evinrude 115 direct injection manual

7/24/2019 Evinrude 115 Direct injection Manual

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115-175 HORSEPOWERFPL, FSL, FPX, FCX, FHL


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2005 BRP US Inc. All rights reserved.TM, Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

1

Our First Words to the Owner/Operator

This Operators Guide is an essential part of your Evinrude outboard. It contains pertinent informationwhich, if followed, will provide you with a thorough understanding needed for proper operation, mainte-nance, care and above all safety!

The safety section of this Guide comes first because it is our first priority and it should be yours too. It isstrongly recommended that you read this Guide from front cover to rear cover. Following this recommen-dation will assure the completeness of the information that is essential to your safety, the safety of anypassengers and other boaters. An Operators Readiness Test has been prepared on the last page of thisGuide.

Be safe! All passengers should be familiar with the proper operation of your boat and Evinrudeoutboard.Be certain they fully understand and respect the controls and operation. Each operator is responsible forthe safety of all passengers and other boaters. Please make safety your first priority and complete a boat-ing safety course through your local Coast Guard, Power Squadron, Red Cross or State Boating LawAgency.

The pleasures of owning and operating an Evinrudeoutboard can be significant. We strongly believe therewards for following our recommendations will be worthwhile. Remember that YOU are the key to safety.Good safety practices not only protect you but also protect the people around you.

Having fun is what its all about and, with your cooperation, the pertinent information in this Guide can en-sure a safe and enjoyable experience.

Enjoy the great outdoors on the water...

The following trademarks are the property of Bombardier Recreational Products Inc. or its affiliates:

WARNING

Be careful! Human error is caused by many factors: carelessness, fatigue, overload, preoccu-pation, unfamiliarity of operator with the product, drugs and alcohol to name a few. Damage toyour boat and outboard can be fixed in a short period of time, but injury or death, has a lastingeffect.

For your safety and the safety of others, read this Guide from cover to cover and follow allsafety warnings and recommendations. Do not disregard any of the safety precautions andinstructions.

Anyone operating your boat should first read and understand this Guide before they operate

your boat and motor.

Evinrude 2+4 fuel conditioner

Evinrude/Johnson Genuine Parts S.L.O.W.

Evinrude/Johnson XD25 formula SystemCheck

Hi-Vis gearcase lubricant Triple-Guard grease

Johnson Ultra-HPF gearcase lubricant


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Contents

GENERAL INFORMATION ................................................................................................... 3SAFETY THE RIGHT PLACE TO GET STARTED ................................................................................................ 3PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS ................................................................... 5BRP LIMITED WARRANTY FOR 2006 EVINRUDEOUTBOARD ENGINES

SOLD IN THE UNITED STATES AND CANADA ................................................................................................ 6BRP LIMITED WARRANTY FOR 2006 EVINRUDEOUTBOARD ENGINES

SOLD OUTSIDE THE UNITED STATES AND CANADA ................................................................................... 8CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT ............................................................................ 9FEATURES ............................................................................................................................................................... 12ENGINE SPECIFICATIONS ...................................................................................................................................... 14REMOTE CONTROL ................................................................................................................................................. 16

ENGINE MONITORING ...................................................................................................... 18

FUEL AND OIL ................................................................................................................... 20FUEL ......................................................................................................................................................................... 20OIL ............................................................................................................................................................................. 20ADDITIVES ................................................................................................................................................................ 21FUEL SYSTEM .......................................................................................................................................................... 21OIL SYSTEM ............................................................................................................................................................. 22BREAK-IN (10 HOURS) ............................................................................................................................................ 24

ENGINE STARTING ........................................................................................................... 25BEFORE START-UP ................................................................................................................................................. 25ENGINE STOPPING ................................................................................................................................................. 27SHIFTING AND SPEED CONTROL ......................................................................................................................... 27FUEL ECONOMY ...................................................................................................................................................... 27

OPERATION ....................................................................................................................... 28POWER TRIM AND TILT .......................................................................................................................................... 28PROPELLER SELECTION ....................................................................................................................................... 31MOORING ................................................................................................................................................................. 31FLUSHING ................................................................................................................................................................ 32ENGINE OVERHEATING .......................................................................................................................................... 33TRAILERING ............................................................................................................................................................. 34

IMPACT DAMAGE .................................................................................................................................................... 35STORING .................................................................................................................................................................. 35SPECIAL OPERATING CONDITIONS ..................................................................................................................... 36

MAINTENANCE .................................................................................................................. 37ENGINE EMISSIONS INFORMATION ...................................................................................................................... 3710-HOUR INSPECTION ............................................................................................................................................ 37OFF-SEASON STORAGE ........................................................................................................................................ 38PRE-SEASON SERVICE .......................................................................................................................................... 39BATTERY .................................................................................................................................................................. 40ADJUSTMENTS ........................................................................................................................................................ 42LUBRICATION .......................................................................................................................................................... 43WATER PRESSURE ................................................................................................................................................. 44START ASSIST CIRCUIT FUSE ............................................................................................................................... 45SPARK PLUGS ......................................................................................................................................................... 45POWER DISTRIBUTION PANEL ............................................................................................................................. 46PROPELLER ............................................................................................................................................................. 47ANTI-CORROSION ANODES ................................................................................................................................... 48TROUBLE CHECK CHART ...................................................................................................................................... 49ENGINE MAINTENANCE AND INSPECTION SCHEDULE ..................................................................................... 50


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General Information - 3

GENERAL INFORMATION

SAFETY THE RIGHT PLACE TO GET

STARTED

This Operators Guide contains essential informa-

tion to help prevent personal injury and damage toequipment. It will acquaint the operator and pas-sengers with the Evinrude outboard and its con-trols, operation, maintenance and boating safetymeasures. Make sure all operators read, under-stand and follow the contents. This Guide should bekept in a waterproof bag with the product at all timesduring operation. If the product ownership is trans-ferred, this Guide should be forwarded to the sub-sequent owners.

This Operators Guide uses the following signalwords identifying important safety messages.

These safety alert signal words mean:ATTENTION!BECOME ALERT!YOUR SAFETY IS INVOLVED!

IMPORTANT: Identifies information that will helpprevent damage to machinery and appears next toinformation that controls correct assembly and op-eration of the product.

Although the mere reading of such information

does not eliminate the hazard, the understandingand application of the information will promote thecorrect use of your outboard engine.

A responsible, educated boater will fully appreciatethe pleasures of boating and will be a safe boater.Boating Safety Classes are conducted by the U.S.Coast Guard Auxiliary, the U.S. Power Squadronand some Red Cross Chapters. For information

about classes, call toll free 1-800-336-BOAT. Foradditional information about boating safety and reg-ulations call: U.S. Coast Guard Boating Safety Hot-line 1-800-368-5647. Outside North Americaplease contact your Dealer or distributor for detailsabout boating safety.

SAFETY MEASURES General

SAFETY MEASURES Operation

DANGER

Indicates an imminently hazardous situa-tion which, if not avoided, WILL result indeath or serious injury.

WARNING

Indicates a potentially hazardous situationwhich, if not avoided, CAN result in severeinjury or death.

CAUTION

Indicates a potentially hazardous situationwhich, if not avoided, MAY result in minor ormoderate personal injury or property dam-age. It also may be used to alert againstunsafe practices.

To fully appreciate the pleasures, enjoymentand excitement of boating there are some ba-sic rules that should be observed and followed

by any boater. Some rules may be new to youand others may be common sense or obvi-ous... irrespective, take them seriously! Fail-ure to follow this safety information and safeboating rules could result in injury to you, yourpassengers or other water users.

Become completely familiar with the controland operation of your boat and motor beforeembarking on your first trip or taking on a pas-senger(s). If you have not had the opportunityto do so with your Dealer, practice driving in asuitable area and feel the response of each

control. Be familiar with all controls before ap-plying the throttle above idle speed. As the op-erator, you are in control and responsible forsafe operation.

Be sure at least one of your passengersknows how to handle your boat in case of anemergency.

All passengers should know the location ofemergency equipment and how to use it.

All safety equipment and personal flotationdevices must be in good condition and suit-able for your type of boat. Always comply withthe regulations that apply to your boat.

Contact with rotating propeller is likely to resultin serious injury or death. Do not allow anyonenear a propeller, even when the engine is off.Propeller blades can be sharp and can contin-ue to turn even after the engine is shut off. Al-ways shut off the engine when boat is nearpeople in the water.


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4- General Information

SAFETY MEASURES Installation and

Maintenance

Outboard Installation

Maintenance

Whenever running the engine, assure there isproper ventilation to avoid the accumulation ofcarbon monoxide (CO), which is odorless, col-orless, and tasteless, and can lead to uncon-sciousness, brain damage, or death if inhaledin sufficient concentrations. CO accumulationcan occur while docked, anchored, or under-way, and in many confined areas such as theboat cabin, cockpit, swim platform, and heads.It can be worsened or caused by weather,

mooring and operating conditions, and otherboats. Avoid exhaust fumes from your engineor other boats, provide proper ventilation, shutoff your engine when not needed, and beaware of the risk of backdrafting and condi-tions that create CO accumulation. In highconcentrations, CO can be fatal within min-utes. Lower concentrations are just as lethalover long periods of time.

Proceed with caution and at very low speed inshallow water. Grounding or abrupt stops mayresult in personal injury or property damage.

Also be alert for debris and objects in the wa-ter.

Be familiar with the waters you are operatingin. The gearcase of this outboard extends be-low the water surface and could potentiallycome in contact with underwater obstructions.Contact with underwater obstructions may re-sult in loss of control and personal injury.

Avoid standing up or shifting weight suddenlyin light weight boats.

Keep your passengers seated in seats. Theboats bow, gunwale, transom and seat backsare not intended for use as seats.

Insist on the use of personal flotation devices,approved by the U.S. Coast Guard, by all pas-sengers when boating conditions are hazard-ous, and by children and nonswimmers at alltimes.

Respect no wake zones, rights of other waterusers and the environment. As the "skipper"and owner of a boat you are responsible fordamage to other boats caused by the wake ofyour boat. Allow no one to throw refuse over-board.

Know the marine traffic laws and obey them.

Remember, gasoline fumes are flammableand explosive. Always adhere to the fuelingprocedure contained in this Operators Guideand those given to you by the fueling station.Always verify fuel level before use and duringthe ride. Apply the principle of 1/3 fuel to des-

tination, 1/3 back and 1/3 reserve fuel supply.Do not carry spare fuel or flammable liquids inany storage or engine compartments.

Do not operate your boat if you are under theinfluence of drugs or alcohol.

High performance boats have a high power-to-weight ratio. If you are not experienced inthe operation of a high performance boat, donot attempt to operate one at, or near, its topspeed until you have gained that experience.

For more information, see your Evinrude/

JohnsonDealer for a copy of Introduction toHigh Performance Boating, P/N 335763.

The outboard must be correctly installed. Fail-ure to correctly install the outboard could re-sult in serious injury, death or propertydamage. We strongly recommend that your

Dealer install your outboard to ensure properinstallation.

Do not overpower your boat by using an en-gine that exceeds the horsepower indicatedon the boats capacity plate. Overpoweringcould result in loss of control. If your boat hasno capacity plate, contact your Dealer or theboats manufacturer.

When replacement parts are required, useEvinrude/Johnson Genuine Partsor partswith equivalent characteristics, including type,strength and material. Using substandardparts could result in injury or product malfunc-tion.

Only perform service procedures which aredetailed in this Operators Guide. Attemptingto perform maintenance or repair on your out-board if you are not familiar with the correctservice and safety procedure could cause per-sonal injury or death. Further information canbe obtained from your authorized Evinrude/Johnson Dealer. In many instances propertools and training are required for certain ser-vice or repair procedures.

Maintain your boat and engine in top conditionat all times. Adhere to the Engine Mainte-nance and Inspection Schedule.

Operate your boat and outboard prudentlyand have fun. Do not forget that all personsmust assist other boaters in case of emergen-cy.

Prevent injury from contact with rotating pro-peller; remove propeller before flushing or be-fore performing any maintenance.


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PRODUCT REFERENCES,

ILLUSTRATIONS AND

SPECIFICATIONS

Bombardier Recreational Products (BRP) reservesthe right to make changes at any time, without no-tice, to features, specifications and model availabil-ity. The right is also reserved to change anyspecification or part at any time without incurringany obligation to update older models. The informa-

tion in the Guide is based on the latest specifica-tions available at the time of publication.

Photographs and illustrations used in this Guidemight not depict actual models or equipment butare intended as representative views for referenceonly. The continuing accuracy of this Guide cannotbe guaranteed.

Certain features of systems discussed in this Guidemight not be found on all models in all marketing ar-eas.

Owners Identification

North America At the time of purchase, yourDealer will complete your outboard registrationforms. Your portion provides proof of ownershipand date of purchase.

Outside North America See your Dealer ordistributor for details.

Model and Serial Numbers

The model and serial numbers appear on a plate at-tached to the stern bracket or swivel bracket.Record your outboards:

Model Number _________________________________

Serial Number _________________________________

Purchase Date _________________________________

Ignition Key Number ____________________________

Stolen Outboards

North America Report your outboard as stolento Customer and Dealer Support Services, 250Seahorse Drive, Waukegan, IL 60085 U.S.A. Givethe outboards model and serial numbers and en-close a copy of the police report.

Outside North America Report the theft to the

Bombardier Recreational Products distributorwhere the outboard was registered.

Technical Literature

BRP offers technical literature specifically for youroutboard. A service manual, a parts catalog, or anextra Operators Guide can be purchased from yourselling Dealer. For the name and location of thenearest EvinrudeDealer in the United States andCanada visit www.evinrude.com.

Declaration of Conformity

BRP declares that the outboard to which this Oper-ators Manual applies conforms to the essential re-quirements outlined in CE Machinery Directive98-37-EC, as amended.

WARNING

When replacement parts are required, use

Evinrude/Johnson Genuine Parts or partswith equivalent characteristics, includingtype, strength and material. Using substan-dard parts could result in injury or productmalfunction.


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BRP LIMITED WARRANTY FOR 2006 EVINRUDEOUTBOARD ENGINES

SOLD IN THE UNITED STATES AND CANADA

1. SCOPE OF THE LIMITED WARRANTY

Bombardier Recreational Products* (BRP) warrants its 2006 Evinrude outboard engines sold by authorized Evinrudedealers in the fifty United States and Canada (Product) from defects in material or workmanship for the period and underthe conditions described below.

2. WARRANTY COVERAGE PERIODThis limited warranty will be in effect from the date of purchase by the first retail consumer or the date the Product is firstput to use, whichever occurs first, for a period of:

THIRTY-SIX (36) CONSECUTIVE MONTHS for private, recreational use; or

TWELVE (12) CONSECUTIVE MONTHS for commercial use, except that emission-related components providing inputto emission controls (e.g. sensors) are warranted for twenty-four (24) months or two hundred (200) hours of engine use,whichever occurs first. The Product is used commercially when it is used in connection with any work or employment thatgenerates income, during any part of the warranty period. The Product is also used commercially when, at any point dur-ing the warranty period, it is installed on a boat that has commercial tags or is licensed for commercial use.

The repair or replacement of parts or the performance of service to Product under this warranty does not extend the lifeof this limited warranty beyond its original expiration date. All Evinrude/Johnson Genuine Partsand accessories in-stalled by an authorized dealer at the time of sale, including but not limited to propellers, bear the standard BRP partsand accessories one-year limited warranty.

California residents who purchased or warranty-registered a Product in California should refer to BRPs California Emis-sions Control Warranty Statement.

3. CONDITIONS TO HAVE WARRANTY COVERAGE

This warranty coverage is available only on Evinrudeoutboard engines purchased as new and unused from a dealer au-thorized to distribute Evinrudeproducts in the country in which the sale occurred (Dealer), and then only after the BRP-specified pre-delivery inspection process has been completed and documented by the purchaser and Dealer. Warrantycoverage only becomes available upon proper registration of Product by Dealer or owner.

Only the original purchaser and any subsequent owners who reside in the United States and Canada and have pur-chased Product from a U.S. or Canadian Dealer are eligible for warranty registration and warranty coverage hereunder.Such limitations are necessary in order to allow BRP to protect the safety of its products, its consumers, and the generalpublic.

As outlined in the Operator's Guide, timely routine required maintenance must be performed to maintain warranty cover-age. BRP may require proof of proper maintenance prior to authorizing warranty coverage.

4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE

The registered owner must notify an authorized Dealer within two (2) days of the appearance of a defect. Owner mustbring Product, including any defective part therein, to Dealer promptly after the appearance of the defect, and in anyevent, within the warranty period, and must provide Dealer with reasonable opportunity to repair the defect. The expensesof transporting Product to and from Dealer for warranty service are to be borne by the owner.

If the Product has not previously been registered, the owner may also be required to present proof of purchase to Dealerfor warranty repairs. Owner is required to sign the repair/work order prior to the start of the repair in order to validate thewarranty repair.

All parts replaced under this warranty become the property of BRP.

5. WHAT BRP WILL DO

BRPs obligations under this warranty are limited to, at its sole discretion, repairing or replacing parts of Product found tobe defective in material or workmanship, in the reasonable judgment of BRP. Such repair or replacement of parts will bedone without charge for parts and labor, at any authorized Dealer. BRPs responsibility is limited to making the requiredrepairs or replacements of parts with new or BRP-certified re-manufactured parts. No claim of breach of warranty shallbe cause for cancellation or rescission of the sale of Product to owner.

In the event that warranty service is required outside of the fifty United States or Canada, owner will bear responsibilityfor any additional charges due to local practices and conditions, such as, but not limited to, freight, insurance, taxes, li-cense fees, import duties, and any and all other f inancial charges, including those levied by governments, states, territo-ries and their respective agencies.

BRP reserves the right to improve, modify or change Products from time to time without assuming any obligation to modifyProducts previously manufactured.


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6. EXCLUSIONS The following are not warranted under any circumstances:

Replacement of parts due to normal wear and tear; Routine maintenance parts and services including but not limited to: maintenance requirements, engine and lower unit

oil changes, lubrication, valve and linkage adjustments and replacement of fuses, zinc anodes, thermostats, timingbelts, starter motor bushings, trim motor brushes, filters, propellers, propeller bushings and spark plugs;

Damage caused by improper or lack of installation, maintenance, winterization and/or storage, failure to follow the pro-cedures and recommendations in the Operator's Guide;

Damage resulting from removal of parts, improper repairs, service, maintenance, or modification, or use of parts oraccessories not manufactured or approved by BRP, which in its reasonable judgment, are either incompatible withProduct or adversely affect its operation, performance, or durability, or resulting from repairs done by a person that isnot an authorized Dealer;

Damage caused by abuse, misuse, abnormal use, neglect, racing, improper operation or operation of the Product in amanner inconsistent with the recommended operation described in the Operator's Guide; Damage resulting from external damage, accident, submersion, water ingestion, fire, theft, vandalism or any act of

God; Operation without proper fuel, oil or lubrication, or with fuels, oils or lubricants which are not suitable for use with the

Product (see the Operator's Guide); Damage resulting from rust or corrosion; Damage caused from cooling system blockage by foreign material; Damage resulting from sand or debris in the water pump; Cosmetic or paint changes due to exposure to the elements.

This warranty will be voided in its entirety and rendered null and voidwhere:

Product has been altered or modified in such a way so as to adversely affect its operation, performance or durability,or change its intended use, horsepower or emission levels; or

Product is or has been used for racing at any point, even by a prior owner.

7. LIMITATIONS OF LIABILITY

ALL WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MER-CHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE LIFE OF THEEXPRESS LIMITED WARRANTY.

ALL INCIDENTAL, CONSEQUENTIAL, DIRECT, INDIRECT OR OTHER DAMAGES OF ANY KIND ARE EXCLUDEDFROM COVERAGE UNDER THIS WARRANTY INCLUDING, BUT NOT LIMITED TO: expense for gasoline, expensefor transporting Product to and from Dealer, removal of Product from a boat and reinstallation, mechanics travel time, in-and-out of water charges, slip or dock fees, trailering or towing, storage, telephone, cell phone, fax or telegram charges,rental of a like or replacement Product or boat during warranty services or down time, taxi, travel, lodging, loss of or dam-age to personal property, inconvenience, cost of insurance coverage, loan payments, loss of time, loss of income, reve-nue or profits, or loss of enjoyment or use of Product.

SOME STATES, PROVINCES, OR JURISDICTIONS DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS OFINCIDENTAL OR CONSEQUENTIAL DAMAGES, OR OTHER EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT,THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC RIGHTS, AND YOU MAY ALSO HAVEOTHER LEGAL RIGHTS WHICH MAY VARY FROM STATE TO STATE, OR PROVINCE TO PROVINCE.

No distributor, Dealer or any other person is authorized to make any affirmation, representation or warranty regardingProduct other than those contained in this limited warranty and, if made, shall not be enforceable against BRP. BRP re-serves the right to modify this warranty at any time, being understood that such modification will not alter the warrantyconditions applicable to the Products sold while this warranty is in effect.

8. TRANSFER

If the ownership of Product is transferred during the warranty coverage period, this warranty shall also be transferred andbe valid for the remaining coverage period provided that the former or new owner promptly contacts BRP or Dealer andgives the name and address of the new owner.

9. CONSUMER ASSISTANCE

In the event of a controversy or dispute in connection with this BRP limited warranty, BRP recommends that you firsttry to resolve the issue at the dealership level by discussing the issue with Dealers service manager or owner;

If further assistance is required, please contact the BRP Customer Support Services, 250 Sea Horse Drive, Waukegan,IL 60085, 1-847-689-7090.

Revision February 2005

* Engines sold in Canada are distributed and serviced by Bombardier Recreational Products Inc.


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BRP LIMITED WARRANTY FOR 2006 EVINRUDEOUTBOARD ENGINES

SOLD OUTSIDE THE UNITED STATES AND CANADA

For a copy of the Limited Warranty, see your Bombardier Recreational Products Inc. (BRP) distributor/dealer authorizedto distribute Evinrudeproducts in the country in which the sale occurs.

If further assistance is required, please contact BRP Customer Support Services, 250 Sea Horse Drive, Waukegan, Illi-nois, 60085, or the affiliate of BRP where the Product was registered for warranty.


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CALIFORNIA EMISSION CONTROL WARRANTY

STATEMENT

Your Evinrudeoutboard with Direct Injection has a special environmental label required by the CaliforniaAir Resources Board. The label has one, two, three, or four stars. A hangtag, provided with your outboard,describes the meaning of the star rating system.

The Star Label means Cleaner Marine Engines

The Symbol for Cleaner Marine Engines:

Cleaner Air and WaterFor a healthier lifestyle and environment.

Better Fuel Economy

Burns up to 30 to 40 percent less gas and oil than conventionalcarbureted two-stroke engines, saving money and resources.

Longer Emission WarrantyProtects consumer for worry free operation.

One Star Low Emission

The one-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet theAir Resource Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission stan-dards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.

Two Stars Very Low Emission

The two-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet theAir Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emission stan-dards. Engines meeting these standards have 20% lower emissions than One Star Low Emission en-gines.

Three Stars Ultra Low Emission

The three-star label identifies engines that meet the Air Resources Boards Personal Watercraft and Out-board marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star Low Emission engines.

Four Stars Super Ultra Low Emission

The four-star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marineengine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may alsocomply with these standards. Engines meeting these standards have 90% lower emissions than One Star Low Emission engines.

For more information: Cleaner Watercraft Get the Facts1-800-END-SMOGwww.arb.ca.gov


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YOUR EMISSION CONTROL WARRANTY RIGHTS AND OBLIGATION

The California Air Resources Board and BRP are pleased to explain the emission control system warrantyon your Evinrudeoutboard with Direct Injection. In California, new outboard engines must be designed,built, and equipped to meet the State's stringent anti-smog standards. BRP must warrant the emissioncontrol system on your outboard for the periods of time listed below provided there has been no abuse,neglect, or improper maintenance of your outboard.

Your emission control system may include parts such as the carburetor or fuel injection system, the igni-tion system, and catalytic converter. Also included may be hoses, belts, connectors, and other emission-

related assemblies.Where a warrantable condition exists, BRP will repair your outboard at no cost to you, including diagnosis,parts, and labor, provided that such work is performed by an authorized BRP Dealer.

Manufacturer's Limited Warranty Coverage

This emission limited warranty covers Evinrudeoutboards with Direct Injection certified and produced byBRP for sale in California, that are originally sold in California to a California resident, or subsequentlywarranty registered to a California resident. The BRP North America Limited Warranty conditions forEvinrudeoutboards with Direct Injection are still applicable to these models with the necessary modifica-tions.

Select emission control parts of your Evinrudeoutboard with Direct Injection are warranted from the dateof purchase by the first retail consumer or the date the product is first put to use, whichever occurs first,for a period of 4 years, or for 250 hours of use, whichever occurs first.

However, warranty coverage based on the hourly period is only permitted for outboards equipped with theappropriate hour meters or their equivalent. If any emission-related part on your engine is defective underwarranty, the part will be repaired or replaced by BRP.

Parts covered are:

1. Electrical System 4. Air Induction System

A. EMM (Engine Management Module) A. Reed Valves

B. Spark Plugs and Wires B. Throttle Body Assembly

C. Ignition Coils C. Throttle LinkageD. Wiring Harness

5. Oil System

2. Exhaust System A. Oil Injector

A. Powerhead to Lower Unit Adapter Plate B. Oil Lift Pump

B. Exhaust Pressure Fitting C. Oil Lines, Fittings, and Clamps

C. Inner Exhaust Housing

D. Exhaust Back Pressure Hose and Diaphragm 6. Sensors

E. Intake Manifold and Exhaust Manifold A. Air Temperature Sensor

B. Crank Position Sensor

3. Fuel System C. Throttle Position Sensor

A. Fuel Lift Pump D. Water Temperature Sensor (Port Cylinder Head)

B. Fuel Supply Pump E. Thermostat

C. Fuel Injectors

D. Vapor Separator 7. Gaskets

E. Fuel Lines, Fittings, and Clamps A. All Emission Component Gaskets


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The emission warranty covers damage to other engine components that is caused by the failure of a war-ranted part.

The BRP Operator's Guide provided contains written instructions for the proper maintenance and use ofyour outboard. All emission warranty parts are warranted by BRP for the entire warranty period of the out-board, unless the part is scheduled for replacement as required maintenance in the Operator's Guide.

Emission warranty parts that are scheduled for replacement, as required maintenance, are warranted byBRP for the period of time before the first scheduled replacement date for that part. Emission warrantyparts that are scheduled for regular inspection but not regular replacement are warranted by BRP for the

entire warranty period of the outboard. Any emission warranty part repaired or replaced under the termsof this warranty statement is warranted by BRP for the remainder of the warranty period of the originalpart. All parts replaced under this limited warranty become the property of BRP.

Maintenance receipts and records should be transferred to each subsequent owner of the outboard.

Owner's Warranty Responsibilities

As the outboard owner, you are responsible for the performance of the required maintenance listed in yourOperator's Guide. BRP recommends that you retain all receipts covering maintenance on your outboard,but BRP cannot deny warranty solely for the lack of receipts or your failure to ensure the performance ofall scheduled maintenance.

However, as the outboard owner, you should be aware that BRP may deny you warranty coverage if youroutboard or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

You are responsible for presenting your outboard to an authorized BRP Dealer as soon as a problem ex-ists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.

For any questions regarding your warranty rights and responsibilities, or for the name and location of thenearest authorized BRP Dealer, contact Bombardier Recreational Products Customer Support Services,250 Sea Horse Drive, Waukegan, IL 60085, 1-847-689-7090, or visit www.evinrude.com.


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FEATURES

Item Description Item Description

1 Power Distribution Panel 13 Oil Supply Fitting

2 Fuses & Spare Fuse Holder 14 Oil Return Fitting

3 Starter Assist Circuit Fuse 15 Battery Cable

4 Accessory Battery Connection 16 Engine Wire Harness

5 Tilt Support 17 Speedometer Pick-up Connector

6 Anti-Corrosion Anode 18 Water Intake

7 Lubricant Drain Fill Plug 19 Air Silencer

8 Lubricant Level Plug 20 Fuel Filter: 100HP-175HP Models

9 Power Tilt & Trim Reservoir 21 SystemCheckGauge (1)

(1) not supplied with outboard

10 Tilt Limiter Cam 22 SystemCheckTachometer (1)

11 Engine Cover Latch 23 Oil Tank Kit (1)

12 Fuel Fitting

1,2

4

5

6

7

18

8

17

9

12

14

000061A

1013

1511

19

203

16

21

22

23


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Item Description Item Description

1 Trailering Tilt Switch: 100HP-175HP 9 Flushing Port

2 Power Tilt & Trim: Manual Release 10 Water Pump Indicator

3 Trailering Bracket 11 Motor Cover Latch

4 Trim Limiter Rod 12 Remote Control (1)

5 Water Intake 13 Steering Connector Kit

6 Trim Tab 14 Trim Gauge (1)

(1) not supplied with outboard

7 ECI Label 15 Oil Return Hose

8 Model & Serial Number Plate

1

4

2

3

5

6

000062

7

8

9,10

1112

15

13

14


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ENGINE SPECIFICATIONS

115 Models

Displacement 105.4 cu. in. (1726 cc)

Engine Type 60 V, 4 Cylinder, Two-Cycle,

Direct Injection

Full Throttle Operating Range 115- 5250 to 5750 RPM

Power (1) 115- 115 HP (85.8 kw) @ 5500 RPM

Idle RPM in Gear (2) 650 50

Ignition Timing (2) Not Adjustable

Emission Control System:

per SAE J1930 (2)ECM, DFI (Engine Control Module, Direct Fuel Injection)

Fuel Requirements (2) 87 Pump Posted AKI (90 RON) - Refer to Fuel and Oil

Oil Evinrude direct injection oil - Refer to Fuel and Oil

Warning Signals Controlled by the engines EMM

Battery, Minimum 500 CCA (620 MCA) 12 volt

Spark Plug (2)(3)

TorqueRefer to ECI Label15-22 ft. lbs. (20-30 Nm)

Start Assist Circuit Fuse EvinrudeP/N 514768

Fuses Refer to Power Distribution Panel

Fuel Filter EvinrudeP/N 502906

Alternator 35-Amp, Fully Regulated

Gearcase - Lubricant

Capacity

Evinrude Ultra-HPFgearcase lubricant

L Models- 26 fl. oz. (770 ml)

X Models- 42 fl. oz. (1250 ml)

Pwr. Trim/Tilt - Fluid Capacity 21 fl. oz. (622 ml)

Propeller (4) Refer to Propeller Selection

Weight (7) L Models- 365 lbs. (166 kg)

X Models- 390 lbs. (177 kg)

Sound at Drivers Ear

(LpA) ICOMIA 39.94

80.8 dB(A)

Transom Height L Models- 19 1/2 to 20 in. (495 to 508 mm)

X Models- 24 1/2 to 25 in. (622 to 635 mm)


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135, 150, 175 Models

Displacement 158 cu. in. (2589 cc)

Engine Type 60 V, 6 Cylinder, Two-Cycle,

Direct Injection

Full Throttle Operating Range 135, 150- 4750 to 5250 RPM

175- 5250 to 5750 RPM

Power (1) 135- 135 HP (100.7 kw) @ 5000 RPM

150 - 150 HP (111.9 kw) @ 5000 RPM

175- 175 HP (130.5 kw) @ 5500 RPM

Idle RPM in Gear (2) 650 50

Ignition Timing (2) Not Adjustable

Emission Control System:

per SAE J1930 (2)ECM, DFI (Engine Control Module, Direct Fuel Injection)

Fuel Requirements (2) 87 Pump Posted AKI (90 RON) - Refer to Fuel and Oil

Oil Evinrude Direct Injectionoil - Refer to Fuel and Oil

Warning Signals Controlled by the engines EMM

Battery, Minimum 675 CCA (845 MCA) 12 volt

OR107 amp-hour (5)(6)

Spark Plug (2)(3)

Torque

Refer to ECI Labels

15-22 ft. lbs. (20-30 Nm)

Start Assist Circuit Fuse EvinrudeP/N 514768

Fuses Refer to Power Distribution Panel

Fuel Filter EvinrudeP/N 502906

Alternator 35-Amp, Fully Regulated

Gearcase - Lubricant

Capacity

Evinrude Ultra-HPFgearcase lubricant

40 fl. oz. (1190 ml) Counter Rotation

44 fl. oz. (1300 ml) Standard Rotation

Pwr. Trim/Tilt - Fluid Capacity 21 fl. oz. (622 ml)

Propeller (4) Refer to Propeller Selection

Weight (7) L Models - 423 lbs. (192 kg)

X Models- 443 lbs. (201 kg)

Sound at Drivers Ear

(LpA) ICOMIA 39.94

78.2 dB(A)

Transom Height L Models- 19 1/2 to 20 in. (495 to 508 mm)

X Models- 24 1/2 to 25 in. (622 to 635 mm)

(1) Rated following the standards of ICOMIA 28.83, ISO 3046 and NMMA.

(2) Emission Control Information.

(3) Any other spark plug will cause ignition problems.

(4) Not supplied in all marketing areas.

(5) Use a 750 CCA (940MCA) battery when operating in temperatures below 32F (0C).

(6) Under extraordinary electrical load or environmental conditions, use of a 107 amp-hour minimum.Generally available in group 29 size.

(7) Does not include propeller or fuel.


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REMOTE CONTROL

IMPORTANT: When selecting the remote control system for your boat, specify Evinrude/Johnsoncom-ponents. Evinrude/Johnsonoffers remote controls, cables and wiring kits designed specifically for yourEvinrude/Johnsonoutboards. Evinrude/Johnsoncontrols deliver the cable stroke your outboard needs forpositive shift and throttle control, and they incorporate such safety and convenience features as:

Start-in-gear prevention Plug-in compatibility with Evinrude/Johnsonmodular wiring system

Evinrude/JohnsonRedesigned side mount control

1. Handle - shift and throttle

2. Trim/tilt switch (where equipped)3. Neutral lock tab4. Fast idle lever5. Throttle friction control6. Emergency stop clip and lanyard

Evinrude/JohnsonConcealed side mount control

1. Handle - shift and throttle2. Trim/tilt switch (where equipped)3. Neutral lock tab

4. Fast idle button5. Throttle friction control

Evinrude/JohnsonSide mount control

1. Handle - shift and throttle

2. Trim/tilt switch (where equipped)3. Neutral lock tab4. Fast idle lever5. Emergency stop clip and lanyard6. Throttle friction control

Evinrude/JohnsonBinnacle mount control

1. Handle - shift and throttle2. Trim/tilt switch (where equipped)3. Fast idle button4. Throttle friction control5. Emergency stop clip and lanyard

WARNING

If you choose a non-Evinrude/Johnsonremote control, be sure it has a start-in-gear preven-tion feature. This feature can prevent injuries resulting from unexpected boat movement whenthe engine starts.

6

2

1

5

3

4


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Emergency Stop/Key Switch

A combination emergency stop switch and keyswitch is a feature of Evinrude prewired remotecontrols and all Evinrudecontrol wiring kits. Use ofthe emergency stop feature is highly recommendedon all boats.

Connect the clip to the emergency stop/key switch.Snap the lanyard to a secureplace on the opera-tors clothing or life vest not where it might tearaway instead of activating the stop switch. Discon-necting the clip and lanyard will stop the engine andprevent the boat from becoming a runaway if thedriver moves beyond the range of the lanyard. If thelanyard is too long, it can be shortened by knottingor looping it. DO NOT cut and retie the lanyard. Inan emergency situation, the engine can be startedwithout the clip in place. Follow the normal startingprocedure. Reinstall a clip as soon as possible.

1. Clip

2. Emergency stop / key switch3. Lanyard

WARNING

Avoid knocking or pulling the clip off thestop switch during normal boating. Avoidbumping the key if operating without theclip on the switch. The resulting unexpectedloss of forward motion can throw occupantsforward, causing injury.

Your emergency stop switch can be effec-tive only when in good working condition.At each outing, inspect clip and lanyard forcuts, breaks, or wear. Replace worn or dam-aged parts.

Keep the lanyard free from obstructions andentanglements.

At each outing, test the systems operation.With the engine running, remove the clipfrom the switch by pulling the lanyard. If theengine does not stop running, see yourDealer.


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18- Engine Monitoring

ENGINE MONITORING

IMPORTANT: Your outboard must be equippedwith the SystemCheckengine monitor. Operatingyour outboard without the SystemCheck enginemonitor will void your warranty for failures related tothe functions monitored on your engine.

When you turn the key switch ON, the System-Checkengine monitor horn performs a self-test bysounding a 1/2-second beep. The gauge self-testsby turning the warning lights on, then off in se-quence. During engine start-up, pause with the keyswitch in the ON position to observe the horn andgauge perform the self-test. If the self-test does nothappen as stated, see your Dealer.

The SystemCheckengine monitor alerts the opera-tor with a 10-second beep of the horn and a warninglight on the gauge when certain engine problemsoccur. The appropriate warning light will stay on

until the problem is corrected or the key switchis turned OFF.

If the engine management module (EMM) sensesthat the problem could cause permanent enginedamage, it will also limit engine speed to 1200RPM. This additional protection feature is referredto as S.L.O.W. If the engine was running fasterthan 1200 RPM when the S.L.O.W. system activat-ed, it will shake noticeably. Under certain operatingconditions the EMMwill shut OFF the engine.

1. SystemCheckgauge2. SystemCheckgauge with tachometer

NO OIL

There is an oil delivery problem. Serious enginedamage can occur quickly. The EMMwill activateS.L.O.W.

If the oil tank is empty, add the recommended oil.

If the oil tank is not empty, seek assistance and/orreturn to safe harbor. DO NOT exceed 1000 RPM.See your Dealer.

WATER TEMP or HOT

The engine is overheating. Serious engine damagecan occur quickly. The EMMwill activate S.L.O.W.Under certain conditions the EMMwill shut OFF theengine.

A continuousWATER TEMP or HOT light withS.L.O.W. The EMMhas identified an overheat-ing condition. Shut OFF the engine and refer imme-diately to Engine Overheating.

A flashingWATER TEMP or HOT light TheEMMhas identified a progressive overheating con-dition. The engine will shut OFF and will not restart

until the engine cools.

CAUTIONIn the S.L.O.W. mode, the engine speed islimited. Under certain conditions, theengines limited speed may reduce maneu-verability of your boat.

If the S.L.O.W. mode is activated and youare unable to correct the problem, seekassistance and/or return to safe harbor.Serious engine damage, engine shutoff,and/or reduced maneuverability may beimminent.

21


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Engine Monitoring - 19

CHECK ENGINE or CHK ENG

The EMMhas identified a potentially serious prob-lem.

A flashing"CHECK ENGINE" or "CHK ENG" light The EMMhas identified an abnormal operatingcondition related to the fuel system. The engine willshut OFF and cannot be restarted.

A continuous "CHECK ENGINE" or "CHK ENG"light with S.L.O.W. The EMM has identified aproblem that will cause engine damage if it is notaddressed. Seek assistance and/or return to safeharbor. See your Dealer.

A continuous "CHECK ENGINE" or "CHK ENG"light without S.L.O.W. The EMMhas identified aproblem that should be addressed by your Dealeras soon as practical to avoid operational difficulties.

LOW OIL

Oil in the oil tank is at reserve level (about 1/4 full).Fill the oil tank with recommended oil as soon aspossible to avoid emptying the tank. Refer to Fillingthe Oil Tank.

WARNINGIf the engine shuts OFF and the CHECKENGINE or CHK ENG light is flashing,the engine cannot be restarted. A hazardousfuel condition may exist. Seek assistance toreturn to port.


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20- Fuel and Oil

FUEL AND OIL

FUEL

Your outboard is certified to operate on unleadedautomotive gasoline with an octane rating equal toor higher than that specified in Minimum Octanechart. When using gasoline that contains MTBE oralcohol, follow these guidelines:

Using unleaded gasoline that contains methyl ter-tiary butyl ether (MTBE) is acceptable ONLYif theMTBE content does not exceed 15% by volume.

Using alcohol-extended fuels is acceptable ONLYifthe alcohol content does not exceed:

10% ethanol by volume5% methanol with 5% cosolvents by volume

Minimum Octane

Your outboard has been designed to operate usingthe above fuels; however, be aware of the follow-ing:

The boats fuel system may have different require-ments regarding the use of alcohol fuels. Refer tothe boats owner guide.

Alcohol attracts and holds moisture that can causecorrosion of metallic parts in the fuel system.

Alcohol blended fuel can cause engine perfor-mance problems.

IMPORTANT: Always use fresh gasoline. Gasolinewill oxidize and weather; the result is loss of octane,volatile compounds and the production of gum andvarnish deposits which can damage the outboard.

OIL

Evinrude direct injection oil is recommendedfor your Evinrude outboard.It is formulated withspecial additives for the cleaning power a direct in-

jection outboard needs for longer life. This syntheticblend oil also provides superior lubrication to re-

duce engine component wear and maintain top per-formance.

Evinrudebrand oils are formulated to give best en-gine performance while controlling piston and com-bustion chamber deposits, providing superiorlubrication, and ensuring maximum spark plug life.

If Evinrude direct injection oil is not available youmust use an NMMA-certified TC-W3 oil such asEvinrude/Johnson XD25 formulaor EvinrudeBio-degradable Outboard oil.

When operating under 32F (0C), EvinrudeBiode-gradable Outboard oil must be used.

IMPORTANT: Failure to follow this recommenda-tion could void the engine warranty if a lubrication-related failure occurs.

WARNING

Gasoline is extremely flammable and highlyexplosive under certain conditions. Followthe instructions in this section explicitly.Improper handling of fuel could result inproperty damage, serious injury or death.

Always turn off the engine before fueling.

Never permit anyone other than an adult torefill the fuel tank.

Do not fill the fuel tank all the way to the top

or fuel may overflow when it expands due toheating by the sun.

Remove portable fuel tanks from the boatbefore fueling.

Always wipe off any fuel spillage.

Do not smoke, or allow open flames, orsparks or use electrical devices such as cel-lular phones in the vicinity of a fuel leak orwhile fueling.

Always work in a well ventilated area.

Inside the U.S. 87 (R+M)/2 AKI

Outside the U.S. 90 RON

WARNING

Leaking fuel is a fire and explosion hazard.All parts in the fuel system should beinspected frequently and replaced if signsof deterioration or leakage are found.

Inspect the fuel system each time yourefuel, each time you remove the enginecover and annually.


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Fuel and Oil - 21

ADDITIVES

IMPORTANT: The only fuel additives approved byBRP for use in your Evinrudeoutboard are 2+4fuel conditioner and EvinrudeFuel System Cleaner.Use of other fuel additives can result in poor perfor-mance or engine damage.

Evinrude 2+4 fuel conditioner will help preventgum and varnish deposits from forming in fuel sys-tem components and will remove moisture from thefuel system. It can be used continuously and shouldbe used during any period when your engine isntbeing operated on a regular basis. Its use will re-duce spark plug fouling, fuel system icing and fuelsystem component deterioration.

EvinrudeFuel System Cleanerwill help keep fuelinjectors in optimal operating condition.

FUEL SYSTEM

Connecting the Fuel Hose

If the fuel hose is disconnected for any reason, sealit to prevent spillage. Cap the fuel fitting to preventcontamination.

Connect the fuel hose to the 3/8 in. (9 mm) fuel fit-ting. Fasten hose securely with clamp (18,5 mm)from owners kit.

1. Fuel hose and fuel fitting - 3/8 in. (9 mm)2. Oil supply fitting - 1/4 in. (6 mm) - Yellow stripe3. Oil return fitting - 5/16 in. (8 mm) - Blue stripe

Prime the fuel system by holding the fuel primerbulb with its outlet end up and squeezing it untilfirm.

IMPORTANT: Fuel distribution hoses in the boatmust deliver fuel at the rate of flow needed by theengine. Minimum inside diameter of fuel hosesmust be 3/8 in. (9 mm).

Fuel systems with built-in tanks, particularly thosethat include antisiphon valves and filter/primerunits, may have restrictions that will not allow theengine fuel pump to deliver sufficient fuel under allconditions. This can result in a loss of performanceand possible engine damage. If a performanceproblem exists, see your Dealer.

To avoid difficulty when restarting, never run theengine with the fuel hose disconnected or run theengine out of fuel.

WARNING

The outboard must be correctly installed.Failure to correctly install the outboardcould result in property damage, seriousinjury or death. We strongly recommendyour Dealer install your outboard to ensureproper installation.


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22- Fuel and Oil

OIL SYSTEM

If the oil hoses are disconnected for any reason,seal them to prevent spillage. Install caps on the oilfittings to prevent contamination.

You must use an oil tank equipped with a filter, anoil supply hose, and an oil return hose. The oil sys-tem must be purged if air is in the oil supply hose.Refer to Installing the Oil Supply Hose.

Install the oil tank by following the instructions pro-vided with the unit.

IMPORTANT: Consider the installation location ofthe oil tank carefully. The oil tank is vented to the at-mosphere. To avoid serious powerhead damage,be sure the oil tank is installed in a location thatdoes not allow constant exposure to sunlight, rain,bilge water, or spray. Periodically inspect the oiltank for evidence of water.

Filling the Oil Tank

Remove the filler cap and fill the tank with recom-mended outboard lubricant, as specified in Fueland Oil. Replace the filler cap and tighten securely.

IMPORTANT: Always keep a supply of oil in thetank. If you run the tank dry, you MUST purge theoil system of air before using the engine.

Installing the Oil Supply Hose

IMPORTANT: To avoid engine damage from lackof lubrication, make sure you purge the system.Make sure all connections are airtight.Anytimethe oil supply hose has been disconnected, youmust prime the oil system before reconnecting thesupply hose and operating the engine.

Connect the oil supply hose to the oil inlet fitting onthe motor. Secure with the small clamp (13.8 mm)

from the owners kit.

1. Oil supply hose - 1/4 in. (6 mm) - Yellow stripe2. Oil inlet fitting - 1/4 in. (6 mm) - Yellow stripe3. Clamp (13.8 mm) from owners kit

Hold the open end of the oil return hose fitting overa container. With its outlet end up, squeeze the oilfill bulb repeatedly until about 8 oz. (250 ml) of oilhave been pumped and the supply hose is purged

of all air.

1. Oil return hose fitting - 5/16 in. (8 mm) - Bluestripe


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Fuel and Oil - 23

Installing the Oil Return Hose

Connect the oil return hose to the oil return hose fit-ting on the motor. Secure with the clamp (15.7 mm)from the owners kit.

1. Oil return hose - 5/16 in. (8 mm) - Blue stripe2. Oil return hose fitting - 5/16 in. (8 mm) - Blue

stripe3. Clamp (15.7 mm) from owners kit

Start the engine and run at idle only. Restrict the oilreturn hose for about 15 - 20 seconds. Shut off theengine.

1. Restrict Oil return hose - 5/16 in. (8 mm) - Bluestripe

WARNING

Prevent injury from moving engine compo-nents. Before starting the engine...

Shift it to NEUTRAL

Keep hands, clothes, hair clear of power-

headRemove the propeller if you use a flushingdevice

Read Engine Starting, ENGINE STOPPING


27/62


28/62

Engine Starting - 25

ENGINE STARTING

BEFORE START-UP

If the fuel hose and/or oil hoses are not connected,refer to Fuel System and Oil System, to install

them now.Review and follow Break-in (10 hours) if the en-gine is new.

You MUST supply water to the engine before at-tempting to start it. Engine damage can occurquickly. Refer to Engine Overheatingor Flushing.

Be sure the engine is in RUN position. Refer toPower Trim and Tiltor Tilting.

If the fuel tank has an operable vent, open it.Squeeze the fuel primer bulb, outlet end up, untilfirm.

If equipped with an electric fuel primer pump, acti-vate it for about 20 seconds.

Connect the clip to the emergency stop/key switch.Snap the lanyard to a secureplace on the opera-tors clothing or life vest not where it might tearaway instead of activating the stop switch.

1. Clip2. Emergency Stop Clip / key switch3. Lanyard

DANGER

DO NOT run the engine indoors or without

adequate ventilation or permit exhaustfumes to accumulate in confined areas.Engine exhaust contains carbon monoxidewhich, if inhaled, can cause serious braindamage or death.

WARNING

The engine cover is a machinery guard. DONOT operate your outboard with the cover

off unless you are performing maintenance,and then be careful to keep hands, hair, andclothing clear of all moving parts. Contactwith moving parts could cause injury.

DANGER

Contact with a rotating propeller is likely toresult in serious injury or death. Assure theengine and prop area is clear of people and

objects before starting engine or operatingboat. Do not allow anyone near a propeller,even when the engine is off. Blades can besharp and the propeller can continue to turneven after the engine is off. Always shut offthe engine when near people in the water.


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26- Engine Starting

IMPORTANT: The engine will start and run withoutthe clip connected to the key switch. However, westrongly recommend that the operator use the clipand lanyard anytime the engine is running. Refer toEmergency Stop/Key Switch.

Move the remote control handle to NEUTRAL.

1. Concealed side mount control2. Binnacle mount control

DO NOTadvance the throttle before start-up. Ad-vancing the throttle overrides the electronic idlecontrol system. After the engine starts, the enginemanagement module (EMM) automatically increas-es idle speed. Idle speed will decrease as the en-gine warms up. Wait until idle speed decreasesbefore you shift into gear.

Turn the key switch fully clockwise to the STARTposition. Crank the engine no longer than 10 sec-onds.

IMPORTANT: The starter motor can be damaged ifoperated continuously for more than 10 seconds.

Upon start-up, release the key.

If the engine did not start, release the key momen-tarily, then try again.

Each time the key switch is turned from OFF to ON,the warning system will self-test. Refer to EngineMonitoring. If the warning system fails to self-testduring start-up, see your Dealer.

If your outboard doesnt react normally to this start-ing procedure or if it fails to start, refer to TroubleCheck Chart.

After Engine Starts

IMPORTANT: DO NOTadvance the throttle whenoperating the engine in NEUTRAL. Advancing thethrottle can cause the engine to over-rev, which canresult in severe engine damage.

Check the water pump indicator. A steady stream ofwater indicates the water pump is working. If a

steady stream of water from the water pump indica-tor is not visible, stop the engine. Refer to EngineOverheating.

Engine temperature will determine the length of theperiod of fast idle after start-up the warmer theengine, the shorter the period of fast idle.

WARNINGDO NOT attempt to shift the engine intoFORWARD or REVERSE while it is runningat fast idle. Shifting under this condition canresult in sudden boat movement, resultingin injury.

16 2


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Engine Starting - 27

ENGINE STOPPING

Move control handle to NEUTRAL.

Turn key switch counterclockwise to the OFF posi-tion. Remove the key when the boat will be unat-tended.

To avoid difficulty when restarting, never stop theengine by running it with the fuel hose disconnectedor otherwise running it out of fuel.

SHIFTING AND SPEED CONTROL

IMPORTANT: Carefully check the function of allcontrol and engine systems before leaving thedock. DO NOT shift the engine into FORWARD orREVERSE while it is shut off.

If the following directions are not suitable for yourboats control, see your Dealer before proceeding.

Shifting

With engine running and control handle in NEU-TRAL:

Concealed Side Mount Control

Unlock the control handle (lift the neutral lock tab bysqueezing the hand grip). Briskly and decisively,move the control handle fore or aft until it engag-es the gear detent.

1. NEUTRAL Lock Tab Hand Grip

Binnacle Mount Control

Briskly and decisively, move the control handle foreor aft until it engages the gear detent.

IMPORTANT: When shifting from FORWARD toREVERSE or from REVERSE to FORWARD,pause at NEUTRAL until the engine is at idle speed

and the boat has slowed.

Speed Control

After gear engagement, move the control handleslowly in the same direction to increase speed.

FUEL ECONOMY

The economy throttle range can save fuel, depend-ing on boat load and hull design. When boat reach-

es top speed, throttle back from FULL SPEED tothe economy throttle range. You will save fuel with-out a noticeable loss of speed.

1. Concealed Side Mount Control2. Binnacle Mount Control


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28- Operation

OPERATION

POWER TRIM AND TILT

The trim system features a trim range of 21:

You can pivot the engine to any position within this

range while underway and at any boat speed.The power trim is normally used to improve accel-eration, speed, and ride quality and to adjust forchanging water conditions.

The tilt system will tilt your engine an additional 54:

While positioned within the tilt range, DO NOT runthe engine faster than idle speed. If idling a tiltedengine, keep its water intakes submerged at alltimes.

The power tilt is often used to tilt the engine forclearance when beaching, mooring, or launching.

1. Trim Range2. Tilt Range

Trim Gauge

The trim gauge indicates the bow position that isachieved by the trim angle of your motor.

DANGER

DO NOT run the engine indoors or without

adequate ventilation or permit exhaustfumes to accumulate in confined areas.Engine exhaust contains carbon monoxidewhich, if inhaled, can cause serious braindamage or death.

DANGER

Contact with a rotating propeller is likely toresult in serious injury or death. Assure the

engine and prop area is clear of people andobjects before starting engine or operatingboat. Do not allow anyone near a propeller,even when the engine is off. Blades can besharp and the propeller can continue to turneven after the engine is off. Always shut offthe engine when near people in the water.

WARNING

Any malfunction of the power trim and tiltunit could result in loss of shock absorberprotection if an underwater obstruction ishit. Malfunction can also result in loss ofreverse thrust capability.


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Operation - 29

Manual Release

If needed, the outboard will tilt up or down manually:

Turn the manual release screw counterclockwise,slowly, until it lightlycontacts its retaining ring about 3 and 1/2 turns.

Reposition the engine.

Tighten the manual release screw to hold the en-gine in its new position.

1. Manual Release Screw

Tilting

To operate the power tilt, push and hold the trim/tiltswitch in the bow-up or bow-down position. The en-gine will tilt up or down until the switch is releasedor the engine reaches the end of its travel.

1. Bow Up2. Bow Down

If the tilted engines cover contacts the boats motorwell, limit the maximum tilt by following the proce-dures in Adjustments, Tilt Limiter Cam.

Trimming

To operate the power trim, push and hold the trim/tilt switch in the desired bow direction, either bow-up or bow-down. The engine will move until theswitch is released or the engine reaches its maxi-

mum position.The boat will be properly trimmed when the trim an-gle provides a bow position that results in the bestboat performance for your operating conditions.

You must use a speedometer and tachometer todetermine boat and engine performance at differenttrim positions. To help maintain steering stabilityand good performance, always maintain the propertrim angle which, varies depending on the combina-tion of boat, motor, propeller and operating condi-tions.

To familiarize yourself with power trim, make test

runs with the boats bow at various positions. Notethe time it takes for the boat to plane, the tachome-ter and speedometer readings, and the ride and ac-tion of the boat.

WARNING

Keep everyone clear of a tilted engine whenbacking out the manual release screw. Theengine could drop suddenly and forcibly. Besure to tighten the manual release screwafter manually repositioning the engine.

Tightening the screw also reactivates theengines shock absorber protection andreverse thrust capability.


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30- Operation

Bow-Up

BOW-UP position will give the best fuel economyand highest top speed.

Operating Conditions:

In the bow-up position, your boat may tend to pull tothe left. If this condition exists, correct it by applyinga clockwise force with the steering wheel to keep ona straight path. The trim tab can also be adjusted tocompensate for steering wheel torque, but adjustthe trim tab only if bow-up is commonly used. Referto Trim Tab.

When the motor is trimmed to full bow-up position,the boats bow will tend to rise above the water.

Excessive bow-up trim may cause propeller ventila-tion, resulting in propeller slippage.

Bow-Down

BOW-DOWN position will give the best accelera-tion onto plane and the best towing power for skiing.

The bow-down position is normally used for accel-erating from a standing start or from idle speed.

Operating Conditions:

In the bow-down position, your boat may tend topull to the right. If this condition exists, correct it byapplying a counterclockwise force with the steeringwheel to keep on a straight path. The trim tab canalso be adjusted to compensate for this steeringwheel torque, but adjust the trim tab only if bow-down is commonly used. Refer to Trim Tab.

When the motor is trimmed to full bow-down posi-tion, the boats bow will tend to go deeper into thewater (plow).

IMPORTANT: Some boats plow, or are difficult toplane, when operated in the trims lowest position.If your boat handles unsuitably when trimmed fullybow-down, set the angle adjusting rod or trim limiterrod to limit the travel of the power trim. If your motoris not equipped with this rod, purchase one fromyour Dealer.

WARNING

When operating in rough water or crossinga wake, excessive bow-up trim may result inthe boats bow suddenly rising skyward;possibly ejecting occupants.

WARNING

Some boat/motor/propeller combinationsmay encounter boat instability and/or highsteering torque when operated at highspeed at or near the motors trim range lim-its (full bow-up or bow-down). Boat stabilityand steering torque can also vary due tochanging water conditions. If any adverseconditions occur, reduce throttle and/oradjust trim angle to maintain control. If youexperience boat instability and/or high

steering torque, see your Dealer to correctthese conditions.

WARNING

If the bow of the boat plows the water athigh speeds, the boat may bow steer or spinsuddenly; possibly ejecting occupants.


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Operation - 31

PROPELLER SELECTION

To select the correct propeller for your boating ap-plication, your boat and motor MUST be water test-ed. See your Dealer for assistance.

Refer to Propeller, before removing or installingpropeller.

IMPORTANT: The correct propeller for your boat,under normal load conditions, will allow the engine

to run near the midpoint of the RPM operatingrange at full throttle. Refer to Engine Specifica-tions.

Right-hand propellers are considered standard ro-tation propellers. When propelling a boat forward,the propeller rotates in a right-hand (clockwise) di-rection as viewed from the rear.

Left-hand propellers are considered counter-rota-tion propellers. When propelling a boat forward, thepropeller rotates in a left-hand (counterclockwise)direction as viewed from the rear.

1. Right-Hand (clockwise)2. Left-Hand (counterclockwise)

MOORING

You may moor your boat with the motors gearcaseout of the water by using its tilt feature. Dependingon the model, refer to Tiltingor Power Trim andTilt.

IMPORTANT: DO NOT use the tilt support leverwhile trailering. Refer to Trailering.

Engagethe tilt support lever if you intend to leave

the motor tilted for a period of time:Tilt the motor UP using the trailering tilt switch.

Flip the tilt support lever down.

Lower the motor until the tilt support lever rests sol-idly on the stern brackets.

Disengagethe tilt support lever:

Tilt the motor UP.

Flip the tilt support lever up.

Lower the motor to operating position.

WARNING

If you have a dual engine installation thatincludes a counter-rotating engine and youremove the propellers, always check to be

sure they are installed on the correctengines before aggressively operating yourboat. Shift each motor individually intoFORWARD or REVERSE, at idle speed only.If the boat moves opposite the directionindicated by the remote control handle, thewrong propeller has been installed on themotor being checked. Install the correctpropeller and confirm your installationusing the above method before any attemptis made to operate the boat.


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32- Operation

FLUSHING

Flush your engine with fresh water as soon as pos-sible after each use in salty, polluted, or brackishwater to minimize the formation of deposits that canclog cooling passages.

Flush the engine on the trailer or at dockside whileit is: tilted or vertical, running or stopped.

Outboard Running

1. Place the engine in vertical position in a well-ventilated area with good drainage.

2. Remove the plug from the flushing port.

3. Install flushing device (if needed) and gardenhose.

4. Start the water keep pressure between 20 -40 psi (140 - 300 kPa).

5. Start the engine run it at idle onlyand flushit for at least five minutes.

6. Shut off the engine, remove the flusher (ifused), and install the plug. If the plug is also thewater pump indicator, turn it so the waterstreams out to the side, where it can be seeneasily from the helm.

7. Leave the outboard in vertical position longenough to completely drain the powerhead.

Outboard Not Running

1. The outboard may be in a tilted or vertical posi-

tion.2. Remove the plug from the flushing port.

3. Install flushing device (if needed) and gardenhose.

4. Start the water and flush the engine for at leastfive minutes keep pressure between 20 - 40psi (140 - 300 kPa).

5. Remove the flusher (if used); install the plug. Ifthe plug is also the water pump indicator, turn itso the water streams out to the side, where itcan be seen easily from the helm.

6. Lower the outboard to vertical position longenough to completely drain the powerhead.

DANGER

DO NOT run the engine indoors or withoutadequate ventilation or permit exhaustfumes to accumulate in confined areas.Engine exhaust contains carbon monoxide

which, if inhaled, can cause serious braindamage or death.

WARNING

Prevent injury from contact with rotatingpropeller; remove the propeller beforeflushing.


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Operation - 33

ENGINE OVERHEATING

IMPORTANT: Do not run your engine even for abrief start-up without supplying water to it. Refer toFlushing.

While boating, the engines water intakes must staycompletely submerged and unobstructed. Observeproper transom height and trim angle. While the en-gine is running, the engines water pump indicatormust discharge a steady stream of water. Checkthe indicator often, especially when operating inweeds, mud and debris-laden water and at extremetrim angles.

1. Water intake screens2. Water pump indicator

If the engine overheats, its SystemCheck enginemonitor will sound the warning horn and turn on theWATER TEMP or HOT light. Also, the S.L.O.W.

protection system will immediately limit the enginesspeed to 1200 RPM. If the engine was running fast-er than 1200 RPM when the S.L.O.W.system acti-vated, it will shake noticeably. The protectionsystem must be RESETbefore the engine will op-erate at speeds over 1200 RPM. Under certain con-ditions the EMMwill shut off the engine.

The following conditions must be met to RESET thesystem:

The engine must be shut off and the cooling tem-perature restored.

IFthe S.L.O.W.protection system activates and thestream from the water pump indicator becomes in-termittent or stops, reduce speed to idle and:

Shift to NEUTRAL.

SHUT OFF the engine.

Tilt the motor up.

Clean the intake screens of any blockage.

Clean the water pump indicator of any blockage.

Lower the motor.Restart the engine and run at idle.

IFcleaning the screens and indicator does not re-store the water pump indicators steady discharge,SHUT OFF the engine and do not attempt to oper-ate it. See your Dealer.

IFcleaning the screens and indicator does restorethe water pump indicators steady discharge, youmight have to run for two minutes in NEUTRAL toallow the engine to cool and the light to go off.

If the warning light stays on after two minutes,STOP the engine and see your Dealer.

IMPORTANT: You must restore cooling to the en-gine to avoid serious engine damage. If you do notrestore cooling to the engine the EMMwill identify aprogressive overheating condition and shut off theengine. The "WATER TEMP" or HOT light will flash.The engine will not restart until the engine is al-lowed to cool.

After any overheat, have your Dealer:

Torque the cylinder head screws.

Inspect the water pump for excessive wear or dam-age.

Inspect the thermostats.

Inspect the engine for leaks.


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34- Operation

TRAILERING

Trailering Bracket

To engage bracket Tilt the motor fully usingthe tilt switch inside the boat or the trailering tiltswitch.

1. Trailering tilt switch2. Tilt switch inside boat

Pull down the trailering bracket. A detent will holdthe bracket in position. Lower the motor until thetrailering bracket locks into place in the stern brack-ets.

To disengage bracket Tilt the motor fully. Re-turn the trailering bracket to its stowed position.Lower the motor to its vertical position.

Trailer your boat with the motor in a vertical posi-tion. If your trailer does not provide adequate roadclearance, the motor can be trailered while tilted byusing the motors trailering bracket.

IMPORTANT: DO NOT use the tilt support leverwhen trailering.

WARNING

Keep everyone clear of stern area whenraising or lowering the outboard. Personalinjury or death can result from contact withmoving parts of the outboard.


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Operation - 35

IMPACT DAMAGE

Your engine has a shock absorption system de-signed to help withstand damage from impact withunderwater objects at low to moderate speeds.However, high speed impacts with rigid underwaterobjects like pilings or boulders can be beyond thecapability of the absorption system. Such impactscan result in serious damage to your engine and in-

jury to boat occupants from the engine or its parts

entering the boat. Occupants can also be ejected orinjured by falling against portions of the boat as aresult of rapid deceleration following impacts. Whenboating in unfamiliar, shallow, or debris-laden wa-ters, seek information on safe boating areas andnavigation hazards from a reliable local source. Re-duce your speed and keep a sharp lookout!

The engines shock absorption system does notwork while operating in reverse. If you back into anobject, either in the water or while trailering, yourboat and engine can be seriously damaged.

If you hit any object, stop immediately and examinethe engine for loosening of attaching hardware andclamp screws, if equipped. Inspect for damage toswivel and stern brackets, steering components,and components in the area of impact. Also, exam-ine the boat for structural damage. Tighten anyloosened hardware. If the collision occurred in thewater, proceed slowly to harbor. Before boatingagain, have your Dealer thoroughly inspect all com-ponents.

STORING

To avoid difficulty when restarting, never run theengine with the fuel hose disconnected or run theengine out of fuel.

If you must tilt the motor to remove it from the water,lower it and allow the cooling system to drain com-pletely as soon as you clear the launch area.

Between uses, store your motor in a vertical posi-tion.

For recommendations on extended periods of stor-age, refer to Off-Season Storage.

WARNING

Failure to inspect for damage could result insudden, unexpected component failure,loss of boat control, and personal injury.Unrepaired damage could reduce your boatand engines ability to resist future impacts.


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36- Operation

SPECIAL OPERATING CONDITIONS

Salt Water

Flush the engine internally after use in salt, pollutedor brackish water to help prevent mineral depositsfrom clogging cooling passages. Your outboard hasa built-in flushing port to facilitate flushing. Refer toFlushing.

During use in salt or brackish water, additional an-odic protection for the boat and outboard may be re-quired.

During long periods of mooring, tilt the gearcase outof the water except in freezing temperatures.Upon removal from salt water, leave it in a verticalposition until its cooling system has drained.

Weedy Water

Weeds block water intakes and cause your out-board to overheat. Weeds on the propeller createvibration and reduce boat speed.

Run at slow speeds and in REVERSE frequently toclear weeds from the propeller and water intakes.Check the water pump indicator often.

If REVERSE operation does not clear away weeds,SHUT OFF the engine. Remove weeds from pro-peller area and water intakes before operating athigher speed.

Boat Bottom and Engine External Finish

The condition of your boats bottom affects perfor-mance. A covering of marine growth reducesspeed. For maximum performance, keep the boatsrunning surface clean by wiping it dry after each useand washing it occasionally.

After operating your outboard, rinse it with fresh wa-ter and wipe it dry. Apply EvinrudeAnti-CorrosionSpray to any surface subject to corrosion, but avoidthe anti-corrosion anode(s).

Periodically, wash the entire boat and outboard withsoapy water and apply a coat of automotive wax.Leave the engine cover in place when washing theoutboard.

High AltitudeYour engines EMMwill automatically compensatefor changes in altitude. However, if you consistentlyboat above 3000 ft. (900 m), you will experience aslight loss of power due to reduced air density.

If your engine drops below the recommended RPMoperating range at full throttle, have your Dealer se-lect a lower pitch propeller.

If you return to sea level, have your Dealer installthe original propeller and verify correct RPM oper-ating range.

Shallow Water

IMPORTANT: Serious engine damage will occur ifthe gearcase is allowed to drag on the waterwaybottom.

Freezing Weather

DURING operation in freezing weather, keep thegearcase submerged at all times.

Upon removing your motor from the water, leave itin a vertical position until its cooling system isdrained.

IMPORTANT: Water that has leaked into the gear-case, or remained in the cooling system or othercomponents can freeze, causing serious enginedamage.

IMPORTANT: If your outboards gearcase isequipped with an integral speedometer pickup, allwater must be cleared from the hose to preventgearcase damage. Refer to Off-Season Storage.

Submerged Engine

If your engine has been under water, have it ser-viced immediately upon recovery. If immediateservice is unavailable, resubmerge it in fresh waterto avoid prolonged exposure to the atmosphere.

After submersion, all boat and engine electrical,fuel and oiling systems must be inspected for signsof water intrusion. Your Dealer should perform thisservice.

Dual Engine Operation

When you are maneuvering at slow speed, be sureboth engines are running, even if one or both are inNEUTRAL.

If it is necessary to return to harbor with one enginenot running, you should not attempt to operate theboat above planing speed. Tilt the inoperative en-gine high enough to keep its propeller out of the wa-ter.

Under Tow

Should you require a tow from another boat:

Shift your engine to NEUTRAL.

Tilt its gearcase out of the water.

Off-load all persons into another boat.

Keep towing speed slower than planing speed.


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Maintenance - 37

MAINTENANCE

Maintenance, replacement, or repair of theemission control devices and systems may beperformed by any marine SI (spark ignition) en-gine repair establishments or individual.

ENGINE EMISSIONS INFORMATION

Manufacturers Responsibility

Beginning with 1999 model year engines, manufac-turers of marine engines must determine the ex-haust emission levels for each engine horsepowerfamily and certify these engines with the UnitedStates of America Environmental Protection Agen-cy (EPA). An emissions control information label,showing emission levels and engine specifications,must be placed on each engine at the time of man-ufacture.

Dealers Responsibility

When performing service on all 1999 and more re-cent Evinrude outboards that carry an emissionscontrol information label, adjustments must be keptwithin published factory specifications.

Replacement or repair of any emission relatedcomponent must be executed in a manner thatmaintains emission levels within the prescribed cer-tification standards.

Dealers are not to modify the engine in any mannerthat would alter the horsepower or allow emissionlevels to exceed their predetermined factory speci-fications.

Exceptions include manufacturers prescribedchanges, such as altitude adjustments, for exam-ple.

Owner Responsibility

The owner/operator is required to have enginemaintenance performed to maintain emission levelswithin prescribed certification standard

evinrude 115 direct injection manual

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