Service Manual 200-250 HP 3.3 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.

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.

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.

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.

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 200.1 cubic inch, 90° V Evinrude E-TEC ® models.

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, DONOT 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