Service Manual 5007215_Evinrude E-TEC 200-250 HP Service Specifications And Special Tools

Standard Torque Chart

IMPORTANT: These values apply only when a specific torque for a specific fastener is not listed in the appropriate section. When tightening two or more screws on the same part, DO NOT tighten screws completely, one at a time.

Torque wrench tightening specifications must be strictly adhered to. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener.
If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts.

Diagnostics

Diagnostic Software for Windows based PC P/N 763724

Bootstrap tool P/N 586551

Interface cable P/N 437955

Universal

Lifting ring assembly P/N 396748

Flywheel holder P/N 771311

Puller Bridge – 432127

Lifting eye P/N 321537

Large puller jaws P/N 432129

Slide hammer P/N 391008

Universal Puller Set P/N 378103

Small puller jaws P/N 432131

Slide hammer P/N 432128

Temperature gun P/N 772018

Tilt tube nut wrench P/N 342680

Tilt tube service kit P/N 434523

Electrical / Ignition

Digital multimeter Ohms resolution 0.01 Purchase through local supplier DRC7265

Peak reading voltmeter P/N 507972

Analog multimeter P/N 501873

Stator Test Adapter P/N 5006211

Connector tool P/N 342667

Tachometer/timing light P/N 507980

Crimping pliers P/N 322696

Test probe kit P/N 342677

AMP† connector tools

Primary Lock Tool P/N 777077

Secondary Lock Tool P/N 777078

Release Tool P/N 351413

Lock Installer P/N 777079

Fuel/Oil Systems

Fuel pressure gauge (100 PSI) P/N 5000902

Fuel pressure gauge (60 PSI) P/N 5007100
90° fitting, P/N 353322

Fuel pressure gauge (15 PSI)
P/N 5006397
90° fitting, P/N 353322

Oetiker† pincers P/N 787145

Injector test fitting kit, P/N 5005844

Powerhead

Cylinder bore gauge P/N 771310

Rod cap alignment fixture P/N 396749

Crankshaft bearing and sleeve installer P/N 338649

Piston stop tool P/N 342679
Replacement tip P/N 5006098

Torquing socket P/N 346187

Seal installation tool P/N 325453

Wrist pin bearing installer P/N 338646

Wrist pin pressing tool P/N 396747

1. Wrist pin retaining ring driver P/N 396747
2. Wrist pin cone P/N 331913

Gearcase

Gearcase filler P/N 501882

Universal driveshaft shimming tool P/N 393185

Gearcase pressure tester P/N 507977 (Stevens P/N S-34)
Gearcase vacuum tester P/N 507982 (Stevens P/N V-34)

Universal shift rod height gauge P/N 389997

1. Collar P/N 341440
2. Gauge bar M-type gearcases P/N 349957

Guide rods P/N 383175

Gearcase Alignment Gauge Kit P/N 5006349

Driveshaft seal protector P/N 31867

1. Pinion nut holder P/N 334455
2. Wrench retainer P/N 341438

Backing plate P/N 325867

Driveshaft socket P/N 311875

Pinion nut starting tool P/N 342216

Driveshaft puller P/N 390706

Prop shaft adapter P/N 432398

Universal pinion bearing remover and installer kit P/N 391257

Lower driveshaft puller P/N 342681

Spanner wrench P/N 432400

Pinion bearing installer P/N 350958

Bearing Installation Tool P/N 339778

Prop shaft bearing installer P/N 432401

Seal installation tool P/N 330268

Prop shaft bearing installer P/N 339750

Prop shaft housing seal installer P/N 336311

Trim and Tilt

Gauge and collar assembly P/N 983975

Tilt cylinder end cap remover P/N 326485

Trim/tilt service kit P/N 390010

Hydraulic cylinder rod holder P/N 983213

Universal spanner wrench P/N 912084

1. Trim/tilt service kit P/N 434524
2. Replacement O-ring kit for adapter tips P/N 434729

Tilt cylinder seal protector P/N 326005

1. Trim cylinder end cap remover/installer P/N 436710
2. Replacement tip for 436710

Cleaning Solvent P/N 771087

Engine Tuner P/N 777185

Anti-Corrosion Spray P/N 777193

6 in 1” Multi-Purpose Lubricant P/N 777192

D.P.L. Spray P/N 777183

Silicone spray P/N 775630

Oil - XD100™ P/N 777118

Oil - XD50™ P/N 777225

Oil - XD30™ P/N 777219

Ultra 4-Stroke Outboard Oil, P/N 775594

4-Stroke Outboard Oil, P/N 775597

HPF XR™ Gear Lube P/N 778747

HI-VIS™ Gearcase Lube P/N 775605

Triple-Guard® Grease P/N 508298

Extreme Pressure Grease™ P/N 508303

Moly Lube P/N 175356

Needle Bearing Grease, P/N 378642

Starter Bendix Lube P/N 337016

Storage Fogging Oil P/N 777186

Power Trim/Tilt and Power Steering Fluid P/N 775612

Biodegradeable TNT Fluid P/N 763439

Lubriplate† 777 P/N 317619

Black Neoprene Dip P/N 909570

Electrical Grease P/N 504824

2 + 4™ Fuel conditioner P/N 775613

Fuel System Cleaner P/N 777184

Carbon Guard™ P/N 775629

Gel-Seal and Gasket Remover P/N 771050

Gel·Seal II P/N 327361

Gasket Sealing Compound P/N 317201

Permatex† No. 2, P/N 910032

ThreeBond† 1104, P/N 351052
ThreeBond 1207B, P/N 351053

Pipe Sealant with Teflon P/N 910048

GE† RTV Silicone Sealant P/N 263753

Gasoila† Thread Sealant P/N 200763

1. Screw Lock P/N 500417 (Loctite† Purple 222 equivalent)
2. Nut Lock P/N 500421 (Loctite Blue 242 Equivalent)
3. Ultra Lock P/N 500423 (Loctite Red 271 Equivalent)

Locquic Primer P/N 772032

Adhesive 847 P/N 776964

Instant Bonding Adhesive P/N 509955

GM† Gear Mark Compound P/N 772666

Thermal Joint Compound P/N 322170