357683 Exhaust Back Pressure KitEXHAUST BACK PRESSURE KIT - P/N 357682 Use this kit on 2007 – 2009...

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*357683*Printed in the United States.© 2014 BRP US Inc. All rights reserved.TM, ® and the BRP logo are registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

Outboard Engines

EXHAUST BACK PRESSURE KIT - P/N 357682

Use this kit on 2007 – 2009 Evinrude® E-TEC® 115 HP V4 (1.7 L) outboards with 2-piece exhaust.Do NOT install on any other outboards

SAFETY INFORMATIONThe following symbols and/or signal words maybe used in this document:

These safety alert signal words mean:

ATTENTION!

BECOME ALERT!

YOUR SAFETY IS INVOLVED!

For safety reasons, this kit must be installed byan authorized Evinrude/Johnson® dealer. Thisinstruction sheet is not a substitute for work ex-perience. Additional helpful information may befound in other service literature.

DO NOT perform any work until you have readand understood these instructions completely.

Torque wrench tightening specifications muststrictly be adhered to.

Should removal of any locking fastener (locktabs, locknuts, or patch screws) be required, al-ways replace with a new one.

When replacement parts are required, use Evin-rude/Johnson Genuine Parts or parts with equiv-alent characteristics, including type, strength andmaterial. Use of substandard parts could result ininjury or product malfunction.

Always wear EYE PROTECTION AND APPRO-PRIATE GLOVES when using power tools.

Unless otherwise specified, engine must be OFF(not running) when performing this work.

Always be aware of parts that can move, such asflywheels, propellers, etc.

Some components may be HOT. Always wait forengine to cool down before performing work.

If you use procedures or service tools that arenot recommended in this instruction sheet, YOUALONE must decide if your actions might injurepeople or damage the outboard.

This instruction sheet may be translated into oth-er languages. In the event of any discrepancy,the English version shall prevail.

TO THE INSTALLER: Give this sheet and theoperating instructions to the owner. Advise theowner of any special operation or maintenanceinformation contained in the instructions.

TO THE OWNER: Save these instructions inyour owner’s kit. This sheet contains informationimportant for the use and maintenance of yourengine.

� DANGERIndicates a hazardous situation which, if notavoided, will result in death or seriousinjury.

� WARNINGIndicates a hazardous situation which, if notavoided, could result in death or seriousinjury

� CAUTIONIndicates a hazardous situation which, if notavoided, could result in minor or moderatepersonal injury.

NOTICEIndicates an instruction which, if not fol-lowed, could severely damage engine com-ponents or other property.

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KIT CONTENTS

PROCEDURERefer to the correct service manual. Remove the engine covers. Remove the exhaust valve actuator.Remove the powerhead.

INSTALLATION1) Center the drill template over the rear of the outer exhaust housing as shown. Use a punch tomark the drill locations.

If the template is not available: From the exhaust housing centerline measure out 1-1/8 inch(28.575 mm). From the top of the exhaust housing measure down 2-11/16 inch (68.2625 mm). Drill two 1/8 inch (3.0 mm) pilot holes in the outer exhaust housing at the locations shown.

009153

Part Number

Description QTY

357682 EXHAUST BACK PRESSURE KIT 1

–HOUSING ASSEMBLY, Inner Exhaust

1

– FITTINGS 2

346152 CLAMP, 25.6 mm 4

354135 GASKET (not shown) 1

009158

2.6875 in. (68.2625 mm)

2.6875 in. (68.2625 mm)

1.125 in.

(28.575 mm)

1.125 in.

(28.575 mm)

Drill Template

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2) Enlarge the pilot holes to 9/16 inch(14 mm). Use a 3/8-18 NPT tap to thread theholes.

3) Apply PST Thread Sealant, P/N 764806,to the threads of the fittings. Install the fittingsas shown.

4) Install the two hoses onto the fittings ofthe new inner exhaust housing. Position thetwo clamps as shown. Use Oetiker pincers tosecure the clamps.

IMPORTANT: Refer to the correct service man-ual for:• the installation of the water tube• application of Gel-Seal II• orientation of exhaust valve linkage• tightening torque values

5) Place hose clamps over each hose. Posi-tion the clamps as shown. Install the newinner exhaust assembly into the outerexhaust housing.

6) Assemble the hose onto the fittings of theouter exhaust housing. Position the twoclamps as shown. Use Oetiker pincers tosecure the clamps.

Refer to the correct service manual. Install thepowerhead, exhaust valve actuator and enginecovers.

Run the outboard and inspect for leaks.

009153

009154

009155

009156

009157

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DRILL TEMPLATEUse the drill template to mark the drill locations on the rear of the outer exhaust housing.

IMPORTANT: If printing this document from an electronic file MAKE SURE the print options are setto “Actual Size.” Do NOT change the scale or the drilled holes will be in the wrong location.

2.6875 in. (68.2625 mm)

2.6875 in. (68.2625 mm)

1.125 in.

(28.575 mm)

1.125 in.

(28.575 mm)

Drill Template

IMPORTANT: Do NOT scale this document when printing!