PL, PX, SL...• Heavy-Duty Use Design • Posi-Lock Latches • Digital Diagnostics • Extra Capacity Water Pump • High Thrust, Large Gearcase • Dual Platinum Spark Plugs •

12 pt12 pt

™™

WARNINGRead this Operator Guide thoroughly. It contains important

safety information. When operating your boat, always have this Operator Guide onboard.

! !*215642*

PL, PX, SL

75/90 HORSEPOWER

2005

Easy to Own and Operate• Three-Year Limited Warranty• No Scheduled Dealer Maintenance for

Three Years of Normal Recreational Use• No Break-In Period• E-Start System (not battery dependent)• Digital Engine Management• Self Flushing Cooling System• Long Term Storage Design• Simplified Winterization Procedure• No Electrical Current Draw in Key Off Mode• Digital Diagnostics• Ultra Low Oil Usage

Durable and Reliable• Full Corrosion Protection• Evinrude E-TEC Lubrication System• Auto-Calibrated Linkage• Heavy-Duty Use Design• Posi-Lock Latches• Digital Diagnostics• Extra Capacity Water Pump• High Thrust, Large Gearcase• Dual Platinum Spark Plugs• Vibration Isolated Electronics• Beltless 25 Amp Charging System• Stainless Steel Thermostats• Nickel/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• 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™

Evinrude® E-TEC™ 2+4® fuel conditioner

Evinrude®/Johnson® Genuine Parts S.A.F.E.™

Evinrude®/Johnson® XD100™ SystemCheck™

Evinrude®/Johnson® XD50™ Triple-Guard® grease© 2004 Bombardier Motor Corporation of America. All rights reserved.TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

�

Dear Boating Enthusiast,

Congratulations on your purchase of our industry-leading Evinrude ® E-TEC™ out-board! Your purchase comes with the full commitment and backing of the Bombar-dier Recreational Products Outboard Engine team. We know your Evinrude E-TECoutboard will provide you with years of reliable use, and we hope you will enjoy usingit as much as we enjoyed designing and building this innovative product.

You can be proud you purchased an Evinrude E-TEC outboard with the followingbenefits.• Easy to Own and Operate – This means fewer time-consuming and expensive

maintenance requirements. Your Evinrude E-TEC outboard has a debris-resistant,flow-through cooling system, and requires no break-in, oil changes, oil filter chang-es, or expensive winterizing. Best of all, there is no scheduled dealer maintenancefor three years of normal recreational use—only common sense pre-launch checksand periodic checks for corrosion when used in salt-water applications.

• Cleaner and Quieter – Your Evinrude E-TEC outboard has the quieter signatureEvinrude sound that rivals any competitive outboard. Additionally, this EvinrudeE-TEC outboard complies with the strictest EPA, European Union, and Californiaemissions regulations for outboard engines, and its sealed fuel system minimizesevaporative 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 competitivepistons. There are no belts, pulleys, powerhead gears, cams, oil scraping rings, ormechanized oil pumps to cause problems. The Evinrude E-TEC E-Start Systemdelivers easy, quick starts every time, and its full magneto electronics are not de-pendant on a battery. All of this guarantees you getting out there on the water and,most importantly, getting back.

• Exceptional Styling – We put a lot of thought into the styling as well as the tech-nology. We know form and function go hand in hand, so we made the hood ergo-nomically correct—should you ever need to lift it off. The packaging style you willfind under the hood is something that has never been seen in the outboard engineindustry. And with molded-in color, your Evinrude E-TEC outboard is more resistantto fading, chipping, peeling, or cracking than any other outboard on the market, giv-ing you years of a great-looking outboard.

We, as a company, are proud you have purchased this technology-leading EvinrudeE-TEC outboard engine. We thank you for your business and wish you many yearsof enjoyable use.

Happy Boating,

Roch LambertExecutive Vice-PresidentProduct Development, Sales and MarketingNorth America

1

Table of Contents

TABLE OF CONTENTSAbout This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Important Safety Messages . . . . . . . . . . . . . . . . . . 5

USING YOUR EVINRUDE E-TEC OUTBOARD Component Identification . . . . . . . . . . . . . . . . . . 10

Starting, Stopping, Shifting . . . . . . . . . . . . . . . . . 12

Oil and Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Instruments and Controls . . . . . . . . . . . . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Routine Inspection Checklist . . . . . . . . . . . . . . . 30

2

�

MAINTENANCEEngine Emissions Information . . . . . . . . . . . . . . 32

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . 33

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 37

PRODUCT INFORMATIONRigging and Accessories . . . . . . . . . . . . . . . . . . 40

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Product Warranty Information . . . . . . . . . . . . . . 46

California Emission Control Warranty . . . . . . . . 48

Readiness Test . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3

ABOUT THIS GUIDE

This Operator’s Guide is an essential part ofyour Evinrude E-TEC outboard. It containspertinent information which, if followed, willprovide you with a thorough understandingneeded for proper operation, maintenance,care, and—above all—safety. Safety is ourfirst priority and it should be yours too. It isstrongly recommended you read this Guidefrom cover to cover. The more you know andunderstand about your Evinrude E-TEC out-board, the greater the safety and pleasureyou will get from using it. Following this rec-ommendation will assure the completeness ofthe information essential to your safety, thesafety of any passengers, and other water us-ers.This Operator’s Guide identifies importantsafety messages.Although the mere reading of such informa-tion does not eliminate the hazard, the under-standing and application of the informationwill promote the correct use of your outboardengine.

This Guide should be kept in a waterproof bagwith the outboard at all times during opera-tion. If the product ownership is transferred,this Guide should be forwarded to the newowners.A responsible, educated boater will fully ap-preciate the pleasures of boating and will be asafe boater. Boating Safety Classes are con-ducted by the U.S. Coast Guard Auxiliary, theU.S. Power Squadron and some Red CrossChapters. For information about classes, calltoll free 1-800-336-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 yourDealer or distributor for details about boatingsafety.

This Operator’s Guide uses the following sig-nal words identifying important safety mes-sages.

IMPORTANT: Identifies information that willhelp prevent damage to machinery and ap-pears next to information that controls correctassembly and operation of the product.These safety notices mean:ATTENTION!BECOME ALERT!YOUR SAFETY IS INVOLVED!Additionally, Bombardier Motor Corporationof America (BMCA) has identified key infor-mation that is essential to the operation ofyour Evinrude E-TEC outboard.

Warning Symbols in this Guide

How can you reduce the risk of death, per-sonal injury, and possible property dam-age? This Operator’s Guide answers suchquestions and are contained in boxes high-lighted by the Safety Alert Symbol. It is im-perative to read, understand, and followthese comments.

DANGER

Indicates an imminently hazardous sit-uation which, if not avoided, WILLresult in death or serious injury.

WARNING

Indicates a potentially hazardous situa-tion which, if not avoided, CAN result insevere injury or death.

CAUTION

Indicates a potentially hazardous situa-tion which, if not avoided, MAY result inminor or moderate personal injury orproperty damage. It also may be usedto alert against unsafe practices.

Key information appears throughout thisGuide in gray boxes with a key above thetext. This highlighted information is a vital ref-erence when using your outboard.

4

� IMPORTANT SAFETY MESSAGES

IMPORTANT SAFETY MESSAGES

This Operator’s Guide contains essential in-formation to help prevent personal injury anddamage to equipment. Safety messages ap-pear throughout this Guide in the applicablesection.

SAFETY MEASURES — General

WARNING

Be careful! Human error is caused bymany factors: carelessness, fatigue,overload, preoccupation, unfamiliarityof operator with the product, drugs andalcohol to name a few. Damage to yourboat and outboard can be fixed in ashort period of time, but injury ordeath, has a lasting effect.

For your safety and the safety of oth-ers, follow all safety warnings and rec-ommendations. Do not disregard anyof the safety precautions and instruc-tions.

Anyone operating your boat shouldfirst read and understand this Guidebefore they operate your boat and out-board.

To fully appreciate the pleasures, enjoy-ment and excitement of boating thereare some basic rules that should be ob-served and followed by any boater.Some rules may be new to you and oth-ers may be common sense or obvious...irrespective, take them seriously!

Be sure at least one of your passengersknows how to handle your boat in caseof an emergency.

All passengers should know the locationof emergency equipment and how touse it.

Know the marine traffic laws and obeythem.

All safety equipment and personalfloatation devices must be in good con-dition and suitable for your type of boat.Always comply with the regulations thatapply to your boat.

Remember, gasoline fumes are flamma-ble and explosive. Always adhere to thefueling procedure contained in this Op-erator’s Guide and those given to you bythe fueling station. Always verify fuel lev-el before use and during the ride. Applythe principle of 1/3 fuel to destination, 1/3 back and 1/3 reserve fuel supply. Donot carry spare fuel or flammable liquidsin any storage or engine compartments.

Whenever running the engine, assurethere is proper ventilation to avoid theaccumulation of carbon monoxide (CO),which is odorless, colorless, and taste-less, and can lead to unconsciousness,brain damage, or death if inhaled in suf-ficient concentrations. CO accumulationcan occur while docked, anchored, orunderway, and in many confined areassuch as the boat cabin, cockpit, swimplatform, and heads. It can be worsenedor caused by weather, mooring and op-erating conditions, and other boats.Avoid exhaust fumes from your engineor other boats, provide proper ventila-tion, shut off your engine when notneeded, and be aware of the risk ofbackdrafting and conditions that createCO accumulation. In high concentra-tions, CO can be fatal within minutes.Lower concentrations are just as lethalover long periods of time.

Avoid standing up or shifting weight sud-denly in light weight boats.

Keep your passengers seated in seats.The boat’s bow, gunwale, transom andseat backs are not intended for use asseats.

5

SAFETY MEASURES — Installation and Maintenance

Insist on the use of personal floatationdevices, approved by the U.S. CoastGuard, by all passengers when boatingconditions are hazardous, and by chil-dren and nonswimmers at all times.

Proceed with caution and at very lowspeed in shallow water. Grounding orabrupt stops may result in personal inju-ry or property damage. Also be alert fordebris and objects in the water.

Be familiar with the waters you are oper-ating in. The gearcase of this outboardextends below the water surface andcould potentially come in contact withunderwater obstructions. Contact withunderwater obstructions may result inloss of control and personal injury.

Respect no wake zones, rights of otherwater users and the environment. As the"skipper" and owner of a boat you areresponsible for damage to other boatscaused by the wake of your boat. Allowno one to throw refuse overboard.

Do not operate your boat if you are un-der the influence of drugs or alcohol.

High performance boats have a highpower-to-weight ratio. If you are not ex-perienced in the operation of a high per-formance boat, do not attempt tooperate one at, or near, its top speed un-til you have gained that experience.

Become completely familiar with thecontrol and operation of your boat andoutboard before embarking on your firsttrip or taking on a passenger(s). If youhave not had the opportunity to do sowith your Dealer, practice driving in asuitable area and feel the response ofeach control. Be familiar with all controlsbefore applying the throttle above idlespeed. As the operator, you are in con-trol and responsible for safe operation.

The outboard must be correctly in-stalled. Failure to correctly install theoutboard could result in serious injury,death or property damage. We stronglyrecommend that your Dealer install youroutboard to ensure proper installation.

Do not overpower your boat by using anengine that exceeds the horsepower in-dicated on the boat’s capacity plate.Overpowering could result in loss ofcontrol. If your boat has no capacityplate, contact your Dealer or the boat’smanufacturer.

When replacement parts are required,use Evinrude®/Johnson® GenuineParts or parts with equivalent character-istics, including type, strength and mate-rial. Using substandard parts couldresult in injury or product malfunction.

Only perform service procedures whichare detailed in this Operator’s Guide. At-tempting to perform maintenance or re-pair on your outboard if you are notfamiliar with the correct service andsafety procedure could cause personalinjury or death. Further information canbe obtained from your authorizedEvinrude/Johnson Dealer. In many in-stances proper tools and training are re-quired for certain service or repairprocedures.

Maintain your boat and engine in topcondition at all times. Adhere to theMaintenance Schedule on page 33.

Operate your boat and outboard pru-dently and have fun. Do not forget thatall persons must assist other boaters incase of emergency.

Prevent injury from contact with rotatingpropeller; remove propeller before flush-ing or before performing any mainte-nance.

6

�

PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONSBMCA reserves the right to make changes at any time, without notice, to features, specifica-tions and model availability, and to change any specification or part at any time without incur-ring any obligation to update older models. The information in the Guide is based on the latestspecifications available at the time of publication.Photographs and illustrations used in this Guide might not depict actual models or equipmentbut are intended as representative views for reference only.Certain features of systems discussed in this Guide might not be found on all models in allmarketing areas.

Owner’s IdentificationUnited 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 NumbersThe 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 OutboardsUnited States and Canada — Report your outboard as stolen to Customer and Dealer Sup-port Services, 250 Seahorse Drive, Waukegan, IL 60085 U.S.A. Give the outboard’s modeland serial numbers and enclose a copy of the police report.Outside United States and Canada — Report the theft to the Bombardier Recreational Prod-ucts distributor where the outboard was registered.

Technical LiteratureBMCA offers technical literature specifically for your outboard. A service manual, a parts cat-alog, or an extra Operator’s Guide can be purchased from your selling Dealer. For the nameand location of the nearest Evinrude Dealer in the United States and Canada visitwww.evinrude.com.

Declaration of ConformityBMCA declares that the outboard to which this Operator’s Manual applies conforms to the es-sential requirements outlined in CE Machinery Directive 98-37-EC, as amended.

7

Bombardier Recreational Products

�

USING YOUR EVINRUDE E-TEC

OUTBOARDUSING YOUR E-TEC

OUTBOARD

9

Using Your E-TEC Outboard

COMPONENT IDENTIFICATION

Item Description Item Description

1 Air Inlet, Tilt Handle 6 Fuel Fitting

2 Water Pump Indicator, Flushing Port 7 Tilt Limiter Cam

3 Engine Cover Latch 8 Tilt Support

4 Anti-Corrosion Anodes 9 Water Intake Screens

5 Battery Cables

8

94

7

3

6

5

2

1

10

� COMPONENT IDENTIFICATION

Item Description Item Description

10 Fuel Filter 16 Trailering Tilt Switch

11 Spark Plugs 17 Flywheel Guard

12 Engine Cover Latch 18 Oil Fill Cap

13 Fuse 19 Oil Tank

14 Spare Fuse 20 EMM (Engine Management Module)

15 Air Silencer

Starboard

12

10

11

Port

15

20

18

16

13

19

14

17

11


STARTING, STOPPING, SHIFTING

SAFETY INFORMATION ENGINE STARTINGRefer to the Routine Inspection Checkliston page 30 for pre-launch checks before us-ing your Evinrude E-TEC outboard.You MUST supply water to the engine beforeattempting to start it. Engine damage can oc-cur quickly.Be sure the water intake screens are belowthe water surface.Connect the clip to the emergency stop/keyswitch. Snap the lanyard to a secure place onthe operator’s clothing or life vest — notwhere it might tear away instead of activatingthe stop switch.

1. Clip2. Emergency stop clip / key switch3. Lanyard

IMPORTANT: The engine will start and runwithout the clip connected to the key switch.The operator should always use the clip andlanyard anytime the engine is running. Referto Emergency Stop/Key Switch on page 22.

DANGER

DO NOT run the engine indoors orwithout adequate ventilation or permitexhaust fumes to accumulate in con-fined areas. Engine exhaust containscarbon monoxide which, if inhaled, cancause serious brain damage or death.

DANGER

Contact with a rotating propeller islikely to result in serious injury ordeath. Assure the engine and prop areais clear of people and objects beforestarting engine or operating boat. Donot allow anyone near a propeller, evenwhen the engine is off. Blades can besharp and the propeller can continue toturn even after the engine is off.Always shut off the engine when nearpeople in the water.

WARNING

The engine cover is a machinery guard.DO NOT operate your outboard withthe cover off unless you are perform-ing maintenance or emergency start-ing, and then be careful to keep hands,hair, and clothing clear of all movingparts. Contact with moving parts couldcause injury.

Always shut off the outboard when yourboat is near people who are in the water.

Be familiar with the waters you are oper-ating in. The gearcase of this outboardextends below the water surface andcould potentially come in contact withunderwater obstructions. Contact withunderwater obstructions may result inloss of control and personal injury.

WARNING

Always use the safety lanyard whenoperating your boat to help prevent arunaway boat and reduce the risk ofpersonal injury or death.

12

� STARTING, STOPPING, SHIFTING

Move the remote control handle to NEU-TRAL.

1. Concealed side mount control2. Binnacle mount control

Turn the key switch fully clockwise to theSTART position. Crank the engine no longerthan 20 seconds.

IMPORTANT: The starter motor can be dam-aged if operated continuously for more than20 seconds.Upon start-up, release the key.If the engine did not start, release the key mo-mentarily, then try again.Each time the key switch is turned from OFFto ON, the warning system will self-test. Referto Engine Monitoring on page 18. If thewarning system fails to self-test during start-up, see your Dealer.If your outboard does not react normally tothis starting procedure or if it fails to start, re-fer to Troubleshooting on page 37.

After Engine StartsCheck the water pump indicator. A steadystream of water indicates the water pump isworking. If a steady stream of water from thewater pump indicator is not visible, stop theengine. Refer to Engine Overheating onpage 20.

ENGINE STOPPINGMove control handle to NEUTRAL.Turn key switch counterclockwise to the OFFposition. Remove the key when the boat willbe unattended.

WARNING

If you are using a remote control thatdoes not have start-in-gear prevention,the outboard can be started while it isin gear. Protect against unexpectedboat movement by always starting youroutboard in NEUTRAL.

DO NOT advance the throttle before start-up.Advancing the throttle overrides the electron-ic idle control system. After the engine starts,the engine management module (EMM) au-tomatically increases idle speed slightly. Idlespeed will decrease as the engine warms up.The SystemCheck™ gauge lights will illumi-nate if the throttle is advanced.

1 2

13


SHIFTING AND SPEED CONTROL

IMPORTANT: Carefully check the function ofall control and engine systems before leavingthe dock. DO NOT shift the engine into FOR-WARD or REVERSE while it is shut off.If the following directions are not suitable foryour boat’s control, see your Dealer beforeproceeding.

ShiftingWith engine running and control handle inNEUTRAL:

Concealed Side Mount ControlUnlock the control handle (lift the neutral locktab by squeezing the hand grip). Briskly anddecisively, move the control handle fore or aftuntil it engages the gear detent.

1. NEUTRAL Lock Tab Hand Grip

Binnacle Mount ControlBriskly and decisively, move the control han-dle fore or aft until it engages the gear detent.

IMPORTANT: When shifting from FOR-WARD to REVERSE or from REVERSE toFORWARD, pause at NEUTRAL until the en-gine is at idle speed and the boat has slowed.

Speed ControlAfter gear engagement, move the controlhandle slowly in the same direction to in-crease speed.

FUEL ECONOMYThe economy throttle range can save fuel, de-pending on boat load and hull design. Whenboat reaches top speed, throttle back fromFULL SPEED to the economy throttle range.You will save fuel with a minimal loss ofspeed.

1. Concealed Side Mount Control2. Binnacle Mount Control

1

14

� OIL AND FUEL

OIL AND FUEL

OILING SYSTEM

FILLING THE OIL TANKRelease the port and starboard engine coverlatches by turning each handle downward.

Pull up on the tilt handle to release the enginecover seal on the engine cover.

1. Tilt handle

Remove the engine cover to access the oiltank.

Remove the filler cap and fill the tank with therecommended outboard lubricant, as speci-fied in Oil Requirements on page 16.

Replace the filler cap and tighten securely.Reinstall the engine cover.

IMPORTANT: The oil tank capacity is 3.0quarts (2.8 liters).

PRIMING THE OILING SYSTEM

If the “LOW OIL” warning light illuminates,you have approximately five hours of normaloperation before running out of oil when us-ing TC-W3RL oil. If using Evinrude/JohnsonXD100™ oil, you have approximately tenhours of normal operation remaining. Refillthe onboard oil tank at next convenient op-portunity. Refer to Priming the Oiling Sys-tem on page 15.

IMPORTANT: Always “top off” your oil tankprior to prolonged usage or long trips.

1

The oiling system must be primed before re-using the outboard if:• You run 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 (Winterization)on page 35.

15


OIL REQUIREMENTS FUEL REQUIREMENTS

IMPORTANT: Always use fresh gasoline.Gasoline will oxidize; the result is loss of oc-tane, volatile compounds, and the productionof gum and varnish deposits which can de-grade the fuel system.

The following outboard oils are recommend-ed for use in your Evinrude E-TEC outboard:• Evinrude/Johnson XD100; • Evinrude/Johnson XD50™; or• Evinrude/Johnson XD30™.Evinrude/Johnson brand oils are formulatedto give best engine performance while con-trolling piston and combustion chamber de-posits, providing superior lubrication, andensuring maximum spark plug life.Evinrude/Johnson XD100 oil is preferredfor your Evinrude E-TEC outboard. It is for-mulated with special additives for cleanerburning and lower consumption. This syn-thetic blend oil also provides superior lubrica-tion and maintains top performance.For added protection and cost reduction, anauthorized dealer can program your EvinrudeE-TEC outboard EMM to cut normal oil con-sumption in half using Evinrude/JohnsonXD100 as compared to using a conventionaloil. Only an authorized Evinrude dealercan program your outboard for this bene-fit.If Evinrude/Johnson brand oils are not avail-able, you must use an oil that meets NMMATC-W3RL certification standards.

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 anoil that meets NMMA TC-W3RL certificationstandards is allowed. If you discontinue usingEvinrude/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 specifica-tions could void the engine warranty if a lubri-cation-related failure occurs.

WARNING

Gasoline is extremely flammable andhighly explosive under certain condi-tions. Follow the instructions in thissection explicitly. Improper handling offuel could result in property damage,serious injury or death.

Leaking fuel is a fire and explosion haz-ard. All parts in the fuel system shouldbe inspected frequently and replaced ifsigns of deterioration or leakage arefound. Inspect the fuel system eachtime you refuel, each time you removethe engine cover and annually.

Follow these instructions to ensuresafety when handing fuel:

• Always turn off the engine before fuel-ing.

• Never permit anyone other than anadult to refill the fuel tank.

• Do not fill the fuel tank all the way tothe top or fuel may overflow when itexpands due to heating by the sun.

• Remove portable fuel tanks from theboat before fueling.

• Always wipe off any fuel spillage.• Do not smoke, or allow open flames,

or sparks or use electrical devicessuch as cellular phones in the vicinityof a fuel leak or while fueling.

• Always work in a well ventilated area.

16

� OIL AND FUEL

Minimum OctaneYour outboard is certified to operate on un-leaded automotive gasoline with an octanerating equal to or higher than:• 87 (R+M)/2 AKI — Inside the U.S.• 90 RON — Outside the U.S.Using unleaded gasoline that contains methyltertiary butyl ether (MTBE) is acceptableONLY if the MTBE content does not exceed15% by volume.

Alcohol FuelsYour outboard has been designed to operateusing the specified fuels; however, be awareof the following:• The boat’s fuel system may have different

requirements regarding the use of alcoholfuels. Refer to the boat’s owner guide.

• Alcohol attracts and holds moisture that cancause corrosion of metallic parts in the fuelsystem.

• Alcohol blended fuel may cause engine per-formance problems.

Using alcohol-extended fuels is acceptableONLY if the alcohol content does not exceed:• 10% ethanol by volume; or• 5% methanol with 5% cosolvents by vol-

ume.

FUEL SYSTEM OPERATION

Connecting the Fuel Hose1) If the fuel hose is disconnected for any rea-

son, seal it to prevent spillage. Cap the fuelfitting to prevent contamination.

2) Connect the fuel hose to the 3/8 in. (9 mm)fuel fitting. Fasten hose securely withclamp (18.5 mm) from owner’s kit.

1. Fuel hose and fitting – 3/8 in. (9 mm)

IMPORTANT: Fuel distribution hoses in theboat must deliver fuel at the rate of flow need-ed by the outboard. Minimum inside diameterof fuel hoses must be 3/8 in. (9 mm).

Fuel systems with built-in tanks, particularlythose that include antisiphon valves and filter/primer units, may have restrictions not allow-ing the engine fuel pump to deliver sufficientfuel under all conditions. This can result in aloss of performance. If a performance prob-lem exists, see your Dealer.

FUEL ADDITIVESBMCA approves only Evinrude 2+4® fuelconditioner fuel additive for use in yourEvinrude E-TEC outboard.Use of other fuel additives can result in poorperformance or engine damage.Evinrude 2+4 fuel conditioner will help pre-vent gum and varnish deposits from formingin fuel system components and will removemoisture from the fuel system.It should be used during any period when yourengine is not being operated on a regular ba-sis. Its use will reduce fuel system icing andfuel deterioration.

1

WARNING

Store fuel tanks in a well-ventilatedarea, away from heat and open flame.Prevent escape of liquid or vaporswhich could accidentally ignite.

Close the filler cap vent screw, ifequipped.

Be sure the disconnected fuel hosedoes not drip.

WARNING

The outboard must be correctlyinstalled. Failure to correctly install theoutboard could result in property dam-age, serious injury, or death. Westrongly recommend your Dealer installyour outboard to ensure proper instal-lation.

17


INSTRUMENTS AND CONTROLS

ENGINE MONITORING

IMPORTANT: Your outboard must beequipped with the SystemCheck engine mon-itor. Operating your outboard without the Sys-temCheck engine monitor will void yourwarranty for failures related to the functionsmonitored on your engine.When you turn the key switch ON, the Sys-temCheck engine monitor horn performs aself-test by sounding a 1/2-second beep. Thegauge self-tests by turning the warning lightson, then off in sequence. During engine start-up, pause with the key switch in the ON posi-tion to observe the horn and gauge performthe self-test. If the self-test does not happenas stated, see your Dealer.The SystemCheck engine monitor alerts theoperator with a 10-second beep of the hornand a warning light on the gauge when certainengine problems occur. The appropriatewarning light will stay on until the problemis corrected or the key switch is turnedOFF.If the engine management module (EMM)senses that the problem could cause perma-nent engine damage, it will also limit enginespeed to 1200 RPM. This additional protec-tion feature is referred to as S.A.F.E.™(Speed Adjusting Failsafe Electronics). If theengine was running faster than 1200 RPMwhen the S.A.F.E. mode activated, it willshake noticeably. Under certain operatingconditions the EMM will shut OFF the engine.

1. SystemCheck gauge2. SystemCheck gauge with tachometer

CAUTION

In the S.A.F.E. mode, the engine speedis limited. Under certain conditions, theengine’s limited speed may reducemaneuverability of your boat.

If the S.A.F.E. mode is activated andyou are unable to correct the problem,seek assistance and/or return to safeharbor. Serious engine damage, engineshutoff, and/or reduced maneuverabil-ity may be imminent.

1 2

18

� INSTRUMENTS AND CONTROLS

The following warnings may appear on the outboard’s indicator lights:

“LOW OIL”

“NO OIL”

Your outboard is designed to run in “get home” mode for up to five hours in the event you runout of oil. Refill the onboard oil tank. Refer to Priming the Oiling System on page 15.

“WATER TEMP” or “HOT”

“CHECK ENGINE” or “CHK ENG”

*Speed Adjusting Failsafe Electronics

Symptom Oil in the oil tank is at reserve level (about 1/4 full)

Result EMM will activate light

Action

• Fill the oil tank with recommended oil as soon as possible to avoid emptyingthe tank. The outboard has approximately five hours (ten hours if usingEvinrude/Johnson XD100 oil) of normal running time before “NO OIL” condi-tion occurs. Refer to Filling the Oil Tank on page 15.

Symptom There is an oil delivery problem

Result EMM will activate S.A.F.E.* mode

Action • If the oil tank is empty, add the recommended oil.• If the oil tank is not empty, seek assistance and/or return to safe harbor.

Symptom The engine is overheating

Result EMM will activate S.A.F.E. mode

Action

• A continuous light with S.A.F.E. mode — The EMM has identified an over-heating condition. Check the water pump indicator for a steady stream of wa-ter. Shut OFF the engine. Clear the water intake screens of any debris. If theoverheat condition still exists, the engine will operate in “get home” mode. Re-turn to harbor immediately.

• A flashing light — The EMM has identified a damaging overheating condi-tion. The engine will not operate. Allow the engine to cool for 20 minutes andreturn to harbor immediately. See your Dealer.

Symptom An abnormal operating condition

Result EMM will activate light

Action

• A flashing light — The EMM has identified an abnormal operating conditionrelated to the fuel system. The engine will shut OFF and cannot be restarted.

• A continuous light with S.A.F.E. mode — The EMM has identified a problemwith the outboard. Seek assistance and/or return to harbor. See your Dealer.

• A continuous light without S.A.F.E. mode — The EMM has identified a prob-lem that should be addressed by your Dealer as soon as practical to avoidoperational difficulties.

WARNING

If the outboard shuts OFF and the “CHECK ENGINE” or “CHK ENG” light is flash-ing, the outboard cannot be restarted. A hazardous fuel condition may exist. Seekassistance to return to port.

19


ENGINE OVERHEATING

IMPORTANT: Do not run your outboard—even for a brief start-up—without supplyingwater to it. Refer to Flushing on page 34.While boating, the outboard’s water intakesmust stay completely submerged and unob-structed. Observe proper transom height andtrim angle. While the outboard is running, theoutboard’s water pump indicator must dis-charge a steady stream of water. Check theindicator often, especially when operating inweeds, mud and debris-laden water, and atextreme trim angles.

1. Water intake screens2. Water pump indicator

If the engine overheats, its SystemCheck en-gine monitor will sound the warning horn andturn on the “WATER TEMP” or “HOT” light. Al-so, the S.A.F.E. (Speed Adjusting FailsafeElectronics) mode will immediately limit theengine’s speed to 1200 RPM. If the enginewas running faster than 1200 RPM when theS.A.F.E. mode activated, it will shake notice-ably. The protection system must be RESETbefore the engine will operate at speeds over1200 RPM. Under certain conditions the EMMwill shut off the engine.

To RESET the system:• The engine must be shut off and the cooling

temperature restored.IF the S.A.F.E. mode activates and thestream from the water pump indicator be-comes intermittent or stops, reduce speed toidle and:1) Shift to NEUTRAL.2) SHUT OFF the engine.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 doesnot restore the water pump indicator’s steadydischarge, the engine will operate only in “gethome” mode. Return to harbor immediately.See your Dealer.IF cleaning the screens and indicator doesrestore the water pump indicator’s steadydischarge, you might have to run for two min-utes in NEUTRAL to allow the engine to cooland the light to go off.

IMPORTANT: If cooling is not restored, theEMM will identify a progressive overheatingcondition and shut off the engine. The “WA-TER TEMP” or “HOT” light will flash. The en-gine will not restart until the engine is allowedto cool.After any overheat causing engine shutdown,see your Dealer for:• Inspection of the water pump for excessive

wear or damage.• Inspection of the thermostats.

IMPORTANT: Although the S.A.F.E. modecan help prevent engine damage, it does notguarantee you can run your engine indefinite-ly without engine damage.

20

� INSTRUMENTS AND CONTROLS

REMOTE CONTROLS

IMPORTANT: When selecting the remotecontrol system for your boat, specify Evinrudecomponents. Evinrude controls deliver the ca-ble stroke your outboard needs for positiveshift and throttle control, and they incorporatesuch safety and convenience features as:• Start-in-gear prevention• Plug-in compatibility with Evinrude modular

wiring system

Evinrude concealed side mount control1. Handle - shift and throttle2. Trim/tilt switch (where equipped)3. Neutral lock tab4. Fast idle button (warm-up)5. Throttle Friction Control

Evinrude binnacle mount control1. Handle - shift and throttle2. Trim/tilt switch (where equipped)3. Fast idle button (warm-up)4. Throttle friction control5. Emergency stop clip and lanyard

Evinrude side mount control1. Handle - shift and throttle2. Trim/tilt switch (where equipped)3. Neutral lock tab4. Fast idle lever (warm-up)5. Emergency stop clip and lanyard

WARNING

If you choose a non-Evinrude remotecontrol, it must have a start-in-gear pre-vention feature. This feature can pre-vent injuries resulting from unexpectedboat movement when the engine starts.

21


Emergency Stop/Key SwitchA combination emergency stop switch andkey switch is a feature of Evinrude prewiredremote controls and all Evinrude control wir-ing kits. Use of the emergency stop feature ishighly recommended on all boats.Connect the clip to the emergency stop/keyswitch. Snap the lanyard to a secure place onthe operator’s clothing or life vest — notwhere it might tear away instead of activatingthe stop switch. Disconnecting the clip andlanyard will stop the engine and prevent theboat from becoming a runaway if the drivermoves beyond the range of the lanyard. If thelanyard is too long, it can be shortened byknotting or looping it. DO NOT cut and retiethe lanyard. In an emergency situation, theengine can be started without the clip in place.Follow the normal starting procedure. Rein-stall a clip as soon as possible.

1. Clip2. Emergency stop / key switch3. Lanyard

WARNING

Always use the safety lanyard whenoperating your boat to help prevent arunaway boat and reduce the risk ofpersonal injury or death.

Avoid knocking or pulling the clip offthe stop switch during normal boating.Avoid bumping the key if operatingwithout the clip on the switch. Theresulting unexpected loss of forwardmotion can throw occupants forward,causing injury.

Your emergency stop switch can beeffective only when in good workingcondition. At each outing, inspect clipand lanyard for cuts, breaks, or wear.Replace worn or damaged parts.

Keep the lanyard free from obstruc-tions and entanglements.

At each outing, test the system’s oper-ation. With the engine running, removethe clip from the switch by pulling thelanyard. If the engine does not stoprunning, see your Dealer.

22

� OPERATION

OPERATION

POWER TRIM AND TILT

Full TiltThe full tilt is often used to tilt the outboard forclearance when beaching, mooring, orlaunching.

1. Trim range2. Tilt range

TiltingIf the tilted outboard’s cover contacts theboat’s motor well, limit the maximum tilt by fol-lowing the procedures in Tilt Limiter Cam onpage 44.

Manually TiltingIf needed, the outboard will tilt up or downmanually, using the manual release screw.

1) Turn the manual release screw counter-clockwise, slowly (about 3 1/2 turns), untilit lightly contacts its retaining ring.

2) Reposition the outboard.3) Tighten the manual release screw to hold

the outboard in its new position.

1. Manual release screw

WARNING

Any malfunction of the power trim andtilt unit could result in loss of shockabsorber protection if an underwaterobstruction is hit. Malfunction can alsoresult in loss of reverse thrust capabil-ity.

Correct fluid level must be maintainedto ensure operation of the impact pro-tection on this unit.

TrimIn most operating conditions, it is recom-mended to trim the outboard to the full downposition when accelerating. Once on plane,trim the outboard up until the exhaust isheard, then back down slightly.

Shallow Water DriveYou can tilt the outboard to any position with-in the tilt range but DO NOT run the enginefaster than idle speed. If idling a tilted out-board, keep its water intakes submerged atall times.

WARNING

Keep everyone clear of a tilted out-board when backing out the manualrelease screw. The outboard coulddrop suddenly and forcibly. Be sure totighten the manual release screw aftermanually repositioning the outboard.Tightening the screw also reactivatesthe outboard’s shock absorber protec-tion and reverse thrust capability.

23


IMPORTANT: Some boats plow, or are diffi-cult to plane, when operated in the trim’s low-est position. If your boat handles unsuitablywhen trimmed fully bow-down, set the angleadjusting rod or trim limiter rod to limit thetravel of the power trim. If your outboard is notequipped with this rod, purchase one fromyour Dealer.

IMPORTANT: DO NOT use the tilt support le-ver while trailering. Refer to Trailering onpage 25.

Engaging Tilt Support LeverIf you intend to leave the motor tilted for a pe-riod of time, engage the tilt support lever:1) Tilt the motor UP using the trailering tilt

switch.2) Flip the tilt support lever down.3) Lower the motor until the tilt support lever

rests solidly on the stern brackets.

Disengaging Tilt Support LeverWhen you are finished tilting the motor, disen-gage the tilt support lever:1) Tilt the motor UP.2) Flip the tilt support lever up.3) Lower the motor to operating position.

WARNING

When operating in rough water orcrossing a wake, excessive bow-uptrim may result in the boat’s bow sud-denly rising skyward, possibly ejectingor otherwise seriously injuring occu-pants.

Some boat/motor/propeller combina-tions may encounter boat instabilityand/or high steering torque when oper-ated at high speed at or near the out-board’s trim range limits (full bow-up orbow-down). Boat stability and steeringtorque can also vary due to changingwater conditions. If any adverse condi-tions occur, reduce throttle and/oradjust trim angle to maintain control. Ifyou experience boat instability and/orhigh steering torque, see your Dealer tocorrect these conditions.

WARNING

If the bow of the boat plows the waterat high speeds, the boat may bow steeror spin suddenly, possibly ejecting orotherwise seriously injuring occupants.

24

� OPERATION

TRAILERING

Trailering Bracket

To engage bracket — Tilt the motor fullyusing the tilt switch inside the boat or thetrailering tilt switch (on port side of engine).

1. Trailering tilt switch2. Tilt switch inside boat

Pull down the trailering bracket. A detent willhold the bracket in position. Lower the motoruntil the trailering bracket locks into place inthe stern brackets.

To disengage bracket — Tilt the motor ful-ly. Return the trailering bracket to its stowedposition. Lower the motor to its vertical posi-tion.

The motor is designed to be trailered in a ver-tical position or tilted, using the traileringbracket. Use the position best suited for yourboat.

IMPORTANT: The motor MUST be in neutralwhen trailering.

WARNING

Keep everyone clear of stern area whenraising or lowering the outboard. Per-sonal injury or death can result fromcontact with moving parts of the out-board.

25


IMPACT DAMAGEYour outboard has a shock absorption systemdesigned to help withstand damage from im-pact with underwater objects at low to moder-ate speeds. High speed impacts with rigidunderwater objects like pilings or boulderscan be beyond the capability of the absorptionsystem. Such impacts can result in seriousdamage to your outboard and injury to boatoccupants from the outboard or its parts en-tering the boat. Occupants can also be eject-ed or injured by falling against portions of theboat as a result of rapid deceleration followingimpacts.When boating in unfamiliar, shallow, or de-bris-laden waters, seek information on safeboating areas and navigation hazards from areliable local source. Reduce your speed andkeep a sharp lookout!

The outboard’s shock absorption systemdoes not work while operating in reverse. Ifyou back into an object, either in the water orwhile trailering, your boat and outboard canbe seriously damaged.

If you hit any object:• STOP immediately and examine the out-

board for loosening of attaching hardware.• INSPECT for damage to swivel and stern

brackets, and steering components.• EXAMINE the boat for structural damage.• TIGHTEN any loosened hardware.If the collision occurred in the water, proceedslowly to harbor. Before boating again, haveyour Dealer thoroughly inspect all compo-nents.

EMERGENCY STARTINGIf the starter fails, your engine can be startedusing a 1/4 in (6 mm) cord about 4 ft. (1.2 m)long.

Be sure:• Key switch is OFF.• Engine is in normal operating position.• Shift lever is in NEUTRAL.

WARNING

Failure to inspect for damage after anaccident or striking an object couldresult in sudden, unexpected compo-nent failure, loss of boat control, andpersonal injury. Unrepaired damagecould reduce your boat and outboard’sability to resist future impacts.

WARNING

Move the shift lever to NEUTRALbefore performing emergency startingprocedures. Failure to do so may resultin unexpected boat movement.

The engine cover is a machinery guard.To prevent injury from moving enginecomponents, keep hands, clothes, andhair clear of powerhead.

Prevent electric shock by keeping clearof the ignition coils and spark plugleads when the motor is being startedor is running. Shock can cause seriouspersonal injury under certain condi-tions.

DO NOT turn flywheel by hand. Usestarter cord only.

26

� OPERATION

1) Release port and starboard side enginecover latches downward. Pull up on the tilthandle to release the engine cover sealand remove the engine cover.

1. Engine cover latch2. Tilt handle

2) Remove fuse holder from flywheel cover.

1. Fuse

3) Raise flywheel guard from the fittings bypulling up on the front two fastening tabs.

1. Fastening tabs

4) Holding the flywheel guard out of the way,hook the knot of your emergency start cordinto the notch on the flywheel. Wind thecord clockwise in the flywheel ridge, mak-ing one and a half full windings with thecord.

1. NEUTRAL2. Knot3. Rope in flywheel ridge

5) Turn key switch ON.6) From a secure position in the boat, pull

hard on emergency starting cord to startengine.

Repeat procedure, if necessary, until enginestarts.7) Refasten flywheel guard in place by push-

ing the three fastening tabs back onto thefittings.

1. Fastening tabs

1 2

1

1

CAUTION

Keep everyone clear of your immediatearea when pulling on emergency start-ing cord, especially behind you.

1

2

3

1

27


If equipped, snap emergency stop switch lan-yard to secure place on clothing. Proceed im-mediately to nearest landing for service.

SALT WATERAdditional anodic protection for the outboardhas been provided for use in salt or brackishwater.Upon removal from salt water, leave outboardin a vertical position until its cooling systemhas drained. During long periods of mooring,tilt the gearcase out of the water, except infreezing temperatures. Flush the outboard, ifdesired. Refer to Flushing on page 34.

Salt Water Lubrication Points

1. Trailering bracket and swivel bracket lubrica-tion points (annually)

1. Tilt tube lubrication points (annually)

Anti-Corrosion AnodesYour outboard is equipped with one or moreanodes that protect it from galvanic corrosion.Disintegration of the anode is normal and in-dicates it is working. Check each anode peri-odically. Replace anodes smaller than 2/3their 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 waterswill accelerate corrosion.Metal-based antifouling paint on the boat oroutboard and the use of improperly installedshore power in the area of your moored boatwill also accelerate corrosion.

IMPORTANT: NEVER paint the anode, itsfasteners, or its mounting surface. Paintingwill reduce its corrosion protection.

WEEDY WATERWeeds block water intakes and may causeyour outboard to overheat. Weeds on the pro-peller create vibration and reduce boat speed.When operating in weedy water, run at slowspeeds and in REVERSE frequently to clearweeds from the propeller and water intakes.Check the water pump indicator often.If REVERSE operation does not clear awayweeds, SHUT OFF the engine. Removeweeds from propeller area and water intakesbefore operating at higher speed.

DANGER

Contact with a rotating flywheel cancause severe personal injury. Useextreme care in re-fastening the fly-wheel guard on the fastening tabs.Keep hands, hair, and clothing awayfrom coming in direct contact withrotating parts.

28

� OPERATION

HIGH ALTITUDEYour outboard’s EMM will automatically com-pensate for changes in altitude. However, ifyou boat above 3000 ft. (900 m), you will ex-perience a slight loss of power due to reducedair density.If your engine drops below the recommendedRPM operating range at full throttle, have yourDealer select a lower pitch propeller.If you return to sea level, have your Dealer in-stall the original propeller and verify correctRPM operating range.

FREEZING WEATHER

IMPORTANT: Use Evinrude/Johnson XD100oil when operating your Evinrude E-TEC out-board in freezing weather. Refer to Oil Re-quirements on page 16.During operation in freezing weather, keepthe gearcase submerged at all times.Upon removing your outboard from the water,leave it in a vertical position until its coolingsystem is drained. After the system drains,briefly crank the engine once to force any re-maining water from the water pump impeller.

IMPORTANT: Store the outboard vertically.Water remaining in the gearcase, cooling sys-tem or other components can freeze, causingserious engine damage.

IMPORTANT: If your outboard’s gearcase isequipped with an integral speedometer pick-up, all water must be cleared from the hose toprevent gearcase damage. Refer to Storageon page 34.

SHALLOW WATERIMPORTANT: Gearcase damage can occur ifthe gearcase is allowed to drag on the water-way bottom.

DUAL OUTBOARD OPERATIONWhen in reverse above slow speed, be sureboth outboards are running, even if one is inNEUTRAL.If it is necessary to return to harbor with oneoutboard not running, tilt the inoperative out-board high enough to keep its propeller out ofthe water.

UNDER TOWShould you require a tow from another boat:• Shift your engine to NEUTRAL;• Tilt its gearcase out of the water;• Off-load all persons into another boat; and• Keep speed slower than planing speed.

FUSE

Fuse ReplacementIMPORTANT: Use only fuses of the same rat-ing. Your Evinrude E-TEC outboard uses 10-amp fuses.Remove engine cover. Install spare fuse inplace of failed fuse.

1. Fuse2. Spare fuse

IMPORTANT: Failure to install cover securelymay cause electrical problems.

A blown fuse will not allow the engine tocrank. Replace it with a fuse of the same rat-ing. A spare fuse is provided.Repeated fuse failures indicate a potentiallyserious problem. Do not replace it with higherrated fuse; see your Dealer for service.

1

2

29


ROUTINE INSPECTION CHECKLIST

Common Sense Pre-launch Checks (Each Use)

Periodic

� Check fuel level.

� Check function of steering, throttle, shift, and emergency stop circuit and lanyard.

� Check condition of propeller.

� Confirm operation of SystemCheck self-test and warning horn.

� Confirm the cooling 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-corrosion spray or Evinrude “6 in 1” multi-purpose lubricant (annually or 100 hours).

30

�

MAINTENANCE

31

Maintenance

ENGINE EMISSIONS INFORMATION

Maintenance, replacement, or repair of theemission control devices and systemsmay be performed by any marine SI (sparkignition) engine repair establishments orindividual.

Manufacturer’s ResponsibilityBeginning with 1999 model year outboards,manufacturers of marine engines must deter-mine the exhaust emission levels for each en-gine horsepower family and certify theseoutboards with the United States of AmericaEnvironmental Protection Agency (EPA). Anemissions control information label, showingemission levels and engine specifications,must be placed on each outboard at the timeof manufacture.

Dealer’s ResponsibilityWhen performing service on all 1999 andmore recent Evinrude outboards that carry anemissions control information label, adjust-ments must be kept within published factoryspecifications.Replacement or repair of any emission relat-ed component must be executed in a mannerthat maintains emission levels within the pre-scribed certification standards.Dealers are not to modify the outboard in anymanner that would alter the horsepower or al-low emission levels to exceed their predeter-mined factory specifications.Exceptions include manufacturer’s prescribedchanges, such as altitude adjustments, for ex-ample.

Owner ResponsibilityThe owner/operator is required to have en-gine maintenance performed to maintainemission levels within prescribed certificationstandards.The owner/operator is not to, and should notallow anyone to, modify the engine in anymanner that would alter the horsepower or al-low emissions levels to exceed their predeter-mined factory specifications.Tampering with the fuel system to changehorsepower or modify emission levels beyondfactory settings or specifications will void theproduct warranty.

EPA Emission RegulationsAll new 1999 and more recent Evinrude out-boards manufactured by BMCA are certifiedto the EPA as conforming to the requirementsof the regulations for the control of air pollu-tion from new watercraft marine spark ignitionengines. This certification is contingent oncertain adjustments being set to factory stan-dards. For this reason, the factory procedurefor servicing the product must be strictly fol-lowed and, whenever practicable, returned tothe original intent of the design. The responsi-bilities listed above are general and in no waya complete listing of the rules and regulationspertaining to the EPA requirements on ex-haust emissions for marine products. Formore detailed information on this subject, youmay contact the following locations:

VIA U.S. POSTAL SERVICE:Office of Mobile SourcesEngine Programs and Compliance DivisionEngine Compliance ProgramsGroup (6403J)401 M St. NWWashington, DC 20460

VIA EXPRESS or COURIER MAIL:Office of Mobile SourcesEngine Programs and Compliance DivisionEngine Compliance ProgramsGroup (6403J)501 3rd St. NWWashington, DC 20001

EPA INTERNET WEB SITE:www.epa.gov

32

� MAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE

Routine maintenance is necessary for all mechanized products. Periodic maintenance contrib-utes to the product’s life span. The following maintenance chart provides guidelines for out-board maintenance and inspection scheduled to be performed by an authorized Dealer. Theschedule should be adjusted according to operating conditions and use.The recommended lubricants have been formulated to protect bearings, gears and enginecomponents. They must be used to avoid damage caused by improper lubrication.

Description

Engine Care

Product

Every 300 Hours or

Three Years(1)

(1) When used in normal recreational use. Common sense dictates when using 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 �

Gearcase lubricant, replace A �

Grease fittings, lubricate (3)

(3) Annually in salt water applications – Refer to Salt Water Lubrication Points on page 28

�

Muffler foam, inspect and replace if necessary �

Power trim/tilt system and fluid level, inspect B �

Propeller shaft splines, inspect and lubricate (3) C �

Spark plugs, inspect and replace if necessary (2)�

Starter pinion shaft, inspect and lubricate D �

Steering system, inspect and lubricate C �

Thermostats, inspect (2)�

Throttle cable, inspect and re-tension �

Water pump, inspect or replace if necessary �

A. Ultra-HPF gearcase lubricant

B. Power Trim/Tilt Fluid

C. Triple Guard grease

D. Starter Bendix Lube Only P/N 337016

33

Maintenance

STORAGE

You must protect against natural environmen-tal conditions that can be damaging to an out-board. Temperature and humidity changeswhile your outboard is not in use can causecorrosion of internal engine parts when theyare not protected. Fuel remaining in your fueltank can oxidize which can result in loss of oc-tane and can cause gum deposits in the fuelsystem. Your warranty does not cover enginefailure caused by these conditions.

TRANSPORTATION

FLUSHINGIf desired, the outboard can be flushed aftereach use on a trailer or at dockside while it isvertical.1) Place the outboard in an area with good

drainage.2) Connect garden hose to flushing port.3) Turn on the water. It is not necessary to

run the engine for a good flushing.

IMPORTANT: The “CHECK ENGINE” or“CHK ENG” SystemCheck gauge light may il-luminate if you are running the outboard dur-ing the flushing procedure. This is normal.The outboard will continue to run as long as itis being supplied with water.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 thanthe powerhead. Any water remaining in theexhaust passages can run into the cylindersand cause serious damage.

SHORT-TERM (BETWEEN USES)If you must tilt the outboard to remove it fromthe water, lower it and allow the cooling sys-tem to drain completely as soon as you clearthe launch area.Between uses, store your outboard in a verti-cal position.

DANGER

DO NOT run the engine indoors or with-out adequate ventilation or permitexhaust fumes to accumulate in con-fined areas. Engine exhaust containscarbon monoxide which, if inhaled, cancause serious brain damage or death.

WARNING

Prevent injury from moving enginecomponents. Before starting the out-board:

• Shift it to NEUTRAL.• Keep hands, clothes, and hair clear of

powerhead.• Remove the propeller.

Store fuel tanks in a well-ventilatedarea, away from heat and open flame.Prevent escape of liquid or vaporswhich could accidentally ignite:

Close the filler cap vent screw, ifequipped.

Be sure the disconnected fuel hosedoes not drip.

If the outboard is laid down for transportationor storage, the oiling system must be primedbefore reusing the outboard. Prime the oilingsystem by performing winterization. Refer toLong-Term (Winterization) on page 35.

34

� STORAGE

LONG-TERM (WINTERIZATION)

PRE-SEASON CHECKRemove your outboard from storage and pre-pare it for a season of reliable service by per-forming a general check and a few preventivemaintenance procedures.Examine all loosened or removed hardware.Replace damaged or missing parts withEvinrude/Johnson Genuine Parts or equiva-lent. Check the gearcase for leakage. If leak-age is evident, the gearcase seals should bereplaced. See your Dealer.

IMPORTANT: Gearcase lubricant is thickand clear. Do not confuse this with engine oil,which may normally appear on the skeg afterperforming the long-term (winterization) stor-age procedure.

Anticorrosion anodes — Check condition.Refer to Anti-Corrosion Anodes on page28.

Battery — Charge fully. Refer to Battery onpage 41.

Review your outboard’s warning system self-test routine. During your preseason start-up,make sure the warning system self-testsproperly. If it does not, see your Dealer.

IMPORTANT: Do not run your outboard—even for a brief start-up—without supplyingwater to it. Refer to Flushing on page 34.

WARNING

Outboard must be in NEUTRAL and thepropeller removed before performingwinterization. Failure to remove propel-ler or starting outboard in gear cancause personal injury or death.

You can winterize your outboard in the water.If you do so, do not remove the propeller andmake sure the water intake screens are com-pletely submerged. Do not start the outboardagain after winterization is completed.Prepare your outboard for the off-season byclosely following these steps.1) Remove the propeller (if winterizing on a

trailer). Outboard 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 flushing port and

turn on the water (winterizing on a trailer).4) Using fast idle lever/button, advance throt-

tle to FULL fast idle warm-up position andstart the outboard. SystemCheck lights willilluminate and the outboard will run at idlespeed. Refer to Remote Controls onpage 21 for location of fast idle lever/but-ton, depending on your remote control.

5) After the SystemCheck lights turn off(about 15 seconds), move throttle to IDLEposition. SystemCheck lights will re-light.Once the SystemCheck lights turn offagain, using the fast idle lever/button,advance throttle again to FULL fast idlewarm-up position. SystemCheck lightswill flash.

IMPORTANT: If the SystemCheck lights donot flash, you may not have used the fast idlelever/button. If the lights are not flashing andthe outboard is not running at fast idle, imme-diately turn key switch OFF and re-start thewinterization procedure at step 4.6) Outboard will automatically go to fast idle

and fog itself. Allow outboard to run until itshuts OFF (about one minute).

7) After the outboard shuts itself off, turn keyswitch OFF, then detach garden hose.

8) With the engine cover removed, top off oilreservoir, inspect the fuel filter. If there isdebris in the fuel filter, it must be replaced.See your Dealer. Reinstall engine cover.

9) Grease propeller shaft splines with recom-mended lubricant and install propeller.

IMPORTANT: When finished, leave the out-board in vertical position long enough to com-pletely drain the powerhead. If equipped,disconnect the speedometer pickup at theupper connection and blow all water out ofthe hose using air pressure of 25 psi or less.Reconnect speedometer pickup after all thewater has been removed.When using this winterization fogging proce-dure, engine oil may appear on the skeg be-low the gearcase area. This is normal.Avoid potential oil stains by placing a shoptowel or suitable container under the propel-ler and skeg for the duration of the storage.

WARNING

Do not use a booster battery andjumper cables to start the outboard.Gasoline fumes can cause explosionand fire, resulting in property damage,personal injury or death.

35

Maintenance

Following Starting, Stopping, Shifting onpage 12, start the outboard. If the outboardwas auto-winterized, it will emit a puff ofsmoke on the first start of the season. Let itidle while you:Observe running quality. If poor, refer toTroubleshooting on page 37 or see yourDealer.Confirm water pump operation. Water mustflow from the water pump indicator in a steadystream. If it does not, shut off the outboardand investigate. Refer to Engine Overheat-ing on page 20.Stop the outboard and check the fuel systemfor leaks.

HULL FINISHThe condition of your boat’s bottom affectsperformance. Marine growth or bottom paint-ing may reduce speed and fuel efficiency.For maximum performance, keep the boat’srunning surface clean by rinsing it with freshwater and wiping it dry. Apply Evinrude anti-corrosion spray to any surface subject to cor-rosion, but avoid the anti-corrosion anode(s).

OUTBOARD EXTERNAL FINISH

SCRATCH REPAIR

SPARK PLUGS

IMPORTANT: The spark plugs should be ser-viced by an Evinrude E-TEC Dealer. Incorrectspark plug maintenance can lead to enginedamage.

SUBMERGED OUTBOARDIf your outboard has been under water, haveit serviced immediately upon recovery. Ifimmediate service is unavailable, resub-merge it in fresh water to avoid prolonged ex-posure to the atmosphere.After submersion, all boat and engine electri-cal, fuel, and oiling systems must be inspect-ed for signs of water intrusion. Your Dealershould perform this service.

WARNING

Failure to check for fuel leakage couldallow a leak to go undetected, resultingin fire or explosion.

Your outboard’s upper and lower engine cov-ers use molded-in color technology, provid-ing a deep, durable gloss with maximumultraviolet (sunlight) protection.The high gloss finish will show polish markswhen 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 ofautomotive wax. Leave the engine cover inplace when washing the outboard.

IMPORTANT: When trailering your outboard,DO NOT cover the engine with canvas—itwill dull the finish of the outboard’s enginecovers.

Surface scratches on the upper and lowerengine covers can be 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 followingthe product directions.

IMPORTANT: Your Dealer has the profes-sional materials to properly repair scratches.Do not attempt to paint over marks orscratches in the composite material. Seeyour Dealer to repair any deep scratches orgouges.

WARNING

The ignition system presents a seriousshock hazard. The primary circuit oper-ates in excess of 200 volts; the second-ary circuit operates in excess of 25,000volts. Use caution to avoid injury fromshock or injury resulting from yourreaction to shock. Do not handle pri-mary or secondary ignition compo-nents while the engine is cranking orrunning.

36

�

TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSEStarter motor will not operate • Shift handle not in NEUTRAL.

• Fuse blown.• Battery is dead.

Engine will not start • Not following starting instructions. Refer to Start-ing, Stopping, Shifting on page 12.

• Fuel tank empty.• Fuel hose kinked.• Fuel system contaminated with water or dirt.• Fuel filter obstructed.• Throttle not at IDLE. Return throttle to IDLE.• Spark plugs incorrect. Refer to Specifications on

page 45.• Spark plugs improperly gapped, carboned,

burned, or wet.• Fuse blown.• Flashing “Water Temp” or hot light, refer to En-

gine Monitoring on page 18 and Engine Over-heating on page 20.

• Flashing “Check Engine” or “Chk Eng” light, referto Engine Monitoring on page 18.

Engine will not idle properly • Debris on propeller.• Spark plugs damaged or incorrect. Refer to

Specifications on page 45.• Fuel system contaminated with water or dirt.

Engine loses power • Spark plugs damaged or incorrect. Refer toSpecifications on page 45.

• Fuel filter obstructed.• Fuel system contaminated with water or dirt.• Water intakes obstructed and cooling system not

operating correctly. Refer to Engine Overheatingon page 20.

• Oiling system malfunction.• S.A.F.E. protection mode activated. Refer to En-

gine Monitoring on page 18.

Engine runs, but makes little or no progress

• Propeller hub loose, slipping.• Propeller blades bent or missing.• Propeller shaft bent.• Propeller debris.

Warning system activates • Refer to Engine Monitoring on page 18.

37

Maintenance

OWNER’S NOTES

38

�

PRODUCT INFORMATION

39

Product Information

RIGGING AND ACCESSORIES

PROPELLER

Propeller Selection

To select the correct propeller for your boatingapplication, your boat and motor MUST bewater tested. See your Dealer for assistance.

IMPORTANT: The correct propeller for yourboat, under normal load conditions, will allowthe engine to run near the midpoint of theRPM operating range at full throttle. Refer toSpecifications on page 45.

IMPORTANT: Apply Triple-Guard grease tothe entire propeller shaft before installing thepropeller. At least annually, remove the pro-peller and check for debris. Clean the shaftand regrease it before reinstalling a propeller.

Standard vs. Counter RotationRight-hand propellers are considered stan-dard rotation propellers. When propelling aboat forward, the propeller rotates in a right-hand (clockwise) direction as viewed from therear.Left-hand propellers are considered counterrotation propellers. When propelling a boatforward, the propeller rotates in a left-hand(counterclockwise) direction as viewed fromthe rear.

1. Right-Hand (clockwise)2. Left-Hand (counterclockwise)

WARNING

Be alert of people in the water. Alwaysshift the outboard to NEUTRAL andshut off the engine immediately whenyour boat is in an area where theremight be people in the water. Seriousinjury or death can result from contact-ing a rotating propeller or moving boatand outboard.

WARNING

When servicing the propeller, alwaysshift the outboard to NEUTRAL posi-tion, turn the key switch OFF, and twistand remove all spark plug wires so theoutboard cannot be started acciden-tally.

WARNING

In dual-outboard installations, check tomake sure correct propellers areinstalled on each outboard beforeaggressively operating your boat. Shifteach engine individually into FOR-WARD or REVERSE, at idle speed only.If the boat moves opposite the direc-tion indicated by the remote controlhandle, the wrong propeller has beeninstalled on the outboard beingchecked.

40

� RIGGING AND ACCESSORIES

InstallationSlide thrust washer onto shaft with shoulderfacing aft.Slide propeller onto shaft, engaging thesplines and seating it on the thrust bushing.Slide spacer onto the shaft and engage thepropeller shaft splines.Wedge a block of wood between the propellerblade and the anti-ventilation plate.Install propeller nut and tighten to a torque of120-144 in. lbs. (13.6-16.3 N·m).Install keeper on propeller nut, align keeperslots and cotter pin hole.Install new cotter pin and bend ends to se-cure.Remove block of wood. Make sure engine isin NEUTRAL; give propeller a spin. It mustturn freely.

RepairIf your propeller hits a solid object, the impactis partially absorbed by the rubber bushing inthe hub to help prevent damage to the out-board. A strong impact can damage the huband propeller blades. Damage to blades cancause unusual and excessive vibration. Dam-age to the hub can cause excessive engineRPM with little forward movement.

IMPORTANT: Avoid or limit operation using adamaged propeller. Carry a spare propeller.Keep your propeller in good condition. Use afile to smooth slight damage to blade edges.See your Dealer for repair of serious damage.

BATTERY

Requirements• 12-volt, heavy-duty, designated for "marine"

use;• Vented/refillable or maintenance-free; and • Rated according to the minimum require-

ments in Specifications on page 45.

Deep-cycle batteries are suitable IF theymeet or exceed the minimum CCA require-ments.Ask your Dealer about your outboard’s re-quirements before installing longer battery ca-bles or a battery switch.

InstallationRead and understand the safety informationsupplied with your battery BEFORE you begininstallation.

IMPORTANT: Make sure all components areclean and free of corrosion.Connect the RED (+) main cable to the posi-tive (+) battery post. Connect the BLACK (–)main cable to the negative (–) battery post.If you have marine battery posts, install eachmain cable on the clamp adapter with a star-washer below it. Install all wires from acces-sories on the threaded portion of the post.

1. Main cable2. Starwasher3. Accessory wires

41

Product Information

If you have automotive battery posts, place astarwasher on the clamp adapter first, thenthe main cable, and then the wires from theaccessories.

1. Main cable2. Starwasher3. Accessory wires

Tighten all connections securely and coat theinstallation with Triple-Guard grease.

IMPORTANT: DO NOT use wing nuts on bat-tery connections even if they came with thebattery. Wing nuts can loosen and cause er-rant warning signals or electrical system dam-age.

ServiceBefore servicing the battery or the outboard,remove both battery cables from the battery,battery negative (–) cable first. Keep metalobjects from contacting either battery post.

IMPORTANT: Service electrical componentsonly while the outboard is NOT running. Becareful when identifying positive and negativebattery cables and posts.

WATER PRESSUREAn optional water pressure gauge is recom-mended to monitor cooling system pressures.Noticing changes in water pressure can helpprevent engine overheating. The water pres-sure gauge must be connected at the correctpoint to ensure the most accurate pressurereadings. Follow the installation instructionsincluded with the water pressure gauge.

1. Water pressure port (starboard side)

WARNING

Keep the battery connections clean,tight, and insulated to prevent theirshorting or arcing and causing anexplosion. If the battery mounting sys-tem does not cover the connections,install covers. Check often to see thatconnections stay clean and tight.

WARNING

Battery electrolyte is acidic — handlewith care. If electrolyte contacts anypart of the body, immediately flush withwater and seek medical attention.

Do not use a booster battery andjumper cables to start the outboard.Gasoline fumes can cause explosionand fire, resulting in property damage,personal injury or death.

1

42

� ADJUSTMENTS

ADJUSTMENTS

Idle RPM in GearThe idle RPM in gear setting can be adjusted,if desired, to provide more idle control, steer-ing, and quietness in certain applications.

IMPORTANT: Only your Dealer can adjustthe idle RPM in gear setting.

Trim Tab

A propeller will generate steering torque whenthe propeller shaft is not running parallel tothe water’s surface. The trim tab is adjustableto compensate for this steering torque.

IMPORTANT: A single trim tab adjustmentwill relieve steering effort under only one setof speed, motor angle and load conditions. Nosingle adjustment can relieve steering effortunder all speed, motor angle and load condi-tions. If the boat pulls to the left or right whenits load is evenly distributed, adjust the trimtab as follows:With the outboard shut OFF, loosen the trimtab screw. If the boat pulled to the right, movethe rear of the trim tab slightly to the right. Ifthe boat pulled to the left, move the rear of thetrim tab slightly to the left.

Tighten the trim tab screw to a torque of 35-40ft. lbs. (47-54 N·m).Test the boat and, if needed, repeat the pro-cedure until steering effort is as equal as pos-sible.

High motor installations — The trim tabmight be above the water when the motor istrimmed out. Steering effort might increase.Steering effort will be reduced if you trim themotor in and submerge the trim tab.

Dual standard rotation motors — Moveboth trim tabs equally and in the same direc-tion.

Dual motors (one counter and one stan-dard rotation) — Set both trim tabs to thecenter position.

WARNING

Improper trim tab adjustment cancause difficult steering.

43

Product Information

Tilt Limiter CamIf your outboard contacts the boat’s motor wellwhile tilting, adjust the tilt limiter cam to limitmaximum tilt-up.

Place the outboard in its normal operatingposition.Rotate the tilt limiter cam — pull its tab for-ward and up to REDUCE the amount of tiltUP.Check your adjustment — tilt the outboardfully and adjust further, if necessary. Returnthe outboard to vertical position for each ad-justment, and repeat your check after eachadjustment.

WARNING

Adjusting the tilt limiter cam will NOTprevent the outboard from tilting fullyand contacting the motor well if thegearcase hits an object at high speed.Such contact could damage the out-board and boat and injure boat occu-pants.

44

� SPECIFICATIONS

SPECIFICATIONS

75, 90 Models

Displacement 79.1 cu. in. (1296 cc)

Engine Type In-line, 3 Cylinder, Two-Cycle, E-TEC

Full Throttle Operating Range

75 HP – 4500 to 5500 RPM90 HP – 4500 to 5500 RPM

Power(1)

(1) Rated following the standards of ICOMIA 28.83, ISO 3046 and NMMA.

75 HP – 75 HP (56 kw) @ 5000 RPM90 HP – 90 HP (67.1 kw) @ 5000 RPM

Idle RPM in Gear(2)

(2) Emission Control Information.

700 ± 50

Idle RPM in Neutral(2) 600 ± 50

Ignition Timing(2) Not Adjustable

Emission Control System:per SAE J1930(2)

ECM, E-TEC (Engine Control Module, 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 153.0 qt. (2.8 l)

Warning Signals Controlled by the outboard’s EMM

Battery, Minimum 640 CCA (785 MCA) 12 volt

Spark Plug(2) Refer to ECI Label

Fuses Refer to Fuse on page 29

Fuel Filter In-line Replaceable

Battery Charging 25-Amp, Fully Regulated

Gearcase – Lubricant– Capacity

Evinrude Ultra-HPF™L Models – 31.6 fl. oz. (935 ml)X Models – 32.8 fl. oz. (970 ml)

Power Trim/Tilt – Fluid Capacity

21 fl. oz. (622 ml)

Propeller Refer to Propeller Selection on page 40

Weight L Models – 320 lbs. (145 kg)X Models – 335 lbs. (152 kg)

Sound at Driver’s Ear(LpA) ICOMIA 39.94

76.8 dB(A)

Transom Height L Models – 19 1/2 to 20 in. (495 to 508 mm)X Models – 24 1/2 to 25 in. (622 to 635 mm)

45

Product Information

PRODUCT WARRANTY INFORMATION

BOMBARDIER MOTOR CORPORATION OF AMERICA LIMITED WARRANTY FOR 2005 EVINRUDE OUTBOARD ENGINES

SOLD IN THE UNITED STATES AND CANADA

1. SCOPE OF THE LIMITED WARRANTYBombardier Motor Corporation of America* (“BMCA”) warrants its 2005 Evinrude® outboard engines sold by authorizedEvinrude dealers in the fifty United States and Canada ("Product") from defects in material or workmanship for the periodand under the conditions described below.

2. WARRANTY COVERAGE PERIODThis limited warranty will be in effect from the date of purchase by the first retail consumer or the date the Product is firstput to use, whichever occurs first, for a period of:

THIRTY-SIX (36) CONSECUTIVE MONTHS for private, recreational use; or

TWELVE (12) CONSECUTIVE MONTHS for commercial use, except that emission-related components providing inputto emission controls (e.g. sensors) are warranted for twenty-four (24) months or two hundred (200) hours of engine use,whichever occurs first. The Product is used commercially when it is used in connection with any work or employment thatgenerates income, during any part of the warranty period. The Product is also used commercially when, at any point dur-ing the warranty period, it is installed on a boat that has commercial tags or is licensed for commercial use.

The repair or replacement of parts or the performance of service to Product under this warranty does not extend the lifeof this limited warranty beyond its original expiration date. All Evinrude/Johnson® Genuine Parts and accessories in-stalled by an authorized dealer at the time of sale, including but not limited to propellers, bear the standard BMCA partsand accessories one-year limited warranty.

California residents who purchased or warranty-registered a Product in California should refer to BMCA's California Emis-sions Control Warranty Statement.

3. CONDITIONS TO HAVE WARRANTY COVERAGEThis warranty coverage is available only on Evinrude outboard engines purchased as new and unused from a dealer au-thorized to distribute Evinrude products in the country in which the sale occurred ("Dealer"), and then only after the BMCAspecified pre-delivery inspection process has been completed and documented by the purchaser and Dealer. Warrantycoverage only becomes available upon proper registration of Product by Dealer or owner.

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 generalpublic.

As outlined in the Operator's Guide, timely routine required maintenance must be performed to maintain warranty cover-age. BMCA may require proof of proper maintenance prior to authorizing warranty coverage.

4. WHAT TO DO TO OBTAIN WARRANTY COVERAGEThe registered owner must notify an authorized Dealer within two (2) days of the appearance of a defect. Owner mustbring Product, including any defective part therein, to Dealer promptly after the appearance of the defect, and in anyevent, within the warranty period, and must provide Dealer with reasonable opportunity to repair the defect. The expensesof transporting Product to and from Dealer for warranty service are to be borne by the owner.

If the Product has not previously been registered, the owner may also be required to present proof of purchase to Dealerfor warranty repairs. Owner is required to sign the repair/work order prior to the start of the repair in order to validate thewarranty repair.

All parts replaced under this warranty become the property of BMCA.

5. WHAT BOMBARDIER MOTOR CORPORATION OF AMERICA WILL DOBMCA's obligations under this warranty are limited to, at its sole discretion, repairing or replacing parts of Product foundto be defective in material or workmanship, in the reasonable judgment of BMCA. Such repair or replacement of partswill be done without charge for parts and labor, at any authorized Dealer. BMCA's responsibility is limited to making therequired repairs or replacements of parts with new or BMCA-certified re-manufactured parts. No claim of breach of war-ranty shall be cause for cancellation or rescission of the sale of Product to owner.

In the event that warranty service is required outside of the fifty United States or Canada, owner will bear responsibilityfor any additional charges due to local practices and conditions, such as, but not limited to, freight, insurance, taxes, li-cense fees, import duties, and any and all other financial charges, including those levied by governments, states, territo-ries and their respective agencies.

BMCA reserves the right to improve, modify or change Products from time to time without assuming any obligation tomodify Products previously manufactured.

46

� PRODUCT WARRANTY INFORMATION

6. EXCLUSIONS — The following are not warranted under any circumstances:• Replacement of parts due to normal wear and tear;• Routine maintenance parts and services including but not limited to: maintenance requirements, engine and lower unit

oil changes, lubrication, valve and linkage adjustments and replacement of fuses, zinc anodes, thermostats, timingbelts, starter motor bushings, trim motor brushes, filters, propellers, propeller bushings and spark plugs;

• Damage caused by improper or lack of installation, maintenance, winterization and/or storage, failure to follow the pro-cedures and recommendations in the Operator's Guide;

• Damage resulting from removal of parts, improper repairs, service, maintenance, or modification, or use of parts oraccessories not manufactured or approved by BMCA, which in its reasonable judgment, are either incompatible withProduct or adversely affect its operation, performance, or durability, or resulting from repairs done by a person that isnot an authorized Dealer;

• Damage caused by abuse, misuse, abnormal use, neglect, racing, improper operation or operation of the Product in amanner inconsistent with the recommended operation described in the Operator's Guide;

• Damage resulting from external damage, accident, submersion, water ingestion, fire, theft, vandalism or any act ofGod;

• Operation without proper fuel, oil or lubrication, or with fuels, oils or lubricants which are not suitable for use with theProduct (see the Operator's Guide);

• Damage resulting from rust or corrosion;• Damage caused from cooling system blockage 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 is or has been used for racing at any point, even by a prior owner.

7. LIMITATIONS OF LIABILITYALL WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MER-CHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE LIFE OF THEEXPRESS LIMITED WARRANTY.

ALL INCIDENTAL, CONSEQUENTIAL, DIRECT, INDIRECT OR OTHER DAMAGES OF ANY KIND ARE EXCLUDEDFROM COVERAGE UNDER THIS WARRANTY INCLUDING, BUT NOT LIMITED TO: expense for gasoline, expensefor transporting Product to and from 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 payments, loss of time, loss of income, reve-nue or profits, or loss of enjoyment or use of Product.

SOME STATES, PROVINCES, OR JURISDICTIONS DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS OFINCIDENTAL OR CONSEQUENTIAL DAMAGES, OR OTHER EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT,THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC RIGHTS, AND YOU MAY ALSO HAVEOTHER LEGAL RIGHTS WHICH MAY VARY FROM STATE TO STATE, OR PROVINCE TO PROVINCE.

No distributor, Dealer or any other person is authorized to make any affirmation, representation or warranty regardingProduct other than those contained in this limited warranty and, if made, shall not be enforceable against BMCA. BMCAreserves the right to modify this warranty at any time, being understood that such modification will not alter the warrantyconditions applicable to the Products sold while this warranty is in effect.

8. TRANSFERIf the ownership of Product is transferred during the warranty coverage period, this warranty shall also be transferred andbe valid for the remaining coverage period provided that the former or new owner promptly contacts BMCA or Dealer andgives the name and address of the new owner.

9. CONSUMER ASSISTANCE• In the event of a controversy or dispute in connection with this BMCA limited warranty, BMCA recommends that you

first try to resolve the issue at the dealership level by discussing the issue with Dealer’s service manager or owner;• If further assistance is required, please contact the Bombardier Motor Corporation of America Customer Support Ser-

vices, 250 Sea Horse Drive, Waukegan, IL 60085, 1-847-689-7090.

BOMBARDIER MOTOR CORPORATION OF AMERICA LIMITED WARRANTY FOR 2004 EVINRUDE OUTBOARD ENGINES

SOLD OUTSIDE THE UNITED STATES AND CANADAFor a copy of the Limited Warranty, see your Bombardier Motor Corporation of America (“BMCA”) distributor/dealer au-thorized to distribute Evinrude products in the country in which the sale occurs.If further assistance is required, please contact Bombardier Motor Corporation of America Customer Support Services,250 Sea Horse Drive, Waukegan, Illinois, 60085, or the affiliate of BMCA where the Product was registered for warranty.

* Engines sold in Canada are distributed and serviced by Bombardier Recreational Products Inc.Limited Warranty Revision February 2004

47

Product Information

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

Your Evinrude E-TEC outboard has a special environmental label required by the California Air ResourcesBoard. The label has one, two, three, or four stars. A hangtag, provided with your outboard, describes themeaning of the star rating system.

The Star Label Means Cleaner Marine Engines

The Symbol for Cleaner Marine Engines:Cleaner Air and Water

For a healthier lifestyle and environment. Better Fuel Economy

Burns up to 30 to 40 percent less gas and oil than conventional carbureted two-strokeengines, saving money and resources.

Longer Emission WarrantyProtects consumer for worry free operation.

One Star – Low EmissionThe one-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet theAir Resource Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission stan-dards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.

Two Stars – Very Low EmissionThe two-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet theAir 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-gines.

Three Stars – Ultra Low EmissionThe three-star label identifies engines that meet the Air Resources Board's Personal Watercraft and Out-board marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star– Low Emission engines.

Four Stars – Super Ultra Low EmissionThe four-star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marineengine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may alsocomply with these standards. Engines meeting these standards have 90% lower emission than One Star– Low Emission engines.For more information: Cleaner Watercraft – Get the Facts

1-800-END-SMOGwww.arb.ca.gov

48

� CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR EMISSION CONTROL WARRANTY RIGHTS AND OBLIGATIONThe California Air Resources Board and Bombardier Motor Corporation of America (“BMCA”) are pleasedto explain the emission control system warranty on your 2004 Evinrude E-TEC outboard. In California,new outboard engines must be designed, built, and equipped to meet the State's stringent anti-smog stan-dards. BMCA must warrant the emission control system on your outboard for the periods of time listedbelow provided there has been no abuse, neglect, or improper maintenance of your outboard.Your emission control system may include parts such as the carburetor or fuel injection system, the igni-tion system, and catalytic converter. Also included may be hoses, belts, connectors, and other emission-related assemblies.Where a warrantable condition exists, BMCA will repair your outboard at no cost to you including diagno-sis, parts, and labor provided that such work is performed by an authorized BMCA dealer.Manufacturer's Limited Warranty CoverageThis emission limited warranty covers Evinrude outboards certified and produced by BMCA for sale in Cal-ifornia, that are originally sold in California to a California resident, or subsequently warranty-registered toa California resident. The BMCA U.S. and Canada limited warranty conditions for Evinrude outboards arestill applicable to these models with the necessary modifications.Select emission control parts of your Evinrude E-TEC outboard are warranted from the date of purchaseby the first retail consumer or the date the product is first put to use, whichever occurs first, for a periodof: 4 years, or for 250 hours of use, whichever occurs first.However, warranty coverage based on the hourly period is only permitted for outboards equipped with theappropriate hour meters or their equivalent. If any emission-related part on your engine is defective underwarranty, the part will be repaired or replaced by BMCA.Parts covered are:

1. Electrical System 4. Air Induction SystemA. EMM (Engine Management Module) A. Reed ValvesB. Spark Plugs and Wires B. Throttle Body AssemblyC. Ignition Coils C. Intake ManifoldD. Wiring Harness

5. Oil System2. Exhaust System A. Oil Injector

A. Inner Exhaust Housing B. Oil Lines, Fittings, and ClampsB. Adaptor (Exhaust Manifold)C. Megaphone (Inner Exhaust) 6. Sensors

A. Air Temperature Sensor

3. Fuel System B. Crank Position Sensor

A. Fuel Lift Pump C. Throttle Position SensorB. Fuel Supply Pump D. Water Temperature SensorC. Fuel Injectors E. ThermostatD. Vapor SeparatorE. Fuel Lines, Fittings, and Clamps 7. Gaskets

A. All Emission Component Gaskets

49

Product Information

The emission warranty covers damage to other engine components that is caused by the failure of a war-ranted part.The BMCA Operator's Guide provided contains written instructions for the proper maintenance and useof your outboard. All emission warranty parts are warranted by BMCA for the entire warranty period of theoutboard, unless the part is scheduled for replacement as required maintenance in the Operator's Guide. Emission warranty parts that are scheduled for replacement, as required maintenance, are warranted byBMCA for the period of time before the first scheduled replacement date for that part. Emission warrantyparts that are scheduled for regular inspection but not regular replacement are warranted by BMCA forthe entire warranty period of the outboard. Any emission warranty part repaired or replaced under theterms of this warranty statement is warranted by BMCA for the remainder of the warranty period of theoriginal part. All parts replaced under this limited warranty become the property of BMCA.Maintenance receipts and records should be transferred to each subsequent owner of the outboard.Owner's Warranty ResponsibilitiesAs the outboard owner, you are responsible for the performance of the required maintenance listed in yourOperator's Guide. BMCA recommends that you retain all receipts covering maintenance on your out-board, but BMCA cannot deny warranty solely for the lack of receipts or your failure to ensure the perfor-mance of all scheduled maintenance.As the outboard owner, you should however be aware that BMCA may deny you warranty coverage if youroutboard or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.You are responsible for presenting your outboard to an authorized BMCA dealer as soon as a problemexists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.For any questions regarding your warranty rights and responsibilities or for the name and location of thenearest authorized BMCA dealer, contact Bombardier Motor Corporation of America Customer SupportServices, 250 Sea Horse Drive, Waukegan, IL 60085, 1-847-689-7090 or visit www.evinrude.com.

50

�

CHANGE OF ADDRESS / CHANGE OF OWNERSHIPIf your address has changed or if there has been a change of ownership, be sure to fill out andmail the card provided on this page.Such notification is likewise necessary for your own safety even after expiration of the originalwarranty, since BMCA will be in a position to contact you if correction to your outboard be-comes necessary. Outside the U.S. and Canada, this card should be sent to the BombardierRecreational Products division where the outboard was registered. Please contact your Dealeror 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

51

Product Information

Bombardier Motor Corporation of America

52

�

CONFIRMATION OF RECEIPT

Your Dealer

Upon delivery of your new Evinrude/Johnson outboard, complete and sign the form below.Your Dealer will take receipt of the form for their records.

Receipt

Name:

Address:

Name:

Address:

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, safetyfeatures and warranty policy, all of which I understand and agree to be bound with. I am also satisfiedwith the predelivery set-up and inspection of my Evinrude/Johnson outboard. I have also received acopy of the Operator’s Guide.

Signature:

Date:

53

Product Information

Bombardier Recreational Products

54

�

OWNER’S NOTES

55

Product Information

Readiness Test

The Operator’s Readiness Test....1. Did you read this Guide from front cover to rear cover?

2. Are you ready to take responsibility for the safe operation of your boat and outboard?

3. Do you understand all the safety precautions and instructions contained in this Guide?

4. Do you understand that this Guide contains essential information to help prevent personalinjury and damage to equipment?

5. Are you ready to follow the recommendations in this Guide and take a boating safetycourse 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 namea few?

WARNING

It is impossible for this Guide to cover every hazardous situation you may encoun-ter; however, your understanding of and adherence to essential information con-tained in this Guide will build good judgment when boating. Always be alert andcareful: a good foundation for safety.

56

FREQUENTLY ASKED QUESTIONS

No dealer-scheduled maintenance for the first three years of normal recreational use? Really?• Yes! Bombardier Motor Corporation of America knows you want to spend your time on the

water, not servicing your Evinrude E-TEC outboard. There are no valves to adjust, belts toservice, chains to replace, or oil to change. We do recommend pre-launch inspections ofyour outboard at each use and at regular intervals. Salt water applications require minimaladditional inspections and lubrication.

What fuel octane is recommended for my Evinrude E-TEC outboard?• Evinrude E-TEC outboards require a minimum octane of 87 (U.S.). Use of higher octane fu-

els is not harmful, but also not necessary.

What kind of oil does my Evinrude E-TEC outboard require?• Any TC-W3RL oil may be used. The outboard can be programmed by your Dealer to run on

Evinrude/Johnson XD100 oil for lower oil consumption and reduced operating cost. Refer toFilling the Oil Tank on page 15; see also Oil Requirements on page 16.

Do I need to mix oil into my fuel?• No. Evinrude E-TEC outboards do not require any mixing of oil and fuel.

Where 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. Bombardier Motor Corporation of America-approved dealers and distribu-tors have received the necessary training to properly service your outboard. ContactBombardier Motor Corporation of America for an authorized Evinrude E-TEC dealer nearyou.

Can I order replacement parts and accessories for my Evinrude E-TEC outboard?• Yes. When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts

with equivalent characteristics, including type, strength, and material. Using substandardparts could result in injury or product malfunction. Your dealer can order the parts and ac-cessories you desire.

Do I need to complete any paperwork when I move or sell my Evinrude E-TEC outboard?• Yes. In order to maintain contact with you or the new Evinrude E-TEC owner, Bombardier

Motor Corporation of America requests you complete the form outlining Change of Address/ Change of Ownership on page 51. This will ensure you or the new owner is made awareof any product announcements and keep the warranty coverage up-to-date.

What do I need to do before storing my Evinrude E-TEC outboard for the winter?• Winterization is minimal. Refer to Storage on page 34 for step-by-step instructions to store

your Evinrude E-TEC outboard for the off-season.

12 pt12 pt

™™

WARNINGRead this Operator Guide thoroughly. It contains important

safety information. When operating your boat, always have this Operator Guide onboard.

! !*215642*

RL

40 HORSEPOWER

2005

Documents

PL, PX, SL...• Heavy-Duty Use Design • Posi-Lock Latches • Digital Diagnostics • Extra Capacity Water Pump • High Thrust, Large Gearcase • Dual Platinum Spark Plugs •