Service Manual 115-200 HP E-TEC Installation And Predelivery [Outboard Installation]

Maximum Capacity

Do not overpower the boat by installing an outboard that exceeds the horsepower indicated on the boat’s capacity plate. Overpowering could result in loss of control.

Before installing outboard:

• Refer to the boat manufacturer's certification label for maximum horsepower rating.

• Refer to ABYC Standards to determine the maximum horsepower capacity for boats with out certification labeling.

Mounting Surface

Inspect transom surface prior to drilling mounting holes.

• The transom should meet ABYC Standards.

• The transom must be flat.

• The transom angle should be approximately 14 degrees.

• Check transom strength and height.

The stern brackets must contact the flat surface of the transom. Modify trim that prevents the stern brackets from resting against the transom surface. Do not modify stern brackets.

DO NOT install an outboard on a curved or irregular surface. Doing so can wear, bind, and damage components, causing loss of control.

Transom Clearances

Make sure the transom and splash well area pro vide adequate clearances:

• The top edge of the transom should be wide enough to allow full steering travel. The ABYC standard for most single outboard installations is 33 in. (84 cm).

• Check cable and hose routing clearances.

• Make sure there is clearance for mounting bolts and washers. Check the inside area of the tran som for obstructions before drilling holes.

Water Flow

Inspect the hull area directly in front of the mounting location.

• Boat-mounted equipment should not create turbulence in the water flow directly in front of the outboard's gearcase. Turbulence or disruptions in the water flow directly in front of the gearcase will affect engine cooling and propeller performance.

• Avoid locating outboard centerlines within 3 in. (76 mm) of bottom strakes on dual-outboard installations.

Transom Brackets and Jack Plates

When mounting an outboard on a jack plate:

• Refer to the manufacturer's recommendations for maximum weight and horsepower.

• The jack plate must provide a rigid, one-piece mounting assembly—either a solid surface, or surfaces adequately connected to prevent flex ing or twisting.

• DO NOT use a jack plate constructed in two separate pieces—lack of support can twist the stern brackets, wear tilt tube bushings and thrust rollers, and bend or break components.

IMPORTANT: Damage caused by use of a two piece jack plate or unstable mounting surface will not be covered by warranty.

Recommended Designs

Not Recommended

Whenever possible, use mounting hardware sup plied with the outboard to install jack plate on transom. Tighten to a torque of 40 ft. lbs. (54 N·m).

To prevent damage to outboard, check installation frequently for:

• Loose mounting bolts and nuts

• Loose tilt tube or steering cable nuts

• Elongated mounting holes

• Bent or deformed washers Replace any hardware that fails to maintain torque specifications.

Mounting Hardware

Use all mounting hardware supplied with the outboard to help ensure a secure installation. Substituting inferior hardware can result in loss of control.

Outboard mounting hardware must meet mini mum specifications for material and strength:

• Material: Stainless steel; Group 1,2,3 per ASTM F593 OR Grade A2 per ISO 3506-1.
• Strength: Minimum proof load.

Outboard mounting bolts, backing plates, washers, and nuts are used to attach the outboard to the shipping pallet. If alternate bolt lengths or replacement parts are required, use only Evinrude/Johnson Genuine Parts.

IMPORTANT: Standard screws offered by local merchants may not provide the high strength required for outboard installations.

Hull Centerline

Use the chines of the boat as reference points to locate the centerline of the boat transom.

Use a straightedge to draw a line connecting the port and starboard chines.

Use a framing square to accurately place a vertical line on the transom. The centerline of the hull should be in line with the keel, and perpendicular to the midpoint of the line connecting the chines.

1. Chine
2. Strake
3. Keel
4. Hull centerline

Dual-Outboard Centerlines

The following table lists standard ABYC centerline spacing between outboards in dual installations:

Some applications may require changes in this dimension to avoid strakes, to adjust for transom height, or for performance reasons. Best performance can be determined only through testing. Refer to boat manufacturer for recommendations. If the standard spacing does not allow full steering travel in a particular installation, it may be necessary to increase the spacing.

IMPORTANT: Some steering systems may require additional spacing. Refer to steering system manufacturer for recommendations.

The top edge of the transom should be more than twice the width of the dual-outboard centerline spacing dimension. Bracket installations may not require this consideration.

Measure the transom for dual-outboard spacing after the centerline of the hull is established.

Divide the spacing dimension by two. Use the resulting number to space the outboard center lines from the hull centerline.

EXAMPLE: A 26 in. (660 mm) dual-outboard spacing would result in two outboard centerlines, each 13 in. (330 mm) from the hull centerline.

1. Port centerline
2. Hull centerline
3. Starboard centerline

Transom Height

Make sure the transom height matches the length of the outboard to be installed.

• A 19 to 21 in. (48.3 to 53.3 cm) transom height uses a 20 in. (50.8 cm) shaft outboard.

• The shaft length of the outboard being installed should come close to matching the transom height of the boat.

Determine transom height by measuring from the top edge of the transom, along the centerline.

For dual-outboard installations, transom height should be measured at the outboard centerlines. Use a straightedge as a reference to extend the bottom of the boat.

Position the straightedge along centerline. The distance from the top edge of the straightedge to the top edge of the transom is the actual transom height.

1. Top edge of transom
2. Actual transom height

Transom Drilling Locations

All models use the standard ABYC 4-Bolt mount ing pattern.

Use Transom drill fixture, P/N 434367 or P/N 385368, as a guide for correct hole placement. If drill fixture is unavailable, refer to Drilling and Hardware Diagrams on p. 54 for measurements.

Position drill fixture on top of transom or bracket and align indicator points with centerline.

Transom drill fixture P/N 434367 (heavy duty)

The indicators are affected by the squareness of the top edge of the transom. If either side of the fixture must be raised more than ¼ in. (6 mm) above the transom's top surface to make both indicators align, the transom must be modified.

IMPORTANT: DO NOT assume that the top edge of the transom is straight. Position the drill fixture based on measurements aligning it to the bottom of the hull.

Maintain at least 1.75 in. (45 mm) of transom surface above the top mounting bolts.

Before drilling any mounting holes:

• Make sure the hole locations provide enough clearance for mounting bolts and washers.

• Check the inside area of the transom for obstructions.

• Check transom height(s) at centerlines.

Drill four ½ in. (13 mm) mounting holes in the appropriate locations.

IMPORTANT: Be sure to drill the required holes perpendicular to transom surface.

115–200 HP, ALL MODELS

IMPORTANT: This is not a template.

1. Center of Transom
2. Top of Transom
3. 1/2” Bolt Hole Locations
4. Outside of Transom
5. Bolt *
6. 318272 Plate
7. 318273 Retainer
8. 319886 Screw
9. 307238 Washer
10. 320248 Washer
11. 313623 Nut
12. 318572 Cap

Quantity

4
2
2
4
2
4
4
4

• Choose from the following bolt sizes:

327053 3 in. (76 mm)
318573 3 1/2 in. (89 mm)
336676 4 1/2 in. (114 mm)
331578 5 in. (127 mm)
354101 6 in. (152 mm)
354102 7 in. (178 mm)
354103 8 in. (203 mm)
354104 9 in. (229 mm)

IMPORTANT: This is not a template.

Lifting Fixtures

To avoid personal injury, make sure the lifting capacity of the hoist is at least twice the weight of the outboard. DO NOT allow the lift hook or chain from the hoist to come in contact with any part of the engine during lifting.

Remove shipping carton.

Use correct Lifting Fixture to lift outboard:

Install Lifting Fixture, P/N 342672, on crankshaft. Tighten mounting screw securely using an Allen 1/4 in. hexagonal wrench.

• 1. Center retaining screw

Fasten appropriate chain hook to eye of tool. Carefully hoist outboard with chain and unbolt out board mounting brackets from frame.

Manual Hydraulic Steering

Manual hydraulic steering systems use hydraulic fluid to transfer motion and load from the helm to the outboard.

Use only a hydraulic steering system designed for the specific application. Refer to the steering system manufacturer’s specifications for recommended applications.

Mechanical Cables

All Evinrude outboards equipped with tilt tubes are compatible with mechanical steering systems that meet ABYC Standard P-17. Single-cable mechanical steering systems can be used on single or dual-outboard installations if an ABYC-approved steering link is used.

Dual-cable mechanical steering helps provide firm steering control at high speeds.

Extend the steering cable and lubricate the inner core before installation.

ABYC-approved Mechanical Steering Cable

IMPORTANT: Install steering cable through tilt tube before mounting outboard on transom. Tighten nut securely.

DO NOT use cable over pulley steering on 40 HP and larger outboards.

TYPICAL Manual Hydraulic Steering

IMPORTANT: Some hydraulic steering systems require additional centerline spacing in dual-outboard installations. Refer to steering system manufacturer’s recommendations and to DualOutboard Centerlines on p. 52.

Drag Links

Use the correct drag link to allow full steering travel:

Install cable wiper nut on tilt tube and connect drag link to the correct location on the steering arm. For single engine, single cable applications, the drag link should be installed in the rear hole.

• 1. Drag link connection
• 2. Wiper nut

• 1. Rear Location (D)–Steering drag link connection
• 2. Middle Location (P)–Power steering connection (Refer to manufacturer’s instructions for hydraulic steering systems.)
• ( 3. Front Location (T)–Bar connection (multiple outboard installations)

IMPORTANT: Some rigging components, such as steering cables, must be fitted to the outboard before the outboard is mounted to the transom. Determine what equipment will be installed before mounting.

Mounting Height

Boat performance depends on outboard mounting height.

Generally, the anti-ventilation plate of the gear case should align with the bottom of the hull. Con ventional V-hulls often perform well with the anti ventilation plate approximately 1 in. (25 mm) above the bottom of the hull.

Boats that exceed 50 MPH may benefit from higher outboard heights. Consult the boat manu facturer for specific outboard mounting height information for a particular hull.

Test outboard and boat performance at different heights until the best performance is achieved.

Be sure that outboard water pressure is not adversely affected by the mounting height of the outboard.

Mounting Bolt Installation

IMPORTANT: Use a marine sealant rated for above or below waterline use. RTV silicone is not approved for below waterline use. Polyurethane sealants are not easily removed and may damage outboard or boat mounting surfaces.

Apply marine sealer under hex heads of bolts, on the mounting plates, and to the bolt shanks.

Assemble transom mounting plates on mounting bolts.

Install the mounting bolts through the transom from the inside of the boat.

Position the square aluminum transom mounting plates (when applicable) so the retainer holes are horizontal.

Position hex head of bolt with flats toward holes in the mounting plates. Install retainer over hex head of the bolt and secure it with screws provided.

Install all washers and nuts. Tighten to a torque of 40 ft. lbs. (54 N·m).

If either side of the transom deforms or cracks when the bolts are tightened to their recommended torque, the transom construction may not be adequate or may be deteriorated. Structural failure of the transom could result in loss of boat control and injury to the occupants.