Service Manual 250-300 HP 3.4 L E-TEC Introduction

Before working on any part of the outboard, read the SAFETY section at the end of this manual.

This manual is written for qualified, factory-trained technicians who are already familiar with the use of Evinrude®/Johnson® Special Tools. This manual is not a substitute for work experience. It is an organized guide for reference, repair, and maintenance of the outboard(s).

This manual uses the following signal words identifying important safety messages.

Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, CAN result in severe injury or death.

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate personal injury or property damage. It also may be used to alert against unsafe practices.

IMPORTANT: Identifies information that will help prevent damage to machinery and appears next to information that controls correct assembly and operation of the product.

These safety notices mean:

ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!

Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so to protect yourself, as well as the people around you.

It is understood that this manual may be translated into other languages. In the event of any discrepancy, the English version shall prevail.

To reduce the risk of personal injury, safety warnings are provided at appropriate times throughout the manual.

DO NOT make any repairs until you have read the instructions and checked the pictures relating to the repairs.

Be careful, and never rush or guess a service procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol use, to name a few. Damage to a boat and outboard can be fixed in a short period of time, but injury or death has a lasting effect.

When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Using substandard parts could result in injury or product malfunction.

Torque wrench tightening specifications must be strictly followed. 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.

If you use procedures or service tools that are not recommended in this manual, YOU ALONE must decide if your actions might injure people or damage the outboard.

Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off. Remove propeller before servicing and when running the outboard on a flushing device.
DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.

Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa).
The motor cover and flywheel cover are machinery guards. Use caution when conducting tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and clothing away from rotating parts.
During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service.
To prevent accidental starting while servicing, disconnect the battery cables at the battery. Twist and remove all spark plug leads.
The electrical system presents a serious shock hazard. DO NOT handle primary or secondary ignition components while outboard is running or flywheel is turning.
Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system.
Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure.
Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling.
Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and causing an explosion.
Always work in a well ventilated area.
Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to tightening must be felt when reusing a locking fastener. If replacement is indicated, use only authorized replacement or equivalent.

Units of Measurement

List of Abbreviations

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine SI (spark ignition) engine repair establishment or individual.

Manufacturer’s Responsibility

Beginning with 1999 model year outboards, manufacturers of marine outboards must determine the exhaust emission levels for each outboard horsepower family and certify these outboards with the United States of America Environmental Protection Agency (EPA). An emissions control information label, showing emission levels and outboard specifications, must be placed on each outboard at the time of manufacture.

Dealer’s Responsibility

When performing service on all 1999 and more recent Evinrude/Johnson outboards that carry an emissions control information label, adjustments must be kept within published factory specifications.

Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed certification standards.

Dealers are not to modify the outboard in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications.

Exceptions include manufacturer’s prescribed changes, such as altitude adjustments, for example.

Owner’s Responsibility

The owner/operator is required to have outboard maintenance performed to maintain emission levels within prescribed certification standards.

The owner/operator is not to, and should not allow anyone to, modify the outboard in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications.

Tampering with the fuel system to change horsepower or modify emission levels beyond factory settings or specifications will void the product warranty.

EPA Emission Regulations

All new 1999 and more recent Evinrude/Johnson outboards are certified to the EPA as conforming to the requirements of the regulations for the control of air pollution from new watercraft marine spark ignition outboards. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, whenever practical, returned to the original intent of the design. The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA requirements on exhaust emissions for marine products. For more detailed information on this subject, you may contact the following locations:

VIA U.S. POSTAL SERVICE:

Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460

VIA EXPRESS or COURIER MAIL:

Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
501 3rd St. NW
Washington, DC 20001

EPA INTERNET WEB SITE:
www.epa.gov

This manual covers service information on all 210 cubic inch, 90° V Evinrude E-TEC ® models.

Identifying Model and Serial Numbers

Outboard model and serial numbers are located on the swivel bracket and on the powerhead.

1. Model and serial number

1. Serial number

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.

BRP US Inc. reserves the right to make changes at any time, without notice, in specifications and models and also to discontinue models. The right is also reserved to change any specifications or parts, at any time, without incurring any obligation to equip same on models manufactured prior to date of such change. Specifications used are based on the latest product information available at the time of publication.

The continuing accuracy of this manual cannot be guaranteed.

All photographs and illustrations used in this manual may not depict actual models or equipment, but are intended as representative views for reference only.

Certain features or systems discussed in this manual might not be found on all models in all marketing areas.

All service technicians must be familiar with nautical orientation. This manual often identifies parts and procedures using these terms.

Nautical Orientation

TABLE OF CONTENTS

DIAGNOSTIC TOOLS...................................................... 14
UNIVERSAL TOOLS ...................................................... 14
ELECTRICAL/IGNITION TOOLS ............................................ 16
FUEL/OIL SYSTEM TOOLS ................................................ 17
POWERHEAD TOOLS ...................................................... 17
GEARCASE TOOLS ....................................................... 18
TRIM AND TILT TOOLS .................................................. 21
SHOP AIDS ............................................................ 22

Diagnostic Software P/N 764642

Bootstrap tool P/N 586551 002276

Interface cable P/N 437955 45583

Universal Puller Set P/N 378103 32885

Lifting eye P/N 321537 23701

Lifting ring assembly P/N 396748 000669

Slide hammer P/N 391008 CO1577

Slide hammer P/N 432128 15345

Flywheel holder P/N 771311 42938

Small puller jaws P/N 432131 23150

Large puller jaws P/N 432129 23148

Bearing puller jaws P/N 432130 23149

Slide hammer adapter P/N 390898 15356

Puller Bridge – 432127 23146

Tilt tube nut wrench P/N 342680 46879

Tilt tube nut wrench P/N 342680 46879

Tilt tube service kit P/N 434523 33249

Oetiker† pincers, P/N 787145 001081

Temperature gun P/N 772018 45240

Fresh water flusher P/N 500542 50110

Digital multimeter Ohms resolution 0.01 Purchase through local supplier DRC7265

Peak reading voltmeter P/N 507972 49799

Test probe kit P/N 342677 45241

Crimping pliers P/N 322696

Stator Test Adapter P/N 5006211 004222

Tachometer/timing light P/N 507980 49789

Connector tool P/N 342667 42004

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 002277

Fuel pressure gauge (60 PSI)
P/N 5007100 90° fitting, P/N 353322 005339

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

Injector test fitting kit P/N 5005844 002465

Cylinder bore gauge P/N 771310 45303

Rod cap alignment fixture P/N 396749 21596

Torquing socket P/N 346187 50242

Piston stop tool P/N 342679
Replacement tip P/N 5006098 46543

Guide rods P/N 383175 000828

Crankshaft bearing and sleeve installer P/N 338649 21953C

Wrist pin pressing tool P/N 396747 23668

1. Wrist pin retaining ring driver P/N 396747
2. Wrist pin cone P/N 331913 DR1641

Seal installation tool P/N 325453 23651

Universal Driveshaft Shimming Tool P/N 5005925

1. Lower Driveshaft Shimming Bolt (S2 gearcase) P/N352878 002601

Universal Pinion Bearing Remover and installer kit P/N 5005927

Universal shift rod height gauge P/N 389997 32872

Gearcase filler P/N 501882 49790

Gearcase pressure tester P/N 507977 (Stevens P/N S-34)
Gearcase vacuum tester P/N 507982 (Stevens P/N V-34) 49794

Pressing fixture P/N 354059 006782

Prop shaft bearing housing installers P/N 354058 (L2) P/N 354057 (M2) 006783

Prop shaft bearing housing remover/puller P/N 354060 006784

Prop shaft bearing housing alignment pins P/N 354140 006788

Gearcase Alignment Gauge Kit P/N 5006349 004315

Gauging Head, “M2” Type Gearcases, P/N 5007749 006822

Gauging Head, “L2” Type Gearcases, P/N 5007750 006823

Backing plate P/N 325867 23621

Bearing Installation Tool P/N 339778 32519

Spanner wrench P/N 432400 15358

Driveshaft socket P/N 311875 23261

Driveshaft Puller P/N 390706 32884

Prop shaft bearing installer P/N 432401 15355

Slide hammer adapter P/N 432398 15356

Driveshaft seal protector P/N 318674 23692

1. Pinion nut holder P/N 334455
2. Wrench retainer P/N 341438 40371

Lower Driveshaft Puller P/N 342681 47257

Prop shaft bearing installer P/N 339750 32880

Seal installation tool P/N 330268 32924

Pinion nut starting tool P/N 342216 40372

Prop shaft housing seal installer P/N 336311 32973

Seal installation tool P/N 354056 006824

Gauge and collar assembly P/N 983975 33023

Trim/tilt service kit P/N 390010 33013

Tilt cylinder seal protector P/N 326005 23694

Hydraulic cylinder rod holder P/N 983213 23665

Tilt cylinder end cap remover P/N 352932, for single-piston tilt systems 005340

Spanner wrench P/N 912084 32213

1. Trim/tilt service kit P/N 434524
2. Replacement o-ring kit for adapter tips P/N 434729 27340

Tilt cylinder end cap remover P/N 326485, for three-piston tilt systems 33741

1. Trim cylinder end cap remover/installer P/N 436710
2. Replacement tip for 436710 33742A

Cleaning Solvent P/N 771087

D.P.L. Spray P/N 777183

Oil - XD30™ P/N 777219

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

Oil - XD50™ P/N 777225

HPF XR™ Gear Lube P/N 778755

Oil - XD100™ P/N 777118

Anti-Corrosion Spray P/N 777193

HPF PRO Gearcase Lube P/N 778755

Engine Tuner P/N 777185

Silicone spray P/N 775630

Moly Lube P/N 175356

Storage Fogging Oil P/N 777186

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

Electrical Grease P/N 503243

Lubriplate† 777 P/N 317619

Black Neoprene Dip P/N 909570

2 + 4™ Fuel conditioner P/N 775613

Triple-Guard® Grease P/N 508298

Starter Bendix Lube P/N 337016

Gel-Seal and Gasket Remover P/N 771050

Needle Bearing Grease, P/N 378642

Biodegradeable TNT Fluid P/N 763439

Permatex† No. 2, P/N 910032

RTV Silicone Sealant P/N 263753

Gasket Sealing Compound P/N 317201

Thermal Joint Compound P/N 322170

Fuel System Cleaner P/N 777184

Pipe Sealant with Teflon P/N 910048

Instant Bonding Adhesive P/N 509955

Gel•Seal II P/N 327361

Locquic Primer P/N 772032

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)

Carbon Guard™ P/N 775629

Adhesive 847 P/N 776964