation:
• Use automotive wax to protect the outboard’s
exterior finish from oxidation
• Clean regularly using clean water and mild
detergent soap
2
• Touch-up damage to painted surfaces promptly.
• Protect moving components with appropriate
5 lubricants.

4. Trim and tilt housing 009241 Storage

5. Stern brackets

IMPORTANT: DO NOT start outboard without a

Visually inspect anodes and metal components
water supply to the outboard’s cooling system.
below water level. Erosion of anodes is normal
Cooling system and/or powerhead damage could
and indicates the anodes are functioning properly.
occur.
IMPORTANT: Anodes that are not eroding may
not be properly grounded. Anodes and the mount- Fuel System Treatment
ing screws must be clean and tight for effective Stabilize the boat’s fuel supply with Evinrude 2+4
corrosion protection. Fuel Conditioner following the instructions on the
container.
For best anode performance:
• Replace all anodes that have eroded or disinte- Internal Engine Treatment
grated to two-thirds of their original size
• Do not paint or apply protective coatings to Remove the propeller, attach garden hose to
anodes or anode fasteners flushing port and turn on water.
• Avoid using metal-based antifouling paint on the
Evinrude E-TEC G2 models are designed to be
boat or outboard.
self-winterizing using one of the following meth-
ods:
Testing Procedure – Continuity
Connect ohmmeter leads between engine ground Throttle Control Method
and anode surface.
1. With the key switch in the OFF position move
The meter should show little or no resistance. If the control lever(s) to the FORWARD wide
resistance is high, check the following: open throttle position.
• Remove the anode and clean the area where 2. Turn the key switch to ON and wait a minimum
the anode is installed of three seconds.
• Clean the mounting screws
• Install the anode and test again. 3. Attempt to start the outboard three times within
three seconds (the starter will not engage or
Metallic Component Protection crank the outboard).
Protect metal components on outboards from cor- 4. Move the lever to NEUTRAL and start the out-
rosion. Use the following products to minimize board(s).
corrosion:
5. Run the outboards at idle for a minimum of
• Anti-Corrosion Spray three seconds.
• “6 in 1” Multi-Purpose Lubricant
6. With the outboard(s) running, attempt to start
the outboard three times within three seconds

27
Routine Service
Maintenance

(the starter will not engage or crank the out-

board).
7. The remote control will send the winterization
message to each outboard. Only running out- 2
board(s) will be winterized.
8. The outboard(s) will automatically shut off
when the process is complete.
IMPORTANT: During the winterization process, 1
the remote control will ignore all throttle, gear, and
switch operations. The control WILL acknowledge
Key OFF or Emergency Stop commands. ICON Touch 7.0 CTS 356596-36
1. Menu/Settings
2. Winterize Tab
Software Control Method
Winterization can also be run using Evinrude
Diagnostics software v 6.1 or higher. With the out-
board running, start the process at the Settings
screen and follow the instructions.

ICON 3.5C 216762-12

1. Mode Select

1. Winterization start button 009243

Digital Gauge Method

The ICON Touch 7.0 CTS, 4.3 CTS, 3.5C, Pro 5
inch and I-Command 3.5 inch digital gauges pro-
1
vide a winterize feature for Evinrude E-TEC G2
models. ICON Pro 5 inch Digital Gauge 008686
1. Mode button
Refer to the digital gauge user’s guide for com-
plete instructions.

To access the winterize feature, use the:

• “Menu”, then “Settings” feature (ICON Touch
7.0 CTS, or ICON Touch 4.3 CTS)
• “Mode Select” feature (ICON 3.5C)
• “Mode” button (ICON Pro 5 inch)
• “Menu” button (I-Command 3.5 inch)

28
 Routine Service
Maintenance

Pre-Season Service
 WARNING
Failure to check for fuel leakage could allow a
leak to go undetected, resulting in fire or
explosion. 2
If the outboard was removed from the boat for
storage, make sure it is reinstalled with factory
1 specified hardware. Refer to the Predelivery and
Installation Guide.
I-Command 3.5 inch Digital Gauge 008191
1. Menu button
Outboard Mounting Bolts
After the outboard shuts itself off, turn key switch • Check and re-tighten outboard mounting bolts
OFF, then detach garden hose. to a torque of 40 ft. lbs. (54 N·m).
IMPORTANT: When finished, leave the outboard
in vertical position long enough to completely drain Gearcase Lubricant
the powerhead. • Check the lubricant level.
• Inspect gearcase for leaks. If leak is apparent,
Additional Recommendations pressure and vacuum test gearcase.
• Repair gearcase as needed.
• Top off oil reservoir.
• Remove and inspect propeller.
Battery(s)
• Clean and grease propeller shaft.
• Inspect outboard, steering system, and con- • Replace batteries that cannot be charged.
trols. Replace all damaged and worn compo-
nents. Operational Checks
• Touch up painted surfaces as needed. Coat • Refer to Operational Checks on p. 46
outer painted surfaces with automotive wax. • Steering system
• Remove battery(s) from boat. Store in a cool, • Remote controls
dry location. Periodically charge battery(s) while • All other accessories and instrumentation
stored. Refer to manufacturer’s maintenance
recommendations when servicing batteries. Check Oil Injection Tank
• Store outboard in upright (vertical) position. • Inspect the oil tank for leaks.
• Check for fuel leakage.
Check Fuel System
 WARNING • Inspect entire fuel system for leaks prior to start-
Failure to check for fuel leakage could allow a ing outboard.
leak to go undetected, resulting in fire or • Repair all leaks.
explosion.
Water Pump
• Make sure a steady stream of water flows from
overboard indicator.

29
Routine Service
Lifting The Outboard

Lifting The Outboard complete engine. The off-set lifting eye is used to
remove and install the powerhead.
 WARNING
To avoid personal injury, make sure the lifting 2 1
capacity of the hoist is at least twice the
weight of the outboard.
DO NOT allow the lift hook or chain from the
hoist to come in contact with any part of the
engine during lifting.

 WARNING
To avoid personal injury, or damage to the
Lifting Fixture, P/N 357667 357667
engine, boat or other property, install the lift- 1. Centerline lifting eye
ing fixture completely into the flywheel. 2. Off-set lifting eye

To properly install the fixture, carefully thread IMPORTANT: Carefully thread the lifting fixture
the lifting fixture into the threads of the fly- into the threads of the flywheel at least 6 complete
wheel at least 6 complete turns. Do NOT turns. Do NOT cross-thread the threads of the lift-
cross-thread or over–torque the fixture ing fixture into the threads of the flywheel.
After the lifting fixture is installed, turn the fly-
wheel clockwise until the off-set lifting eye of Install the lifting fixture completely into the fly-
the fixture is in line to the back of the engine. wheel. If needed, turn the flywheel until the lifting
rings of the fixture are aligned front to back as
Release the rear latch to remove the top cap of shown.
the engine cover.
Back Front
1

1. Fixture aligned front to back 009100

1. Rear latch 009099

Use Lifting Fixture, P/N 357667, to lift the out-

board. The centerline lifting eye is used to lift the

30
 Routine Service
Lifting The Outboard

Fasten appropriate chain hook to the centerline 2. Install the 3.5 inch Air Duct Plug, P/N 357310,
lifting eye of the tool. to help cool the stator.

1 2

1. Centerline lifting eye 009100 1. 3.5 inch air duct plug 009103

3. Install the 4.0 inch Center Frame Plug,

Plug Installation P/N 356050, and the 2.0 inch Timing Pointer
Plug, P/N 356468, to provide correct air flow to
NOTICE the engine.
Install plugs as indicated. Plugs MUST be
installed to prevent water entry and/or engine
performance issues.
Install the following plugs from the Owner’s Kit: 1
2
1. Apply Triple Guard grease to the threads of the
flywheel. Then install the Flywheel Thread
Plug, P/N 357323 to protect the threads from
corrosion.

1. 4 inch center frame plug 009104

2. 2 inch timing pointer plug

1. Flywheel thread protector 009102

31
Routine Service
Rigging Information

Rigging Information Remove four screws from the cable entry cover.
Remove the rigging center covers.
Rigging related information in this section sup-
ports re-installation after completing service pro-
cedures.

If installing a new engine package, use the current

Evinrude E-TEC G2 Installation and Predeliv-
ery Guide for complete installation details. 2
1
Rigging Center
Evinrude E-TEC 74° V6 models utilize a central 3
rigging center. All buss cables, hydraulic steering 1. Four screws 009106
hoses, fuel and oil hoses and related rigging enter 2. Rigging center cable entry cover
the rigging center through a cable entryway. 3. Cover

The cable entryway is configured for starboard Rigging Hose Requirement

cable entry but can be adapted for port cable entry
if needed. NOTICE
Remove the two lower screws, then remove the A 12 in. (304.8 mm) or longer length of rigging
two upper screws (front) retaining the engine hose such as P/N 770392, or P/N 770393 is
cover. REQUIRED to prevent damage to buss
cables, hoses, harnesses or other wiring
entering the outboard rigging center.

2
Rigging Hose Options
Allow one rigging hose per engine. The rigging
hose can enter from the starboard or port side.
1
Buss Cable, Hoses, Wire Routing
and Connections
1. Lower screws 009105
2. Upper screws (front)
NOTICE
Remove the front engine cover to access the rig- After installation, make sure there is enough
ging center. clearance for all cables to avoid binding or
chafing through all engine steering and tilting
angles.

All hydraulic steering hoses, battery cables, buss

cables, fuel and oil hoses and related rigging
enter the rigging center through a cable entryway.

32
 Routine Service
Rigging Information

The cable entryway is configured for starboard Rigging Hose Length

cable entry but can be adapted for port cable entry
if needed. Determine the length of the rigging hose BEFORE
installing cables and hoses through the rigging
hose. Then determine the lowest point of the rig-
ging hose in the installed position.
2
Use a drill and drill bit to make three 3/8 in.
(10 mm) drain holes in the rigging hose:
1 • make the first drain hole at the lowest point.
• make the second and third drain hole 1.5 in.
(38 mm) each side of the first drain hole.

1. Rigging center cable entry 009117

Hose and cable lengths are measured from the

cable entryway to the connection point in the rig-
ging center. Refer to Rigging Center Hose and
Cable Lengths on p. 34.

Route all steering hoses, battery cables, fuel and 1.5 in.
(38 mm)
oil hoses, buss cables, and optional accessories
such as auxiliary battery charging cable, or
Drain Holes
remote oil tank hose from the boat through a pro-
tective conduit into the rigging center cable entry.

When installing hoses and cables through the

flexible tubing, install in this order:
1. steering hoses
2. battery cables
3. fuel hose
4. optional oil or flush hoses
5. buss cables
6. optional accessory connections

33
Routine Service
Rigging Information

Rigging Center Hose and Cable Lengths

8 6
4
7
9 10

1 2

0 5 10 15 20
Component inches mm 254 508
1. Starboard Steering Hose 10.5 267
2. Port Steering Hose 12 305

3. Battery Cables 21.5 546

4. NMEA 2000 Network 13.25 337

5. Control Network 12 305

6. Flush Hose 13 330

7. Remote Oil Tank Connector 12 305

8. Auxiliary Battery Connector 14.5 368

9. Fuel Hose 10.5 267

10. Remote Oil Tank Hose 9 229

009137

34
 Routine Service
Rigging Information

Hydraulic Steering Hoses Hydraulic Hose Connections

Connect the PORT hydraulic hose from the helm
 WARNING to the PORT hydraulic steering fitting on the stern
Incorrect connection of hydraulic hoses will bracket. Tighten the nut by hand until fittings are
cause the engine to steer in the opposite seated.
direction of the helm input.
Connect the STARBOARD hydraulic hose from
2
This can result in loss of boat control and the helm to the hydraulic steering fitting on the
injury to the occupants. STARBOARD stern bracket. Tighten the nut by
hand until fittings are seated.
Hydraulic Hose Routing Tighten both hydraulic hose fittings to a torque of
First install the hydraulic steering hoses through 15 ft. lbs (20.3 N·m).
the flexible conduit.
NOTICE
Install steering hose anti-kink retainer,
P/N 357893 from the owners kit to prevent
hydraulic hose damage.

Next, install steering hose anti-kink retainer onto

the:
• PORT hydraulic hose IF the port cable entry is
used.
• STARBOARD hydraulic hose IF the starboard
cable entry is used (shown).
IMPORTANT: Make sure the steering hose anti-
kink retainer is installed on the hydraulic hose as
shown:
• anti-kink retainer should touch the strain relief
on the hydraulic hose.
• anti-kink retainer should be positioned to pre-
vent the hydraulic hose from chafing against the
rigging center.

1. Anti-kink retainer 009108

Then route the hydraulic steering hoses through

the rigging center as shown. Take care NOT to
kink the hoses during installation.

35
Routine Service
Rigging Information

Connections connectors until they align. This could result in a

mismatched connection. It is possible for each
Also see Rigging Center Connections on the pin to enter a socket even if the tabs are mis-
next page. aligned.
• Carefully align pins and sockets of connectors.
1. Install the positive (+) battery cable to the posi- Do NOT force connectors together.
tive stud on the starboard side of the top frame.
Tighten nut to a torque of 120 to 144 in.lb.
(13.5 to 16.5 N·m).
2. Install the negative (–) battery cable to the neg-
ative stud on the port side of the top frame.
Tighten nut to a torque of 60 to 84 in.lb. (7 to
9.5 N·m).
3. Connect the fuel supply hose from fuel tank to
hose fitting on the outboard. Secure hose with 1
Oetiker clamp.
1. Tabs 009138
4. If installing optional remote oil tank, connect
the oil supply hose from the oil tank to the fit- • Pull back the coupler of the female buss con-
ting on the outboard. Secure hose with Oetiker nector as the connectors are joined. Do NOT
clamp. force connectors together.

5. Connect the remote control network buss cable

to the outboard’s buss cable. Refer to Network
Connections on p. 36.
6. Connect the NMEA 2000 buss cable from a tee
in the boat to the outboard’s NMEA 2000 buss
cable.
7. If installing optional remote oil tank, remove the
protective cover from the harness on the out- 2 1
board. Connect the electrical connector from
1. Female buss connector 009139
the oil tank to the connector on the outboard. 2. Coupler
8. If installing optional auxiliary battery charging • Release the coupler to lock the connectors
kit, remove plug from outboard harness and together.
discard plug. Connect the auxiliary battery
• Gently try to pull the connectors apart to ensure
charge cable to the connector on the outboard.
they are locked together.

Network Connections
IMPORTANT: Do not force connectors or locking
rings. Properly aligned connectors assemble easi-
ly.

Do NOT use Electrical Grease on buss cable

connectors.
To assemble the connectors:
• Use the tabs to carefully align buss cable con-
nectors.
• Look at the tabs to ensure connector alignment
prior to making the connection. Do not rotate

36
 Routine Service
Rigging Information

Rigging Center Connections

4 5 2
12
7 8

13
10
9

11 6

1 2 3

Rigging Center 009118

1. Flexible Conduit
2. Starboard Steering Hose
3. Port Steering Hose
4. Positive (+)Battery Stud
5. Negative (–) Battery Stud
6. NMEA 2000 Network Cable
7. Remote Control Network Cable
8. Engine Flushing Hose (optional)
9. Remote Oil Tank Electrical Connector (optional)
10. Auxiliary Battery Charge Connector (optional)
11. Fuel Supply Hose
12. Remote Oil Tank Oil Hose (optional)

37
Routine Service
Rigging Information

Water Pressure Connection Install the rigging hose to the entry port of the rig-
ging center.
To send water pressure data to the EMM, along
with an NMEA 2000 display, install 50 psi Water
Pressure Transducer Kit, P/N 5008640.

Water pressure readings in excess of 40 psi (275

kpa) are possible for 90° V6 models at boat
speeds in excess of 50 mph (80 kph/43 kts).

Remove the accessory water pressure plug from

the engine to install the water pressure trans-
ducer. Refer to the installation instructions pro-
vided with the water pressure transducer kit.
Rigging Hose Installation 009094

Hose and Cable Clips

After completing connections, re-position the two
clips, P/N 352531, from the fuel and oil supply
hoses as shown:
1 • Attach one clip to the fuel hose and oil supply
hose.
• Attach the second clip to the oil supply hose
and positive battery cable.
1. Accessory water pressure plug 009119

Use the Configuration screen of Evinrude Diag-

nostics software v6.1 to set the water pressure
transducer.

1. Water pressure transducer 009237

Connect the transducer lead to the engine wiring

harness connector.

38
 Routine Service
Rigging Information

Make sure the crimp of each Oetiker clamp is Install cover on cable entryway with four screws.
positioned forward and cannot cut into or chafe Make sure cables are not pinched between cable
any other cable or hose. entryway cover and housing.

2
4

3
2

1 1

1. Cables NOT pinched 009170

Install the front engine cover. Install the two upper

1. Clips 009168
2. Fuel hose
screws (front) first, then install the two lower
3. Oil supply hose screws.
4. Positive battery cable

Make sure there is loose slack in all hoses and

cables.
1
• If port cable entry is used, slack should be to the
starboard side of the cable entryway.
• If starboard cable entry is used, slack should be
to the port side of the cable entryway (shown
below). 2

1. Upper screws (front) 009105

2. Lower screws
1

1. Slack 009169

Hoses and cables should NOT bind or be pulled

taught when engine is in a full turn.

39
Routine Service
Filling and Bleeding the Hydraulic Steering System

Filling and Bleeding the Hydraulic Steering System

Hydraulic Steering Fluid 4. Turn the steering wheel clockwise until engine
is turned fully to STARBOARD and resistance
 WARNING is felt. Be sure to maintain fluid level at the
Use ONLY approved hydraulic fluids. helm/reservoir.
Non-approved fluids can cause steering sys-
tem damage, or reduced steering control.
This can result in loss of boat control and
injury to the occupants.

Use ONLY Hydraulic Fluid, P/N 770891.

Single Station / Single Engine

Steering Installations
The following instructions describe the fill and
bleed procedure for a single engine installation.
For multiple engine installations refer to Single 009110
Station / Multiple Engine Installations on p. 42
5. Turn the steering wheel counter–clockwise
Manual Method until engine is turned fully to PORT and resis-
Also refer to the instructions provided with the tance is felt. Be sure to maintain fluid level at
hydraulic steering helm pump. the helm/reservoir.
IMPORTANT: Turn the key switch to the ON po-
sition for models with DPS.
IMPORTANT: Make sure the engine is trimmed
to the full DOWN position before beginning this
procedure. Air will NOT bleed completely from the
steering system if the engine is even slightly
trimmed up.
1. Remove the filler cap from the helm.
2. Install the threaded end of the filler tube (sup-
plied with helm) into the helm.
3. Fill the helm with the recommended fluid. Fluid
should always be visible in the filler tube. Use 009111
additional bottles of fluid as needed. Do NOT
proceed with the next step until the helm is full
of fluid.

40
 Routine Service
Filling and Bleeding the Hydraulic Steering System

6. Install the Steering Lock Tool, P/N 357717, to – Be sure to maintain fluid level at the
hold engine in full PORT turn. helm/reservoir.

2
1

Steering Lock Tool, P/N 357717 357717 1. Lower bleed valve 009109

7. Use a shipping bracket screw to attach the long 9. Close the LOWER bleed valve.
end of the steering lock tool to the steering
arm. 10.Then remove the steering lock tool.
Attach the short end of the tool to the stern 11.Turn the steering wheel clockwise until engine
bracket using the provided nut and washer. is turned fully to STARBOARD and resistance
is felt. Be sure to maintain fluid level at the
helm/reservoir.

1 2

1. Steering arm 009112

2. Stern bracket

Attach a length of clear hose to the LOWER bleed

valve. Use an appropriate container to catch fluid
flowing from the bleed valve. 009110

8. Open the LOWER bleed valve one–half turn.

Then turn the steering wheel clockwise.
– Continue turning the steering wheel clock-
wise until there are no air bubbles present in
the flow of fluid coming out of the bleed valve.

41
Routine Service
Filling and Bleeding the Hydraulic Steering System

12.Install the steering lock tool, P/N 357717, to Single Station / Multiple Engine
hold engine in full STARBOARD turn.
Installations
Filling and bleeding multiple engine installations is
similar to single engine installations.

Follow the instructions starting on page 48 in this

order:
2 1
• Complete steps 1 through 7.
• Starting with the STARBOARD engine, perform
steps 8 and 9.
1. Steering arm 009113
2. Stern bracket
• Leave the steering lock tool in place.
• Repeat steps 8 and 9 on each engine:
Attach the length of clear hose to the UPPER
bleed valve. – Bleed one engine at a time.
– Work on engines from starboard to port until
13.Open the UPPER bleed valve one–half turn. the LOWER bleed valve on all engines has
Then turn the steering wheel counter–clock- been bled.
wise.
– Continue turning the steering wheel counter– • Proceed with steps 10 through 12.
clockwise until there are no air bubbles present • Starting with the starboard engine, perform steps
in the flow of fluid coming out of the bleed 13 and 14.
valve.
– Be sure to maintain fluid level at the • Leave the steering lock tool in place.
helm/reservoir. • Repeat steps 13 and 14 on each engine:
– Bleed one engine at a time.
– Work on engines from starboard to port until
the LOWER bleed valve on all engines has
been bled.
1
• Complete the process with steps 15 through 17.

1. Upper bleed valve 009109

14.Close the UPPER bleed valve.

15.Tighten both bleed valves to a torque of 84 to
120 in.lb. (9.5 to 13.5 N·m).
16.Remove the steering lock tool.
17.Remove the filler tube from the helm. Install the
fill cap on the helm, tighten securely.
18.Proceed to Steering System Checks on
p. 44.

42
 Routine Service
Filling and Bleeding the Hydraulic Steering System

Power Purge Method 4. Turn the steering wheel counter–clockwise

until engine is turned fully to PORT and resis-
A Teleflex Power Purge system can be used to
tance is felt.
bleed the steering system. Make sure the purging
unit has the correct hydraulic fluid. See Hydraulic
Steering Fluid on p. 40. Purge the steering sys- 1
tem manually if the fluid in the purging unit is a 2
non-approved or unknown type. See Manual
Method on p. 40.
IMPORTANT: Turn the key switch to the ON po-
sition for models with DPS.
2
If installing dual outboards a Teleflex Dual Cylin-
der Purging Kit is also required.

1. Hydraulic fluid supply line 009116

2. Hydraulic fluid return lines

5. Install the steering lock tool, P/N 357717, to

hold engine in full PORT turn.

Teleflex Power Purge Jr. 009114

1. Remove the fill cap from the helm. Connect the

hydraulic fluid supply line of the purging unit to
the helm.
2. Connect the hydraulic fluid return lines of the
purging unit to the two bleed valves of the Steering Lock Tool, P/N 357717 357717

steering system.
6. Use a shipping bracket screw to attach the long
end of the steering lock tool to the steering
arm.
Attach the short end of the tool to the stern
bracket using the provided nut and washer.
1
1

1. Bleed valves 009109

1 2
3. Loosen both bleed valves one-half turn. Then
turn the purge unit ON.
After air bubbles are no longer visible: 1. Steering arm 009112
2. Stern bracket

43
Routine Service
Filling and Bleeding the Hydraulic Steering System

6. Rotate the steering wheel both clockwise and 12.Disconnect the return lines of the power purge
counter–clockwise until air bubbles are no lon- from the two bleed valves of the steering sys-
ger visible. tem.
7. Remove the steering lock tool. 13.Disconnect the hydraulic fluid supply line of the
power purge from the helm.’
8. Turn the steering wheel clockwise until engine
is turned fully to STARBOARD and resistance 14.Install the fill cap on the helm, tighten securely.
is felt.
15.Proceed to Steering System Checks on
p. 44.
1
Steering System Checks
1. Turn steering wheel to PORT. After engine is
turned fully to PORT, apply enough force to the
steering wheel to exceed the pressure relief
2 valve pressure of the helm.
2. While pressure is maintained on helm, check
all PORT lines and fittings for leaks.
3. Turn steering wheel to STARBOARD. After
1. Hydraulic fluid supply line 009115
engine is turned fully to STARBOARD, apply
2. Hydraulic fluid return lines
enough force to the steering wheel to exceed
9. Install the steering lock tool, P/N 357717, to the pressure relief valve pressure of the helm.
hold engine in full STARBOARD turn.
4. While pressure is maintained on helm, check
Use a shipping bracket screw to attach the long all STARBOARD lines and fittings for leaks.
end of the steering lock tool to the steering arm. 5. Repair all leaks. Repeat steps 1 through 4
Attach the short end of the tool to the stern before continuing.
bracket using the provided nut and washer.
6. Cycle the steering system from full PORT turn
to full STARBOARD turn several times. Definite
resistance should be felt when the steering
wheel is turned full PORT or full STARBOARD.
IMPORTANT: If definite resistance is NOT felt, or
if steering feels loose or “soft” wait 15 minutes and
repeat the bleeding process.
2 1 7. Check the fluid level of the helm pump and fill
per the manufacturers recommendation.

1. Steering arm 009113

2. Stern bracket

10.Rotate the steering wheel both clockwise and

counter–clockwise until air bubbles are no lon-
ger visible.
11.Tighten both bleed valves to a torque of 84 to
120 in.lb. (9.5 to 13.5 N·m). Then turn the
purge unit OFF.

44
 Routine Service
Before Start-up

Before Start-up Trim and Tilt Fluid

Gearcase Lubricant  CAUTION
With outboard vertical, check the gearcase lubri- Correct fluid level must be maintained to
cant level: ensure operation of the impact protection
• Inspect the lubricant level in the lubricant reser- built into the unit. 2
voir.
The trim and tilt system is filled, tested and sealed
at the factory. It is NOT necessary to check fluid
level.

Check the fluid level ONLY if the trim and tilt is

NOT operating normally:
• Tilt the outboard to the full UP position.
1 • Remove filler cap and check fluid level.
• Add Power Trim/Tilt and RAVE Fluid,
P/N 767969, as needed, to bring level to the
bottom of the fill plug threads.

1. Lubricant reservoir 009140

• Lubricant level should be between the marks as

shown.

1
1.5 in.
(38 mm) { 2
1. Filler cap 009127

Lubricant Level 009141

1. Maximum
2. Minimum

Add HPF PRO gearcase lubricant if needed.

2-Stroke Engine Oil Level

Make sure the on-board oil tank contains an ade-
quate supply of the correct lubricant for the out-
board. Refer to Recommended Lubricants on
p. 66.

45
Routine Service
Operational Checks

Operational Checks Remote Control Operation

Make sure that control can be easily moved into
 DANGER all gear and throttle settings.
DO NOT run the engine indoors or without
adequate ventilation or permit exhaust fumes
to accumulate in confined areas. Engine
Emergency Stop / Key Switch
exhaust contains carbon monoxide which, if Check emergency stop function. With outboard
inhaled, can cause serious brain damage or running at IDLE, pull safety lanyard from emer-
death. gency stop switch. Outboard must stop immedi-
ately. If equipped, be sure to check emergency
 WARNING stop function of second station.
Contact with a rotating propeller is likely to
result in serious injury or death. Assure the Digital Displays and Gauges
engine and prop area is clear of people and
objects before starting engine or operating Complete basic set up of digital display or gauges.
boat. Do not allow anyone near a propeller, Configure engine and fuel tank, set fuel tank
even when the engine is off. Blades can be capacity etc. Refer to User’s Guide.
sharp and the propeller can continue to turn
even after the engine is off. Tachometer Pulse Setting (SystemCheck)
Confirm accuracy of tachometer reading.
 CAUTION • Adjust dial on back of tachometer to required
DO NOT run outboard without a water supply setting (the outboard should not be running).
to the outboard’s cooling system. Cooling Outboard Model Tachometer Setting
system and/or powerhead damage could
occur. 15–300 HP 6 Pulse or 12 Pole

Start-In-Gear Prevention Engine Monitoring System

 WARNING Attach emergency stop lanyard.
Make certain that the starter will not operate
when the outboard is in gear. The start-in- Turn key switch to the ON position.
gear prevention feature is required by the Evinrude Touch-Screen Display — The touch
United States Coast Guard to help prevent screen system will run a start up sequence and
personal injuries. then display the Evinrude welcome page. When
the start up sequence is complete, the default dig-
Start outboard and shift to FORWARD.
ital display will appear.
Turn outboard OFF while control is in FORWARD.
ICON — The ICON system self-tests by sounding
Try to restart the outboard. Outboard should not a beep. The ICON tachometer and speedometer
start. LCD screens display SELF TEST MODE IN
OPERATION. When the self test is complete, the
Shift back to NEUTRAL and restart outboard. gauges will beep a final time and then display
SELF TEST COMPLETE!
Shift to REVERSE. Turn outboard OFF while con-
trol is in REVERSE. I-Command — The I-Command system self-tests
by displaying the Evinrude E-TEC welcome
Try to restart the outboard. Outboard should not
screen, followed by the default digital display.
start.

46
 Routine Service
Propellers

SystemCheck — The SystemCheck monitor self- Break-In

tests by sounding a half-second beep. System-
Check gauges self-test by turning the indicator Evinrude E-TEC outboards require no break in.
lights on simultaneously, then off in sequence. When the outboard is delivered, refer the cus-
tomer to the Oiling System information in the
Water Pump Overboard Indicator Operator’s Guide.
2
A steady stream of water should flow from the
overboard indicator. Propellers
Propeller Selection
 CAUTION
Selection of the wrong propeller could reduce
1 engine service life, affect boat performance,
or cause serious damage to the powerhead.

Water testing with various propeller designs and

sizes is the best method of propeller selection.

The correct propeller, under normal load condi-

tions, will allow the engine to run near the mid-
1. Water pump overboard indicator 009128
point of the RPM operating range at full throttle.
Refer to SERVICE SPECIFICATIONS in the Ser-
Operating Temperature vice Manual for RPM range.
An outboard run at idle speed should achieve a Operating Range
temperature based on the engine’s thermostatic Peak HP
control. In general, the powerhead temperature H 100%
should reach at least 104°F (40°C) after five min- o 90%
r
utes of idling. Check that the powerhead reaches s 80%
idle temperature. e 70%
p 60%
o 50%
Leaks w 40%
e 30%
r
Perform running checks of the as follows:
2000 3000 4000 5000 6000
• Start outboard. RPM
• Inspect all fuel hoses and connections.
• Inspect all oil hoses and connections. 008329
• Inspect all cooling water hoses and connec-
tions.
• Repair any leaks or misrouted hoses immedi- NOTICE
ately. If the propeller blades have too much pitch,
the engine will operate below its normal range
Idle Speed at full throttle. Power will be lost, and power-
head damage could occur. If the propeller
Make sure the outboard idles within the specified blades have too little pitch, the engine will
idle RPM range. If the outboard is run on a flush- operate above its normal range and damage
ing device, the idle speed and quality may not be from overspeeding could occur.
representative of actual in water use.

47
Routine Service
Propellers

When selecting a propeller, consider the following: Propeller Hardware Installation

• Use an accurate tachometer to determine the
engine’s full-throttle RPM.  WARNING
• The outboard should be trimmed for top speed.
• Select a propeller that suits the customer’s When servicing the propeller, always shift the
application and allows the engine to run near outboard to NEUTRAL position, turn the key
the midpoint of the full-throttle operating range switch OFF and remove the key, so the out-
when the boat has a normal load. board cannot be started accidentally.
• Occasionally, one propeller will not cover a wide
IMPORTANT: Evinrude E-TEC G2 outboards
range of boat applications — water skiing to
high speed performance boating. In such cases, REQUIRE Propeller Hub Kit, P/N 767683, and Nut
it might be necessary to have a propeller for & Keeper Assembly, P/N 5008966.
each situation.
Apply Triple Guard grease to the entire propeller
• Refer to the Evinrude Genuine Parts and
shaft before installing the propeller.
Accessories Catalog for propeller styles and
sizes. Install thrust bushing onto propeller shaft with
• Right-hand propellers are considered standard taper of bushing matching taper of shaft.
rotation propellers. When propelling a boat for-
ward, the propeller rotates in a right-hand Install the bushing and sleeve into the propeller.
(clockwise) direction as viewed from the rear.
• Left-hand propellers are considered counter- Align splines of propeller and shaft. Push propeller
rotation propellers. When propelling a boat for- until seated on the thrust bushing.
ward, the propeller rotates in a left-hand (coun-
terclockwise) direction as viewed from the rear. Install the spacer over the propeller shaft splines.

Wedge a block of wood between propeller blade

and the anti-ventilation plate.

2 1
1. Right-hand rotation (clockwise) 009079
2. Left-hand rotation (counterclockwise)

 WARNING 001992
For multiple outboard installations always
Install the propeller nut. Tighten to a torque of 70
check to be sure propellers are installed on
to 80 ft. lbs. (95 to 109 N·m).
the correct engines before aggressively oper-
ating the boat. Install the keeper, then install a new cotter pin.

48
 Routine Service
Adjustments

Install the anode and screw on the propeller shaft.

Tighten the screw to 177 to 204 in. lbs. (20 to 23
Adjustments
N·m). An in the water test is required to make sure the
outboard(s) and boat are rigged correctly, propel-
ler selection is correct, and that all accessories
function properly. 2
Pay special attention to the following, especially if
the boat is re-powered with new outboard(s):
• Engine mounting height
• Jack plate adjustment
• Correct propeller selection and WOT RPM
• Fuel system vacuum
• Engine water pressure/optional water screens
1. Thrust bushing 009129
2. Torsion bushing
3. Bushing and sleeve Make all needed adjustments or repairs and retest
4. Propeller nut before delivery.
5. Keeper
6. Cotter pin
7. Anode
When ready for delivery, give all instruction
8. Screw sheets, operating instructions and user guides
provided with accessories to the owner. Advise
IMPORTANT: After installation, make sure out- the owner of any special operation or mainte-
board is in NEUTRAL and carefully spin propeller. nance information contained in the instructions.
Propeller must turn freely and should not spin off
center. If propeller appears to wobble, check for IMPORTANT: Complete the Predelivery Check-
possible bent propeller shaft. list and obtain owner’s signature at the time of de-
livery. The Predelivery Checklist must be kept on
file for seven years.

Engine Mounting Height and Jack

Plate Adjustment
Goals include:
• Engine RPM within the full throttle operating
range
• Best acceleration and top speed
• No excessive ventilation while boat is coming
onto plane.
Start with the engine lower on the transom. Make
a test run, taking note of engine RPM, water pres-
sure, trim level and boat speed.

Raise the engine or jack plate and repeat the pro-

cess until the best acceleration and boat speed
are achieved.

Fuel System Vacuum

Test fuel system vacuum. Refer to the appropriate
service manual. The maximum inlet fuel vacuum

49
Routine Service
Adjustments

should not exceed 4 in. Hg. (13.5 kPa) at the inlet Tilt Limit Setting
to the fuel lift pump under any operating condi-
tions (IDLE to WOT).  WARNING
A higher vacuum indicates an excessive restric- If the outboard does not clear all boat parts
tion in the fuel supply. Repair as needed. when tilted fully or turned side to side, safety
related parts could be damaged in the course
of such outboard movement. Injuries could
Engine Water Pressure result from loss of boat control.
Check engine water pressure. Confirm adequate
water pressure at all engine speeds and in turns.  WARNING
Adjusting the tilt limit will NOT prevent the
If water pressure falls below acceptable levels,
outboard from tilting fully and contacting the
adjust outboard alignment (multiple engine instal-
motor well if the gearcase hits an object at
lations.
high speed. Such contact could damage the
outboard and boat and injure boat occupants.
Trim & Tilt
NOTICE
The trim and tilt functions of Evinrude E-TEC G2
outboards are controlled by the engine EMM. The tilt limit setting will not prevent the out-
board from overriding the adjustment if the
IMPORTANT: Activating any trim button while outboard is tilted manually.
the key switch is in the OFF position will briefly turn
on the system. This will cause the electric fuel Check the tilt limit on all new outboard installa-
pump to run and the remote control and any dis- tions.
plays or gauges to turn on. There will be a short de-
lay before the trim system operates. This is normal. Check the clearance between outboard(s) and the
The system will turn off after a few seconds of non- boat’s motor well and transom area. Tilt out-
use. board(s) to highest point of clearance and turn the
steering system lock to lock.
If the outboard contacts the boat's motor well
when fully tilted, set the tilt limit to reduce full-tilt
position.
To prevent damage to equipment, provide addi-
tional motor well clearance when needed. Con-
sider either changing the outboard mounting
position or modifying the boat if the possibility for
interference and damage exists.

Manual Method
You MUST use the trim switch on the starboard
engine cover to set the tilt limit with this method.

Tilt the engine up to the desired maximum tilt posi-

tion.

50
 Routine Service
Adjustments

Then, simultaneously press and hold for at least Repeat this procedure until the tilt limit stops the
three seconds, both the up and down trim buttons. outboard's upward travel before it contacts the
motor well.

Trim Gauge Calibration

Observe the trim gauge. If needed, use Evinrude
2
1
Diagnostics software v 6.1 or higher to calibrate
the upper and lower trim range of the gauge.

1. Press and hold for at least three seconds, both the 009142
up and down trim buttons
1
Check your adjustment — tilt the outboard fully
and adjust further, if necessary. Check after each
adjustment.
To change or clear this setting, tilt the engine to
the full down position.

Then, simultaneously press and hold for at least

three seconds, both the up and down trim buttons. 1. Calibrate Trim Sender 009237

Diagnostic Software Method i-Trim

Your Dealer must use Evinrude Diagnostic soft- Evinrude E-TEC G2 outboards are equipped with
ware v 6.1 or higher to limit maximum tilt-up. i-Trim, an automatic trim-assist feature. By default,
this feature is disabled from the factory.

Use the Evinrude ICON-Touch or ICON CS digital

display to enable i-Trim. If the boat is not equipped
1 with an ICON digital display, use the Configuration

1. Set Tilt Limit 009143

Check your adjustment — tilt the outboard fully

and adjust further, if necessary. Check after each
adjustment.

51
Routine Service
Adjustments

screen of Evinrude Diagnostics software v 6.1 or Dynamic Power Steering (DPS)

higher to enable trim assist.
 WARNING
Selection of power steering assist level is
operator preference.
Be aware that changing the power steering
assist level can affect boat handling.
After changing the level of power steering
assist, operate the boat with care to become
familiar with any changes in boat handling
characteristics.
1 Most Evinrude E-TEC G2 models are equipped
with Dynamic Power Steering (DPS). DPS offers
three power steering assist levels.
1. Trim Assist 009237
Power Steering Assist Levels
To activate the i-Trim: All power steering assist levels provide the same
• the key switch must be in the ON position rate of assist at engine speeds below 4500 RPM.
• use the trim/tilt switch to trim the engine to the
full DOWN position. As engine speed increases above 4500 RPM,
During operation, the outboard will automatically assist levels progressively decrease.
trim up or down to an acceptable trim angle based
The factory default assist level is “Minimum”. Use
on pre-programmed parameters.
the Evinrude ICON-Touch or ICON CS digital dis-
Use the trim/tilt switch on the control lever to fine play to change the power steering assist level.
tune to an optimum trim angle.
Refer to the Evinrude ICON-Touch or ICON CS
IMPORTANT: Use of the trim/tilt switch to manu- user’s guide.
ally adjust the outboard trim angle will temporarily
deactivate i-Trim. If the boat is not equipped with an ICON digital
display, use the Configuration screen of Evinrude
To reactivate i-Trim: Diagnostics software v 6.1 or higher to change the
• use the trim/tilt switch to trim the engine to the power steering assist level.
full down position
• bring the engine to idle speed.

1. DPS Assist 009237

52
 Routine Service
Adjustments

Multiple-Outboard Alignment tion must be thoroughly tested until the ideal

combination of performance, steering, and cooling
Dual outboards must be connected with a tie bar
is found.
and adjusted to align the outboards for correct
water flow to the gearcases and propellers. A common practice is to set-up the outboards par-
allel, or with a small amount of “toe-out,” and
Incorrect outboard alignment could cause one or
adjust inward until best results are achieved. 2
more of the following:
• A typical set-up, with outboards mounted
• Propeller ventilation directly on the transom, often runs best with a
• Reduction of top speed slight amount of “toe-in.”
• Improper boat tracking • Outboards mounted behind the transom on
• Engine overheat and powerhead damage motor brackets usually require parallel align-
ment or “toe-out.”
Follow the instructions provided by the tie-bar
manufacturer for tie bar installation and adjust- Adjust the outboard alignments by adjusting tie
ment. bar. Follow the tie bar manufacturer’s adjustment
procedures.
Measure Alignment
The “toe-in” (gearcase leading edges closer Check steering operation. Make sure that the
together than propeller shaft centers) or “toe-out” steering system operates properly at various trim
(gearcase leading edges farther apart than propel- angles.
ler shaft centers) is determined as follows:
• Position outboards straight with the anti-ventila- Confirm Alignment
tion plates parallel with the bottom of the boat. To confirm proper alignment, perform the following
• Measure between propeller shaft centers. steps:
• Water test the boat.
• Monitor the water pressure for both outboards.
• Run the boat at various trim angles.
• Perform steering maneuvers and vary the throt-
tle settings.
• Monitor boat and outboard performance.
A sudden loss of water pressure or excessive pro-
peller ventilation on one or both outboards may
indicate a misalignment of the gearcases. Reset
009130
the outboard alignment and retest
• Measure between leading edges of gearcase.

009131

Alignment Adjustment
Various boat/motor combinations respond differ-
ently to dual-outboard alignments. Each applica-

53
Routine Service
Submerged Engines

Submerged Engines Prime oil system and fuel system. Refer to Fuel
System Priming on p. 165 and Oil Supply Prim-
Once an outboard has been submerged it must be ing on p. 198. Make sure all oil injection hoses are
serviced within three (3) hours of recovery. Imme- clean and filled with oil.
diate service can minimize the corrosive affect
that air has on the polished surfaces of the crank- Make sure high pressure fuel system does not
shaft, connecting rods, and internal powerhead contain water. Flush as needed.
bearings. Inject a small amount of outboard lubricant into
IMPORTANT: If outboard cannot be started or spark plug holes and install new spark plugs.
serviced immediately, it should be resubmerged in Refer to Spark Plug Installation on p. 24.
fresh water to avoid exposure to the atmosphere.
Reinstall all removed or disconnected parts.

Engine Submerged (Not Running) Use Evinrude Diagnostics software to:

• Start break-in oiling
Disconnect the battery cables at the battery. • Check fuel pump operation
• Check injector operation (fuel and oil)
Rinse powerhead with clean water.
• Check timing (once outboard is running at full
Remove spark plug leads and spark plugs. operating temperature)

Place outboard in horizontal position (cylinder Run outboard below 1500 RPM for one-half hour.
heads down). Slowly rotate flywheel in a clock-
wise rotation to work all water out of powerhead. Engine Submerged (Running)
IMPORTANT: If sand or silt may have entered Follow the same procedures as Engine Sub-
the outboard, DO NOT attempt to start it. Disas- merged (Not Running). However, if there is any
semble and clean. binding when the flywheel is rotated, it may indi-
cate a bent connecting rod and no attempt should
Disassemble all electrical connectors. Clean con-
be made to start the outboard. Powerhead must
nectors and terminals, and treat with water dis-
be disassembled and serviced immediately.
placing electrical spray. Apply Electrical Grease to
terminals prior to reassembly. Coat all exposed
solenoid terminals and engine grounds with Black Engine Submerged (In Salt Water)
Neoprene Dip.
Follow the same procedures used for Engine
Clean and inspect all electrical components. Submerged (Not Running) and Engine Sub-
Replace damaged or corroded components prior merged (Running). Disassemble and clean out-
to returning the outboard to service. Electric start- boards that have been submerged in salt water for
ers should be disassembled, cleaned, flushed prolonged periods of time. Clean or replace elec-
with clean water, and treated with water displacing trical components as necessary.
electrical spray prior to reassembly.

Disconnect fuel supply hose from outboard. Drain

Prolonged Submersion
and clean all fuel hoses, filters, and fuel tanks. (Fresh or Salt Water)
Disconnect oil supply hose and oil return hose Outboards that have been dropped overboard and
from outboard. Drain and clean all oil hoses, fil- not recovered immediately, must be serviced
ters, and oil tank assemblies. within three hours of recovery. Follow the same
procedures used for Engine Submerged (Not
Refill fuel tank with fresh fuel and oil tank with rec-
Running) and Engine Submerged (Running).
ommended oil.

54
 Routine Service
Submerged Engines

55
Routine Service
Notes

Notes
Technician’s Notes Related Documents
Bulletins

Instruction Sheets

Other

56