Evinrude E-TEC 40RL 2008 Operator'S Manual Download

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Easy to Own and Operate

• Three-Year Limited Warranty

• No Scheduled Dealer Maintenance for

Three Years of Normal Recreational Use

• No Operational Break-In Procedure

• Easy Starts (no choking or priming)

• Digital Engine Management

• Self Flushing Cooling System

• Long Term Storage Design

• Simplified Winterization Procedure

• Digital Diagnostics

• Low Oil Usage

• CANbus Capable

Durable and Reliable

• Full Corrosion Protection

•

Evinrude E-TEC

Lubrication System

• Auto-Calibrated Linkage

• Robust, Heavy-Duty Design

• Posi-Lock Latches

• Extra Capacity Water Pump

• Iridium Spark Plugs

• Vibration Isolated Electronics

• Beltless 25 Amp Charging System

• Stainless Steel Thermostat

• Nickel/Chrome-Faced Piston Rings

• Micro Finished Connecting Rods/Crankshaft

Cleaner and Quieter

• EPA Emissions Compliance

• European Union 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

• Idle Air Bypass

FEATURES AT A GLANCE

The following trademarks are the property of Bombardier Recreational Products Inc. or its affiliates:

Evinrude®

Evinrude®/Johnson® XD30™

I-Command

™

Evinrude® E-TEC®

BRP Logo

S.A.F.E.

™

Evinrude®/Johnson® Genuine Parts

2+4™ Fuel Conditioner

SystemCheck

™

Evinrude®/Johnson® XD100™

HPF XR™

Gearcase Lubricant

Triple-Guard™

Grease

Evinrude®/Johnson® XD50™

HPF Pro™

Gearcase Lubricant

Summary of Contents for E-TEC 40RL 2008

Page 1: ... PERATORgS UIDE 51 1 5HDG WKLV 2SHUDWRU XLGH WKRURXJKO W FRQWDLQV LPSRUWDQW VDIHW LQIRUPDWLRQ KHQ RSHUDWLQJ RXU ERDW DOZD V KDYH WKLV 2SHUDWRU XLGH RQERDUG RL 40 23 0 7 2 2008 Model Year 93 ...

Page 2: ...40 HORSEPOWER RL 2008 Model Year ...

Page 3: ......

Page 4: ... Steel Thermostat Nickel Chrome Faced Piston Rings Micro Finished Connecting Rods Crankshaft Cleaner and Quieter EPA Emissions Compliance European Union 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 I...

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Page 6: ...inrude E TEC outboards have been engineered to outperform anything on the wa ter acceleration top end speed any size any horsepower across the line And for your buddies who own a four stroke Well they cannot touch our power to weight ratio And you can tell them that no four stroke comes close to the pure power and torque of an Evinrude E TEC outboard DURABILITY QUALITY RELIABILITY Fewer parts Fewe...

Page 7: ...ments 15 Fuel System Operation 16 Fuel System Priming 16 Fuel Additives 16 Operation 17 Safety Information 17 Engine Starting 17 Engine Stopping 19 Shifting and Speed Control 20 Tilting 20 Tilt Support Bracket 21 Trailering 21 Trim Angle Adjustment 22 Impact Damage Protection 22 Engine Overheating 23 Salt Water 24 Weedy Water 25 High Altitude 25 Freezing Weather 25 Shallow Water 25 Under Tow 26 Fu...

Page 8: ...eason Check 34 Spark Plugs 34 Scratch Repair 35 Hull Finish 35 Outboard External Finish 35 Submerged Outboard 35 Troubleshooting 36 PRODUCT INFORMATION Installation 38 Adjustments 41 Specifications 42 Product Warranty Information 43 California Emission Control Warranty 46 Readiness Test 49 Frequently Asked Questions 50 Change of Address Change of Ownership 51 Confirmation of Receipt 53 ...

Page 9: ... BOAT 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...

Page 10: ...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 lev el before use and during the ride Apply the principle of 1 3 fuel to desti...

Page 11: ... 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 12: ...all marketing areas Owner s Identification United States and Canada At the time of purchase your Dealer will complete your out board registration forms Your portion provides proof of ownership and date of purchase Outside United States and Canada See your Dealer or distributor for details Model and Serial Numbers The model and serial numbers appear on a plate attached to the stern bracket or swive...

Page 13: ... Craft Relevant Directive s Directive 89 336 CEE Eletromagnetic Compatibility Relevant Harmonized Standard s As referenced by Council and Relevant Directives Product Type Marine Outboard 2 Stroke Cycle SI Engine Manufacturer BRP US Inc 10101 Science Drive Sturtevant WI 53177 EC Type Certificate I the undersigned hereby declare that the product specified above conforms to the above Di rective s and...

Page 14: ...11 X USING YOUR EVINRUDE E TEC OUTBOARD USING YOUR E TEC OUTBOARD ...

Page 15: ...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 16: ...iption 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 17: ...rogram your outboard for this op tional benefit Oil consumption is reduced if the outboard is programmed for exclusive use of Evinrude Johnson XD100 as compared to using a con ventional oil IMPORTANT If your EMM has been pro grammed for 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 me...

Page 18: ... completely out of oil or The outboard is laid down for transportation or storage Prime the oiling system by performing winter ization Refer to Long Term Storage Win terization on page 33 WARNING Gasoline is extremely flammable and highly explosive under certain condi tions Follow the instructions in this section explicitly Improper handling of fuel could result in property damage serious injury o...

Page 19: ...e only fuel additives approved for use in your Evinrude E TEC outboard are Evinrude Johnson 2 4 Fuel Conditioner Evinrude Johnson Fuel System Cleaner Use of other fuel additives can result in poor performance or engine damage Evinrude Johnson 2 4 Fuel Conditioner will help prevent gum and varnish deposits from forming in fuel system components and will remove moisture from the fuel system It can b...

Page 20: ... 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 WARNING The engine cover is a machinery guard DO NOT operate your outboard with the cover of...

Page 21: ...ing procedure or if it fails to start re fer to Troubleshooting on page 36 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 23 WARNING Always shift to NEUTRAL before start ing the outboard to prevent sudden boat ...

Page 22: ...f the lanyard If the lanyard is too long it can be shortened by knotting or looping it DO NOT cut and retie the lanyard 1 Clip 2 Emergency stop clip key switch 3 Lanyard An extra clip is provided on the tiller handle If the operator is thrown from the boat another person can insert the extra clip in the stop switch and start the outboard 1 Extra clip 1 3 1 2 DANGER Always use the safety lanyard wh...

Page 23: ...nd 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 Economy Fuel economy can vary depending on boat load hull design and throttle setting When boat reaches top speed throttle back from FULL SPEED to a lower throttle setting You will save fuel with a minimal loss o...

Page 24: ...fully and pull tilt support bracket to un lock position Lower outboard 1 Tilt support bracket unlock position TRAILERING Trailer your boat with the outboard in a verti cal position If your trailer does not provide ad equate road clearance support the outboard with an accessory trailering bracket IMPORTANT The outboard must be re strained when trailering Bouncing during transport may damage the out...

Page 25: ...ts like pilings or boulders can be beyond the capability of the absorption system Such impacts can result in serious damage to your outboard and injury to boat occupants from the outboard or its parts entering the boat Occupants can also be ejected or in jured by falling against portions of the boat as a result of rapid deceleration following im pacts When boating in unfamiliar shallow or de bris ...

Page 26: ...completely submerged and unob structed Observe proper transom height and tilt angle While the outboard is running the outboard s water pump indicator must dis charge a steady stream of water Check the indicator often especially when operating in weeds muddy and debris laden water and at extreme trim angles 1 Water intake screens 2 Water pump indicator If the engine overheats the S A F E Speed Adju...

Page 27: ... 3 Tilt the outboard up 4 Clean the intake screens of any blockage 5 Clean the water pump indicator of any blockage 6 Lower the outboard 7 Restart the engine and run at idle IF cleaning the screens and indicator does not restore the water pump indicator s steady discharge the engine will operate only in get home mode Return to harbor immediately See your Dealer IF cleaning the screens and indicato...

Page 28: ...om propeller area and water intakes before operating at higher speed HIGH ALTITUDE Your outboard s EMM will automatically com pensate for changes in altitude However if you boat above 3000 ft 900 m you will ex perience a slight loss of power due to reduced air density If your engine drops below the recommended RPM operating range at full throttle have your Dealer select a lower pitch propeller If ...

Page 29: ...nrude E TEC outboard uses 10 amp fuses Remove engine cover Install spare fuse in place of failed fuse 1 Fuse 2 Spare fuse IMPORTANT Failure to install cover securely may cause electrical problems On outboards equipped with an accesso ry electric starter a blown fuse will not allow the engine to start Replace it with a fuse of the same rating A spare fuse is provided Repeated fuse failures indicate...

Page 30: ...ake 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 shaft requires propeller removal 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 ...

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Page 32: ...29 X MAINTENANCE ...

Page 33: ...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 34: ...ardware re torque 40 ft lbs 3 Fasteners inspect any loosened components 3 Fuel and oil system components inspect and repair leaks 2 2 Emission related component Refer to Owner Responsibility on page 30 Product Warranty Information on page 43 and if applicable California Emission Control Warranty Statement on page 46 3 Fuel filter replace 3 Gearcase lubricant replace A 3 Grease fittings lubricate 3...

Page 35: ... flushing 4 Leave the outboard in vertical position long enough to completely drain the power head IMPORTANT If you cannot store the out board in the recommended 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 STORAGE Betw...

Page 36: ...ate to fast idle speed and fog itself 4 Allow outboard to run until it shuts itself OFF automatically less than one minute After Winterization 1 After the outboard shuts itself off remove emergency stop clip key switch Do not start the outboard again after winterization is completed 2 If winterizing on a trailer turn off water and detach garden hose Grease propeller shaft splines with recommended ...

Page 37: ...gs should be serviced by an Evinrude E TEC Dealer Incorrect spark plug maintenance can lead to engine damage IMPORTANT Replacement spark plugs MUST be indexed correctly Marine Engine Duty Cycles The International Council of Marine Industry Associations ICOMIA Standard No 36 88 specifies a marine engine duty cycle based on documented studies A duty cycle is a profile of engine running and usage Thi...

Page 38: ... polished out with buff ing compound Treat affected areas using these steps 1 Sand the affected area with 800 grit sand paper 2 Wet sand the area with 1200 grit sandpa per 3 Using a composite material buffing com pound polish the area closely following the product directions IMPORTANT Your Dealer has the profes sional materials to properly repair scratches Do not attempt to paint over marks or scr...

Page 39: ...r wet Fuse blown Engine will not idle properly Debris on propeller Spark plugs damaged or incorrect Refer to Spark Plugs on page 34 Fuel system contaminated with water or dirt Engine loses power Spark plugs damaged or incorrect Refer to Spark Plugs on page 34 Fuel filter obstructed Fuel system contaminated with water or dirt Water intakes obstructed and cooling system not operating correctly Refer...

Page 40: ...37 X PRODUCT INFORMATION ...

Page 41: ...ed IMPORTANT Be sure that outboard water pressure is not adversely affected by the mounting height of the outboard WARNING Your outboard must not exceed the maximum horsepower indicated on the boat s capacity plate Such overpower ing can cause loss of control Contact your Dealer or the boat s manufacturer if your boat lacks a capacity plate Boats designed for remote steered out boards might be ove...

Page 42: ... to transom 1 Transom plate 2 Small washers 3 Large washers The kit also includes clamp pads which must be used to secure mounting bolts in slots at the bottom of the outboard stern brackets 1 Clamp pad Install the mounting bolts through the stern brackets and transom Install round backing plates and locknuts onto bolts and tighten se curely WARNING The outboard must be correctly installed Failure...

Page 43: ...ts a solid object the impact is partially absorbed by the rubber bushing in the hub to help prevent damage to the out board A strong impact can damage the hub and propeller blades Damage to blades can cause unusual and excessive vibration Dam age to the hub can cause excessive engine RPM with little forward movement IMPORTANT Avoid or limit operation using a damaged propeller Carry a spare propell...

Page 44: ...htly 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 outboard installations The trim tab might be above the water when the out board is trimmed out Steering effort might in crease Steerin...

Page 45: ...AE J1930 2 ECM Engine Control Module Evinrude E TEC Fuel Requirements 2 87 Pump Posted AKI 90 RON Refer to Fuel Requirements on page 15 Oil Lubricant Capacity TC W3 NMMA certified oil or Evinrude Johnson XD100 oil Refer to Oil Requirements on page 14 2 0 qt 1 9 l Spark Plug 2 Refer to ECI Label Fuses Refer to Fuse on page 26 Fuel Filter In line Replaceable Gearcase Lubricant Capacity Evinrude HPF ...

Page 46: ...kage by foreign material Damage resulting from sand or debris in the water pump Cosmetic or paint changes due to exposure to the elements This warranty will be voided in its entirety and rendered null and void where Product has been altered or modified in such a way so as to adversely affect its operation performance or durability or change its intended use horsepower or emission levels or Product...

Page 47: ...or Canadian Dealer are eligible for warranty registration and warran ty coverage hereunder Such limitations are necessary in order to allow BRP to protect the safety of its products its consumers and the general public As outlined in the Operator s Guide timely routine required maintenance must be performed to maintain warranty coverage BRP may require proof of proper maintenance prior to authoriz...

Page 48: ...is required please contact Bombardier Recreational Products Customer Support Services 250 Sea Horse Drive Waukegan IL 60085 1 847 689 7090 BOMBARDIER RECREATIONAL PRODUCTS LIMITED WARRANTY FOR 2008 EVINRUDE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA For a copy of the Limited Warranty see your Bombardier Recreational Products BRP distributor dealer authorized to distribute Evinrude ...

Page 49: ...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 50: ...fornia resident The BRP 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 put to use whichever occurs first for a period of 4 years or for 250 hours o...

Page 51: ...ce 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 BRP recommends that you retain all receipts covering maintenance on your outboard but BRP cannot deny warranty solely for the lack of receipts or your failur...

Page 52: ...ide 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 It is impo...

Page 53: ...should I take my Evinrude E TEC outboard for service For repairs covered under warranty you must take your Evinrude E TEC outboard to an au thorized dealer BRP approved dealers and distributors have received the necessary train ing to properly service your outboard Contact BRP for an authorized Evinrude E TEC dealer near you Can I order replacement parts and accessories for my Evinrude E TEC outbo...

Page 54: ... Bombardier Recreational Products divi sion 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 number Signature Date New Address New Owner Last name First name M I Address City State Zip code Country Phone number Sig...

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Page 56: ...dress 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 Sig...

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