Evinrude e-tec 2005 Manual Download Page 1

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12 pt

™

WARNING

Read this Operator Guide thoroughly. It contains important

safety information. When operating your boat, always

have this Operator Guide onboard.

*215638*

40 HORSEPOWER

2005

Summary of Contents for e-tec 2005

Page 1: ... WARNING Read this Operator Guide thoroughly It contains important safety information When operating your boat always have this Operator Guide onboard RL 40 HORSEPOWER 2005 ...

Page 2: ...l Chrome Faced Piston Rings Micro Finished Connecting Rods Crankshaft Cleaner and Quieter EPA 2006 and Beyond Compliance European Union 2006 and Beyond Emissions Compliance California 3 Star Emissions Compliance Sealed Fuel System Low Friction Design No powerhead gears belts cams oil scraping rings or mechanical oil pump Full Length Insulated Lower Pans Quiet Signature Sound Air Intake Silencer Id...

Page 3: ... and its sealed fuel system minimizes evaporative emissions Durability Quality and Reliability Your Evinrude E TEC outboard utilizes prov en extremely durable engine components such as pistons made from material de veloped by NASA which are two and a half times stronger than competitive pistons There are no belts pulleys powerhead gears cams oil scraping rings or mechanized oil pumps to cause prob...

Page 4: ...s TABLE OF CONTENTS About This Guide 4 Important Safety Messages 5 USING YOUR EVINRUDE E TEC OUTBOARD Component Identification 10 Starting Stopping Shifting 12 Oil and Fuel 15 Operation 18 Routine Inspection Checklist 25 ...

Page 5: ...mation 28 Maintenance Schedule 29 Storage 30 Troubleshooting 33 PRODUCT INFORMATION Installation 35 Accessories 37 Adjustments 38 Specifications 39 Product Warranty Information 40 California Emission Control Warranty 42 Readiness Test 48 ...

Page 6: ... For additional information about boating safe ty and regulations call U S Coast Guard Boating Safety Hotline 1 800 368 5647 Outside North America please contact your Dealer or distributor for details about boating safety This Operator s Guide uses the following sig nal words identifying important safety mes sages IMPORTANT Identifies information that will help prevent damage to machinery and ap p...

Page 7: ...floatation devices must be in good con dition and suitable for your type of boat Always comply with the regulations that apply to your boat Remember gasoline fumes are flamma ble and explosive Always adhere to the fueling procedure contained in this Op erator s Guide and those given to you by the fueling station Always verify fuel level before use and during the ride Ap ply the principle of 1 3 fu...

Page 8: ... the response of each control Be familiar with all controls before applying the throttle above idle speed As the operator you are in con trol and responsible for safe operation The outboard must be correctly in stalled Failure to correctly install the outboard could result in serious injury death or property damage We strongly recommend that your Dealer install your outboard to ensure proper insta...

Page 9: ...e model and serial numbers appear on a plate attached to the stern bracket or swivel brack et Record your outboard s Model Number _______________________ Serial Number ________________________ Purchase Date _______________________ Ignition Key Number ___________________ Stolen Outboards United States and Canada Report your outboard as stolen to Customer and Dealer Sup port Services 250 Seahorse Dr...

Page 10: ...Bombardier Recreational Products ...

Page 11: ...9 USING YOUR EVINRUDE E TEC OUTBOARD USING YOUR E TEC OUTBOARD ...

Page 12: ...tem Description Item Description 1 Air Inlet Tilt Handle 5 Stop Button Emergency Stop Switch 2 Water Pump Indicator Flushing Port 6 Tilt Support 3 Engine Cover Latch 7 Clip and Lanyard Assembly 4 Anti Corrosion Anodes 8 Water Intake Screens 6 8 4 3 7 5 2 1 ...

Page 13: ...ption 9 Fuel Filter 14 Steering Handle and Twist Grip Throttle 10 Spark Plugs 15 Air Silencer 11 Throttle Friction Screw 16 Oil Fill Cap 12 Shift Lever 17 Oil Tank 13 Starter Handle 18 EMM Engine Management Module Starboard 9 10 Port 15 18 16 13 17 14 12 11 ...

Page 14: ...ER 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 Always shut off the engine when near people in the water WA...

Page 15: ...on page 33 After Engine Starts Check the water pump indicator A steady stream of water indicates the water pump is working If a steady stream of water from the water pump indicator is not visible stop the engine Refer to Engine Overheating on page 21 WARNING Always shift to NEUTRAL before start ing the outboard to prevent sudden boat movement which can cause injury DO NOT advance the throttle befo...

Page 16: ...e is at idle speed and the boat has slowed Speed Control With the outboard running twist throttle grip Clockwise to decrease speed or Counterclockwise to increase speed 1 Decrease speed 2 Increase speed FUEL SYSTEM PRIMING FUEL ECONOMY The economy throttle position can save fuel depending on boat load and hull design When boat reaches top speed throttle back from FULL SPEED You will save fuel with...

Page 17: ...NG THE OILING SYSTEM Your outboard is designed to run in get home mode in the event your oil tank runs low You will have approximately five hours of normal operation before running out of oil when using TC W3RL oil If you are using Evinrude Johnson XD100 oil you have ap proximately ten hours of normal operation re maining Refill the onboard oil tank as soon as possible Refer to Priming the Oiling ...

Page 18: ...Evinrude Johnson XD100 DO NOT use any other oil unless in an emer gency If Evinrude Johnson XD100 is tempo rarily unavailable a one time only use of an oil that meets NMMA TC W3RL certification standards is allowed If you discontinue using Evinrude Johnson XD100 you MUST first re turn to your Dealer to have the EMM repro grammed back to the original factory setting IMPORTANT Failure to follow oil ...

Page 19: ...ution hoses in the boat must deliver fuel at the rate of flow need ed by the outboard Minimum inside diameter of fuel hoses must be 3 8 in 9 mm Fuel systems with built in tanks particularly those that include antisiphon valves and filter primer units may have restrictions not allow ing the engine fuel pump to deliver sufficient fuel under all conditions This can result in a loss of performance If ...

Page 20: ... Support on page 20 Turn the angle adjusting rod handle up Push in against spring so retainer will re lease then slide rod assembly all the way out Insert rod in desired position Make sure rod passes through both stern brackets Push in against spring and turn rod handle down Make sure the retainer dropped into lock position WARNING Boat stability and steering torque can vary due to changing water ...

Page 21: ...ition 1 RUN position Grasp tilt grip on engine cover and raise out board slightly 1 Tilt grip Tilt support will automatically disengage Slowly lower outboard to its normal operating position WARNING While outboard is tilted leave tilt lever in the TILT position When the tilt run lever is in the RUN position tilt support can release unexpectedly and allow outboard to drop creating a risk of serious...

Page 22: ...teering handle Use of the emergency stop feature is highly recommended on all boats Connect the clip to the emergency stop switch Snap the lanyard to a secure place on the operator s clothing or life vest not where it might tear away instead of activating the stop switch Disconnecting the clip and lanyard will stop the engine and prevent the boat from becoming a runaway if the driver moves beyond ...

Page 23: ... lanyard for cuts breaks or wear Replace worn or damaged parts Keep the lanyard free from obstructions and entanglements At each outing test the system s operation With the engine running remove the clip from the switch by pulling the lanyard If the engine does not stop running see your Dealer To RESET the system The engine must be shut off and the cooling temperature restored IF the S A F E mode ...

Page 24: ... from a reliable local source Reduce your speed and keep a sharp look out The outboard s shock absorption system does not work while operating in reverse If you back into an object either in the water or while trailering your boat and outboard can be seriously damaged If you hit any object STOP immediately and examine the out board for loosening of attaching hardware INSPECT for damage to swivel a...

Page 25: ...er than 2 3 their original size See your Dealer for re placements Galvanic corrosion destroys underwater met al parts and can occur in fresh or salt water however salt brackish and polluted waters will accelerate corrosion Metal based antifouling paint on the boat or outboard and the use of improperly installed shore power in the area of your moored boat will also accelerate corrosion IMPORTANT NE...

Page 26: ...board vertically Water remaining in the gearcase cooling sys tem or other components can freeze causing serious engine damage IMPORTANT If your outboard s gearcase is equipped with an integral speedometer pick up all water must be cleared from the hose to prevent gearcase damage Refer to Storage on page 30 SHALLOW WATER IMPORTANT Gearcase damage can occur if the gearcase is allowed to drag on the ...

Page 27: ...g system is operational water intake screens and water pump indicator Confirm this Operator s Guide is onboard and readily accessible Check condition of anti corrosion anodes annually or every 100 hours Check for debris on propeller Clean and wax upper and lower engine covers annually or every 100 hours In salt water applications check lubrication points and corrosion protection Use Evinrude anti ...

Page 28: ...26 Using Your E TEC Outboard Bombardier Recreational Products ...

Page 29: ...27 MAINTENANCE ...

Page 30: ...ed to maintain emission levels within prescribed certification standards The owner operator is not to and should not allow anyone to modify the engine in any manner that would alter the horsepower or al low emissions levels to exceed their predeter mined factory specifications Tampering with the fuel system to change horsepower or modify emission levels beyond factory settings or specifications wi...

Page 31: ...g an Evinrude E TEC outboard for commercial or other heavy use that you check these items more frequently annual checks are recommended Electrical and ignition wires inspect for wear or chafing Engine to transom mounting hardware re torque 40 ft lbs Fasteners inspect any loosened components Fuel and oil system components inspect and repair leaks 2 2 Emission related component Fuel filter replace G...

Page 32: ...mended vertical position be sure the cooling system is drained com pletely Never place the gearcase higher than the powerhead Any water remaining in the exhaust passages can run into the cylinders and cause serious damage SHORT TERM BETWEEN USES If you must tilt the outboard to remove it from the water lower it and allow the cooling sys tem to drain completely as soon as you clear the launch area ...

Page 33: ...make sure the water intake screens are com pletely submerged Do not start the outboard again after winterization is completed Prepare your outboard for the off season by closely following these steps 1 Remove the propeller if winterizing on a trailer Throttle must be in NEUTRAL 2 Following bottle directions add 2 4 fuel conditioner to fuel tank and fill it with fuel 3 Attach garden hose to flushin...

Page 34: ...loss finish will show polish marks when viewed closely in certain light condi tions This glossing is NORMAL Periodically wash the entire boat and out board with soapy water and apply a coat of automotive wax Leave the engine cover in place when washing the outboard IMPORTANT When trailering your outboard DO NOT cover the engine with canvas it will dull the finish of the outboard s engine covers Su...

Page 35: ...oned burned or wet Fuse blown Engine will not idle properly Debris on propeller Spark plugs damaged or incorrect Refer to Specifications on page 39 Fuel system contaminated with water or dirt Engine loses power Spark plugs damaged or incorrect Refer to Specifications on page 39 Fuel filter obstructed Fuel system contaminated with water or dirt Water intakes obstructed and cooling system not operat...

Page 36: ...PRODUCT INFORMATION ...

Page 37: ...wer than 2 in 51 mm below it If the resulting position of the antiventilation plate is above or below the 0 to 2 in 0 to 51 mm range the outboard shaft length must be changed or the boat s transom must be mod ified Vent Line Clamp In compliance with Federal regulations this outboard was shipped with a vent line clamp installed This clamp must be removed prior to attempting to prime the fuel system...

Page 38: ...aulk on and around bolts between stern brackets and transom to keep water out of the drilled holes Retighten clamp screws Install the large washers and two of the locknuts on the bot tom bolts Install the small washers and the other two locknuts on the top bolts Tighten all nuts securely 1 Clamp screws 2 Small washers 3 Large washers After 30 minutes of operation retighten clamp screws by hand DO ...

Page 39: ... shaft splines Wedge a block of wood between the propeller blade and the anti ventilation plate Install propeller nut and tighten to a torque of 120 144 in lbs 13 6 16 3 N m Install keeper on propeller nut align keeper slots and cotter pin hole Install new cotter pin and bend ends to se cure Remove block of wood Make sure engine is in NEUTRAL give propeller a spin It must turn freely Repair If you...

Page 40: ...ightly to the right If the boat pulled to the left move the rear of the trim tab slightly to the left Tighten the trim tab screw to a torque of 35 40 ft lbs 47 54 N m Test the boat and if need ed repeat the procedure until steering effort is as equal as possible High motor installations The trim tab might be above the water when the outboard is trimmed out Steering effort might increase Steering e...

Page 41: ...AE J1930 2 ECM Engine Control Module Evinrude E TEC Fuel Requirements 2 87 Pump Posted AKI 90 RON Refer to Oil and Fuel on page 15 Oil Lubricant Capacity TC W3RL NMMA certified oil or Evinrude Johnson XD100 oil Refer to Oil and Fuel on page 15 2 0 qt 1 9 l Spark Plug 2 Refer to ECI Label Fuses Refer to Fuse on page 24 Fuel Filter In line Replaceable Gearcase Lubricant Capacity Evinrude Ultra HPF 2...

Page 42: ...r Only the original purchaser and any subsequent owners who reside in the United States and Canada and have pur chased Product from a U S or Canadian Dealer are eligible for warranty registration and warranty coverage hereunder Such limitations are necessary in order to allow BMCA to protect the safety of its products its consumers and the general public As outlined in the Operator s Guide timely ...

Page 43: ... Dealer removal of Product from a boat and reinstallation mechanic s travel time in and out of water charges slip or dock fees trailering or towing storage telephone cell phone fax or telegram charges rental of a like or replacement Product or boat during warranty services or down time taxi travel lodging loss of or dam age to personal property inconvenience cost of insurance coverage loan payment...

Page 44: ...hese engines are equivalent to the U S EPA s 2006 standards for marine engines Two Stars Very Low Emission The two star label identifies Personal Watercraft Outboard Sterndrive and Inboard engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2004 exhaust emission stan dards Engines meeting these standards have 20 lower emissions than One Star Low Emission en g...

Page 45: ...ia to a California resident or subsequently warranty registered to a California resident The BMCA U S and Canada limited warranty conditions for Evinrude outboards are still applicable to these models with the necessary modifications Select emission control parts of your Evinrude E TEC outboard are warranted from the date of purchase by the first retail consumer or the date the product is first pu...

Page 46: ...imited warranty become the property of BMCA Maintenance receipts and records should be transferred to each subsequent owner of the outboard Owner s Warranty Responsibilities As the outboard owner you are responsible for the performance of the required maintenance listed in your Operator s Guide BMCA recommends that you retain all receipts covering maintenance on your out board but BMCA cannot deny...

Page 47: ... contact you if correction to your outboard be comes necessary Outside the U S and Canada this card should be sent to the Bombardier Recreational Products division where the outboard was registered Please contact your Dealer or Distributor Change of address Change of ownership Model number Serial Number Old address Previous owner Last name First name M I Address City State Zip code Country Phone n...

Page 48: ...46 Product Information Bombardier Motor Corporation of America ...

Page 49: ...ddress Owner of Model No Serial No To be completed by customer or selling Dealer The Dealer named on this document has instructed me on the operation maintenance safety features and warranty policy all of which I understand and agree to be bound with I am also satisfied with the predelivery set up and inspection of my Evinrude Johnson outboard I have also received a copy of the Operator s Guide Si...

Page 50: ...n this Guide and take a boating safety course before you operate your boat and outboard 6 Do you know who to ask if you have any questions about your boat and outboard 7 Do you know your local marine traffic laws 8 Do you understand that human error can be caused by carelessness fatigue overload preoccupation unfamiliarity of operator with the product drugs and alcohol just to name a few WARNING I...

Page 51: ... for service For repairs covered under warranty you must take your Evinrude E TEC outboard to an au thorized dealer Bombardier Motor Corporation of America approved dealers and distribu tors have received the necessary training to properly service your outboard Contact Bombardier Motor Corporation of America for an authorized Evinrude E TEC dealer near you Can I order replacement parts and accesso...

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