Evinrude E-tec 2011 Series Product Service Update Download Page 3 | Manualshive

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Product Service Update

BRP US Inc.
Technical Publications
300 Sea Horse Drive
Waukegan, Illinois 60085 United States

† AMP is a registered trademark of Tyco International, Ltd.
† Champion is a registered trademark of Federal-Mogul Corporation.
† MicroSoft, MicroSoft Windows XP, Windows Vista and Windows 7 are registered trademarks of MicroSoft Corporation.
† Molex is a registered trademark of Molex Inc.
† NMEA is a registered trademark of the National Marine Electronics Association.
† Oetiker is a registered trademark of Hans Oetiker AG Maschinen

The following trademarks are the property of BRP US Inc. or its affiliates:

Printed in the United States
© 2011 BRP US Inc. All rights reserved.
TM, ® and the BRP logo are registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

Evinrude

®

E-TEC

®

S.A.F.E.

Evinrude

®

/ Johnson

®

XD30™

Outboard Oil

Johnson

®

SystemCheck™

Evinrude

®

/ Johnson

®

XD50™

Outboard Oil

FasTrak™

Triple-Guard

Evinrude

®

/ Johnson

®

XD100™

Outboard Oil

I-Command™

DealerPort

®

TBX™

Evinrude

®

ICON™

BossWeb

Viper™

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Summary of Contents for E-tec 2011 Series

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Page 3: ...a registered trademark of the National Marine Electronics Association Oetiker is a registered trademark of Hans Oetiker AG Maschinen The following trademarks are the property of BRP US Inc or its aff...

Page 4: ...90 V4 V6 MODELS 18 SERVICE INFORMATION 23 15 30 HP MODELS 24 75 90 HP 1 3L MODELS 26 115 300 HP 60 90 V4 V6 MODELS 27 200 300 HP 90 V6 MODELS 28 MAINTENANCE 29 ELECTRICAL SYSTEM 30 FUEL SYSTEM 33 OILI...

Page 5: ...6 FUSES 67 EVINRUDE E TEC SPARK PLUG SERVICE CHART 68 EMM SERVICE CHART 69 EVINRUDE E TEC GEARCASE LINE DRAWINGS 70 2011 EVINRUDE E TEC GEARCASE APPLICATION CHART 72 EVINRUDE E TEC SHIFT ROD CHART 74...

Page 6: ...4...

Page 7: ...5 GENERAL INFORMATION...

Page 8: ...r Support BRP US Inc Customer Support Services 250 Sea Horse Drive Waukegan IL 60085 Ph 1 847 689 7090 Non authorized dealers consumers Fax 1 847 689 6902 Non authorized dealers consumers Parts Access...

Page 9: ...LE EAST AND AFRICA BRP International Division 5 7 CH Chemin du Messidor Lausanne Switzerland Phone 41 21 318 78 00 FRANCE Bombardier Recreational Products France Les Jardins de la Duranne B timent C 5...

Page 10: ...upport Dealers are not authorized to rebuild assemblies without prior authorization Have your dealer number the engine model and serial number part number and invoice date available Certain parts or a...

Page 11: ...ery Checklist Included in Shipping Crate A Predelivery Checklist is now included in the shipping crate owner s package of all Evinrude E TEC outboards A pack of ten 10 predelivery checklist forms P N...

Page 12: ...nstructors at Dallas Tacoma and Laval Training Cen ters TSR s provide the following OEM partner support All aspects of rigging technical training to ensure safety and maximum performance for BRP power...

Page 13: ...outlined in steps 3 through 5 above If a technician allows their Certification to lapse Master Technician status is lost A technician can take a missed exam at any time to have Certified status reinst...

Page 14: ...12 NOTES GENERAL INFORMATION...

Page 15: ...13 2011 PRODUCT IMPROVEMENTS...

Page 16: ...ftware on engines with serial numbers 5283875 to 5289986 Refer to Warranty Bulletin 2010 09 W Engine Wiring Harness Change 15 30 HP Models Evinrude E TEC 15 30 HP C H R and S suffix model outboards ha...

Page 17: ...or the cylinder block DO NOT allow the flywheel holder to rest against the mounting boss for the recoil starter Also refer to Service Bulletin 2010 08 S or the 2011 Service Manual Lower Mount 15 30 H...

Page 18: ...newer 15 30 HP models and 2010 and newer 40 90 HP F suffix models Electric Starter Motor Change 40 65 HP Models The electric starter motor used on Evinrude E TEC 40 65 HP models has been changed The s...

Page 19: ...newer 40 65 HP models Exhaust Housings 40 65 HP Models A change was made to the exhaust housing for 40 65 HP models Retainer tabs have been added to the exhaust housing to better secure the engine wi...

Page 20: ...ing removal and installation Service parts for older product will supersede to new part numbers Refer to the correct Parts Catalog for parts ordering information Note Do not use power impact tools to...

Page 21: ...replaces the rear oil manifold on 250 300 HP 3 4 L mod els The oil pump is a positive displacement oil pump which supplies oil to each piston IMPORTANT Correct oil priming procedure is required when i...

Page 22: ...rrupt reduces shift effort when the engine is shifted out of gear Neutral rpm limit limits engine speed to approximately 1100 rpm when shift lever is in NEUTRAL position Note DE model engines ICON Ele...

Page 23: ...on 225 300 HP 90 Models The L2 Type gearcase with 0 58 gear ratio has been replaced by the M2 Type gearcase with 0 54 gear ratio on all 225 300 HP models The larger gear set used in the M2 Type gearc...

Page 24: ...y positioned Refer to the appropriate Service Manual for installation instructions Exhaust grommet P N 5008518 services all 2005 and newer 115 300 HP Evinrude E TEC models Fuel Hoses All Models New an...

Page 25: ...23 SERVICE INFORMATION...

Page 26: ...ed Code 43 Engine temperature above range Recorded maximum engine temperature If any of these service codes are stored and the maximum engine temperature is over 248 F 120 C remove the gearcase Inspec...

Page 27: ...nce of the water pump This change affects engine water pressure and REQUIRES stron ger pressure relief valve and thermostat springs IMPORTANT REPLACE the pressure relief valve and thermostat springs w...

Page 28: ...nstallation can result in the low oil switch being held ON by the oil pick up assembly The fix Be sure to install the oil pump pick up assembly straight into oil tank Refer to the correct Service Manu...

Page 29: ...itor the exhaust back pressure on an engine that is difficult to start or runs poorly Normally exhaust back pressure readings are erratic If the data log shows read ings which tend to be linear check...

Page 30: ...t the correct M2 Type replacement gearcase Refer to the Parts Catalog for replacement gearcase part numbers Select the correct gearcase conversion kit order P N 5008535 for 20 inch models order P N 50...

Page 31: ...resolve any service codes X Electrical and ignition wires inspect for wear or chafing X Description Engine Care Product Every 300 hours or 3 years 1 Fuel filter replace 2 X Gearcase lubricant replace...

Page 32: ...omplete instructions FAQ Spark Plugs All Models The Service Teams are frequently asked if it is permissible to substitute spark plugs the answer is NO unless there is an APPROVED substitution At this...

Page 33: ...DC check that connections are clean tight and free of corrosion Clean or replace any corroded or damaged cables or connections Note Disconnect the Crankshaft Position Sensor CPS to prevent the engine...

Page 34: ...it momentarily stops current flow through the coil primary winding The surrounding magnetic field collapses creating high voltage in the coil secondary winding IDI Ignition Coil Tests Because the ign...

Page 35: ...ial Number SN and the 5 digit Checksum CS number from the injector serial number label Log on to DealerPort or BossWeb to download injector coefficient files from the internet Refer to Service Bulleti...

Page 36: ...m Engine damage As part of routine maintenance inspect fuel hoses from the tank to the outboard Make sure fuel supply hoses have not deteriorated Replace deteriorated fuel hoses Routine inspection of...

Page 37: ...rapidly connecting and disconnecting the pump s internal coil to ground Refer to the 2011 Service Manual for code description Possible Causes Damaged wire harness or electrical connector between EMM a...

Page 38: ...intakes tempo rarily cover auxiliary water inlets as follows 15 30 HP Models Temporarily cover the two small auxiliary water inlet holes on each side of the gearcase with waterproof tape 150 300 HP M...

Page 39: ...models in 2007 Hydraulic Trim and Tilt Assembly P N 5005756 superseded to P N 5007776 starting in 2008 Some service parts for these hydraulic trim and tilt assemblies are NOT inter changeable Use the...

Page 40: ...ot machined to accept the alignment pins remove the alignment pins from the replacement gearcase Failure to remove the exhaust housing to gearcase alignment pins can damage the exhaust housing mountin...

Page 41: ...39 EVINRUDE DIAGNOSTICS SOFTWARE...

Page 42: ...ware Requirements Personal Computer IBM compatible laptop computer Operating System Microsoft Windows 7 Vista XP 2008 or 2003 CPU Speed Pentium II 133 MHz or higher Memory 64 megabyte or more Hard dis...

Page 43: ...nding on your sub scription service Changes to these selections may be made at any time by selecting the Tools menu and selecting Options Software Registration Software registration is required to run...

Page 44: ...42 NOTES EVINRUDE DIAGNOSTICS SOFTWARE...

Page 45: ...43 EVINRUDE ICON REMOTE CONTROL SYSTEM...

Page 46: ...newer Evinrude E TEC 150 300 HP models To add digital electronic shift and throttle control to an Evinrude E TEC outboard order ICON Conversion Kit P N 764979 for 200 300 HP 90 V6 models ICON Conversi...

Page 47: ...nel P N 765378 765375 765376 765377 Trim Switch Panel P N 765388 765389 765390 Network Power Cable P N 764921 ICON Gateway Module Kit P N 764922 ICON Accessory Power Relay P N 765296 ICON Hubs 2 P N 7...

Page 48: ...ts Include ICON Remote Control P N 765381 765382 765383 765384 765385 Emergency Stop Switch Panel P N 765379 765380 765372 765372 765372 Start Stop Switch Panel P N 765375 765376 765377 Trim Switch Pa...

Page 49: ...r Tighten locking rings of connectors finger tight Do not rotate the connectors to align pins to sockets This can damage the pins of the connector A damaged connector can cause an electrical short in...

Page 50: ...nfirm FORWARD gear engagement Move the control lever to the REVERSE detent Manually turn the propeller shaft to confirm REVERSE gear engagement Move the control lever to the NEUTRAL detent Rotate the...

Page 51: ...HP 90 V6 Models When installing an ICON conversion kit on 2011 and newer 200 300 HP 90 V6 models the shift switch must be removed Install protective cover P N 586821 on shift switch connector of the...

Page 52: ...ke repairs to an ICON network Additional copies may be ordered from Evinrude Johnson Genuine Parts and Accessories Remote Control Neutral Position Before attempting to change ICON network settings set...

Page 53: ...and charge Run the engine connected to the battery for the ICON network or use a battery charger to support the battery voltage Visually inspect the 3A fuse for the master power key switch and the 10...

Page 54: ...as ter power key switch or wire harness is not damaged or the fuse fails again con tinue with Step 3 Step 3 Turn the master power key switch OFF Replace 3 amp fuse Step 4 Disconnect ALL hubs the back...

Page 55: ...53 I COMMAND...

Page 56: ...a common network When adding devices to the NMEA 2000 network Unconfigured devices MUST be added one device at a time Preconfigured device kits can be added to the network all at one time In either ca...

Page 57: ...psi 0 to 206 kPA Refer to the installation instructions provided with the kit for correct installation The water pressure sensor MUST be installed in a vertical position Hose instal lation MUST provid...

Page 58: ...rds during certain CANBus commu nication modes 2007 01 P I Command Network Connector s 2005 newer 200 250 HP 90 V6 2007 newer 115 200 HP 60 V4 V6 2008 newer 40 90 HP This bulletin provides information...

Page 59: ...57 PARTS AND ACCESSORIES...

Page 60: ...Part Numbers The following items are frequently requested part numbers and should be ordered as needed Predelivery Checklist P N 5008381 10 pack Warranty Allowance Requests warranty claim forms P N 77...

Page 61: ...ropeller hardware and propeller are installed Insufficient clamp load causes the propeller to loosen and can result in scoring of the propeller shaft by the thrust bushing The area that is scored by t...

Page 62: ...60 NOTES PARTS AND ACCESSORIES...

Page 63: ...61 SERVICE TOOLS...

Page 64: ...5008371 is used to check a boat s fuel system for fuel flow restrictions and air leaks without having to start the outboard or run the vessel through the water Developed for Evinrude E TEC 115 300 HP...

Page 65: ...or use with Windows XP or Windows Vista Windows 7 Log into DealerPort www dealerport com or BOSSWeb www boss web brp com to download the latest I Command software and information This tool was shipped...

Page 66: ...64 NOTES TOOLS...

Page 67: ...65 REFERENCE...

Page 68: ...2 Midsection Gearcase PRIMER Gray W42650 W29741 Use for white engines PRIMER Black SEP61993 W29585 Use for blue engines BLACK Gloss 777179 W28610 W28792 Engine cylinder crankcase BLACK Military 351066...

Page 69: ...512129 AGA 5 Glass 0 625 x 0 25 5 510884 AGA 20 Glass 0 625 x 0 25 10 5031911 AGA 25 Glass 0 625 x 0 25 1 511386 AGA 30 Glass 0 625 x 0 25 1 123852 AGC 1 Glass 1 25 x 0 25 1 5030348 AGC 20 Glass 1 25...

Page 70: ...P QC10WEP QC10WEP 115 130 HP 60 V4 QC10PEPB QC10WEP QC10WEP QC10WEP QC10WEP 150 200 HP 60 V6 QC10PEPB QC10WEP QC10WEP QC10WEP QC10WEP 200 250 HP 90 V6 3 3L QC10WEP QC10WEP QC10WEP QC10WEP QC8WEP QC8WE...

Page 71: ...ne on an older engine Changes in the newer models will result in damage to the EMM if installed on an older engine Model 2004 2005 2006 2007 2008 2009 2010 2011 15 30 HP 587062 587062 587062 40 50 HP...

Page 72: ...AWINGS S Type 75 90 HP 20 inch I3 and S2 Type 115 130 HP 20 inch V4 O Type 90 130 HP 25 inch I3 V4 and 150 200 HP 20 inch 60 V6 4 124 19 079 19 20 4 918 H Type 15 H O 30 HP I2 F Type 40 65 HP I2 14 24...

Page 73: ...No longer produced L2 Type 150 H O 60 V6 20 inch and 200 H O 90 V6 3 3L 20 inch 19 20 4 918 4 918 19 20 M Type No longer produced M2 Type 150 200 HP 60 V6 25 inch and 200 300 HP 90 V6 20 25 inch 19 2...

Page 74: ...oz 620 ml S Type 5006555 Blue 75 90 HP 20 13 26 500 2 1 436746 F P 345992 31 6 oz 935 ml 5006426 White 75 90 HP 20 13 26 500 2 1 436746 F P 345992 31 6 oz 935 ml S2 Type 5006326 Blue 60 V4 20 13 26 50...

Page 75: ...7389 F P R 347373 38 9 oz 1150 ml 5007669 White 90 V6 3 3L 20 25 30 13 24 542 1 85 1 5007389 F P R 347373 38 9 oz 1150 ml 5007669 White 90 V6 3 4L 25 30 13 24 542 1 85 1 5007389 F P R 347373 38 9 oz 1...

Page 76: ...O 44 352957 25 15 16 in 65 90 cm 35 55 in 90 29 cm 150 200 HP 60 V6 2007 2011 20 L L2 54 350464 20 15 16 in 53 20 cm 30 57 in 77 65 cm 2007 2011 20 O 54 350464 20 15 16 in 53 20 cm 30 57 in 77 65 cm 2...

Page 77: ...350946 350945 0 160 Aerated Ultra High Flow 1 4 P N 5007081 350790 350791 0 410 Severely aerated Screws P N 337061 Note Kits include both screens screws and instruction sheet O Type Gearcase Individua...

Page 78: ...P 90 V6 3 3L 4500 5800 5500 5700 5150 250 H O 90 V6 3 4L 4500 6000 5500 5850 5250 300 HP 90 V6 3 4L 5000 6000 5500 5850 5500 How to Use the RPM Quick Reference Chart When selecting a propeller for an...

Page 79: ...124 16 18 110 124 13 15 89 103 15 17 103 117 16 18 110 124 19 21 131 144 20 22 137 151 115 130 HP 60 V4 5 6 34 41 9 10 62 68 12 14 82 96 15 17 103 117 18 20 124 137 20 21 137 144 20 22 137 151 21 23...

Page 80: ...4 5008335 Literature Sets 2011 Illustrated Parts Accessory Catalog 5008324 2011 Parts Catalog Set Paper 5008325 2011 Service Manual Set English 5008340 2011 Service Manual Set French 5008341 2011 Serv...

Page 81: ...155 Literature Sets 2010 Illustrated Parts Accessory Catalog 5008005 2010 Parts Catalog Set Paper 5008004 2010 Service Manual Set English 5008158 2010 Service Manual Set French 5008159 2010 Service Ma...

Page 82: ...rude E TEC 15 300 HP Outboards Damaged Wiring Resulting from Improper Rigging or Faulty Connec tions 2010 03 S Evinrude E TEC 75 90 HP Outboards Gearcase Alignment Gauge Kit P N 5006349 Replaces Servi...

Page 83: ...EPA CAMPAIGN Fuel Hose and Primer Bulb Assembly Replacement 2010 04 W 2010 and 2011 Evinrude E TEC 40 90 HP Outboards SAFETY CAMPAIGN Incorrectly Installed Clamps on Fuel Hoses 2010 05 W 2011 Evinrude...

Page 84: ...82 NOTES REFERENCE...

Page 85: ...83 APPENDIX...

Page 86: ...81 90 HP 81 115 HP and larger 81 115 H O 130 HP 83 150 200 HP 60 V6 83 150 300 HP 60 V6 and 90 V6 83 200 H O 250 HP 90 V6 83 250 H O 300 HP 90 V6 84 300 HP 85 4 Stroke 85 All 85 ICON Remote Control Sy...

Page 87: ...S 25 30 Oil recirculation diagram new model 2009 Oiling Systems 25 30 New accessory kits for Evinrude E TEC 25 30 HP 2009 Parts Accessories 40 Tilt assist kit for manual tilt models 2008 Parts Access...

Page 88: ...feedback not detected 2008 Service Codes 40 90 Change to flywheel service procedures 2009 Ignition Electrical 40 90 New oil tank and oil pump assemblies 2010 Product Improvements 40 90 Neutral switch...

Page 89: ...rvice Codes 75 300 O ring P N 314728 supersedes to P N 354731 2010 Product Improvements 90 Manual tilt midsection not compatible with trim and tilt 2008 Midsection 90 250 Water pump grommet and seal a...

Page 90: ...e test port changed 2009 Fuel System 115 200 60 models Rear oil manifold bracket 2009 Oiling Systems 115 200 60 models Improved shift lever eliminates lost motion 2009 Gearcase 115 200 60 models only...

Page 91: ...2008 Gearcase 150 250 L2 Type Gearcase information 2008 Gearcase 150 250 Forward gear and bearing changes 2008 Gearcase 150 250 Propeller shaft bearing housing retainer tabs 2008 Gearcase 150 250 Whi...

Page 92: ...oduct Improvements 200 250 3 3 L Models Water plate P N 347251 2010 Service Tips 200 300 90 models Ignition coil mounting location coil damage 2009 Ignition Electrical 200 300 90 models Pinched oil li...

Page 93: ...ms 250 H O 300 90 3 4 L models F suffix Adapter P N 5007973 2009 Midsection 250 H O 300 90 3 4 L models C or S suffix Adapter P N 5007971 2009 Midsection 300 Important engine management software updat...

Page 94: ...e and vacuum tests 2008 Fuel System All Fuel control adjustment not available 2008 Fuel System All 2008 Gearcase application chart 2008 Gearcase All 2009 Gearcase application chart 2009 Gearcase All G...

Page 95: ...Powerhead All Break in oil cycle 2008 Powerhead 2009 Powerhead All Different WOT rpm on multiple engine applications propeller 2008 Rigging OMC Service Bulletin 2092 All Poor acceleration propeller 20...

Page 96: ...or message Windows NT v 5 0 2009 Diagnostic Software All Error message Invalid Chipset 2009 Diagnostic Software All Diagnostic power supply P N 587005 2009 Diagnostic Software All EMM service chart 20...

Page 97: ...Tips ICON Control Features 2010 Evinrude ICON Remote Control ICON Control ICON rigging kits 2010 Evinrude ICON Remote Control ICON Control ICON conversion kits 2010 Evinrude ICON Remote Control ICON...

Page 98: ...ator sensor fault 2010 Evinrude ICON Remote Control ICON Control Code 152 Shift actuator motion fault 2010 Evinrude ICON Remote Control I Command Fuel Level Does Not Display 2008 Rigging I Command Alt...

Page 99: ...issue 2009 Parts Accessories P A OMS replacement checklist 2009 Parts Accessories P A TBX Torsion bushing damage 2009 Parts Accessories P A Rectifier regulator no purple wire 2009 Parts Accessories P...

Page 100: ...ion number changes 2008 Engine Management Software 2009 Engine Management Software Software Software version updates 2008 Engine Management Software 2009 Engine Management Software Software Inline upd...

Page 101: ...thout gearcase disassembly 2009 Gearcase Service Bulletin 2008 02 S Tools Gearcase alignment gauge 2008 Gearcase Service Bulletin 2004 011 S Tools Enigne lift kit P N 354717 2010 Service Tools Predeli...

Page 102: ...100 NOTES APPENDIX...

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