Service Manual 5007213_Evinrude E-TEC 115-200 HP Maintenance [Lubrication]

Inspect condition of water intake screens. Clean or replace as needed.

Confirm function of overboard water pressure indicator.

1. Water intake screen
2. Overboard water pressure

• Confirm function of SystemCheck engine monitor.

• Check operation or visually inspect thermostats and pressure relief valve. Clean or replace as needed.

• Check that all water passages, hoses, and fit tings for both the EMM and the vapor separator flow water freely.

• Replace water pump.

Steering System

Failure to regrease as recommended could result in steering system corrosion. Corrosion can affect steering effort, making operator control difficult.

Grease the stainless steel output end of the steering cable with Triple-Guard grease.

Use an appropriate cleaning solvent to remove corrosion and dirt from output end of cable prior to coating it with grease. Make sure wiper nut is installed and not damaged.

1. Steering cable
2. Wiper nut

Lubricate the swivel bracket with Triple-Guard grease.

Apply grease until the grease begins to flow from the upper or lower swivel bracket areas.

Coat the pivot points of the trailering bracket with Triple-Guard grease.

1. Grease fitting
2. Pivot points
3. Lower swivel bracket area

Lubricate the tilt tube grease fittings with Triple- Guard grease.

1. Tilt tube fittings

Disconnect the battery cables at the battery.

Remove cable trunnion cover. Carefully, remove throttle and shift cables from trunnion block.

IMPORTANT: DO NOT disturb cable trunnion adjustments.

Shift remote control into FULL THROTTLE/ REVERSE position to fully extend the plastic casing guides.

Apply Triple-Guard grease to:

• Pivot and slide area of the shift interrupt switch bracket

• Cable attachment pins of both the throttle and shift levers

• Brass inner casings of both the throttle and shift cables

1. Attachment pins, throttle and shift cables
2. Shift shaft grease fitting
3. Brass inner casings, throttle and shift cables

Shift the remote control to the NEUTRAL/IDLE position.

Install control cables in trunnion block(s) and install trunnion cover(s) and screw(s) securely. Check proper throttle and shift function.

Debris from the water can become lodged around propeller shaft. Frequent inspection can minimize potential gearcase damage.

When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and disconnect the battery cables at the battery.

Remove propeller. Refer to Propeller Hardware Installation on p. 74.

Inspect bushing and blade surfaces. Replace damaged or worn propellers.

Clean propeller shaft. Inspect propeller shaft seals. Replace damaged or worn seals.

Apply Triple-Guard grease to entire length of propeller shaft prior to installing propeller.

Reinstall propeller hardware and propeller.

IMPORTANT: Always check the fill level of the gearcase lubricant prior to removing drain/fill plug. A tie strap can be used to check lubricant level.

1. Tie strap

Examine drained lubricant for excessive metal fragments and for any indication of water in oil (cloudy or milky appearance). Lubricant that is black in color with a burnt odor indicates worn, overheated oil. Pressure and vacuum check gear cases with apparent leaks. Repair all leaks.

Refer to the INSPECTION AND MAINTENANCE SCHEDULE on p. 80 for service frequency and recommended lubricants.

Refer to LUBRICANT on p. 307 for complete gearcase lubricant filling procedures.

1. Magnetic level and drain/fill plugs
2. Drain/fill hole
3. Lubricant level hole

Refill the gearcase with HPF XR Gearcase Lubricant.

If HPF XR Gearcase Lubricant is not available, Hi- Vis gearcase lubricant can be used as an alternative; however, long term durability may be affected with continued use.

IMPORTANT: The recommended gear lubricants include special additives for marine applications. Do not use any automotive gear lubricants, 2-stroke or 4-stroke engine oil, or any other oil or grease for gearcase applications.

Position outboard in FULL TILT (UP) position.

Engage the tilt support bracket.

1. Tilt support bracket

Inspect for fluid leaks. Repair all leaks.

Remove the fill plug and check fluid level. The fluid level must be even with bottom of the reservoir fill cap hole.

Single Piston Trim System

1. Fill cap

Three Piston Trim System

1. Fill cap

• Single Piston System–Add Evinrude/Johnson Biodegradable TNT Fluid, as needed, to bring level to the bottom of the fill plug threads.

• Three Piston System–Add Power Trim/Tilt Fluid or GM Dexron II, as needed, to bring level to the bottom of the fill plug threads.

Install the fill plug and torque 45 to 55 in. lbs. (5 to 6 N•m).

Correct fluid level must be maintained to ensure operation of the impact protection built into the unit.