01 - Reference - 04ldYSAAY
01 - Reference - 04ldYSAAY
Technical Publications
P.O. Box 597
Sturtevant, Wisconsin 53177 United States
www.evinrude.com or www.johnson.com
The following trademarks are the property of BRP US Inc. or its affiliates:
Evinrude ® SystemCheck™
Evinrude ® E-TEC ® 2+4 ® Fuel Conditioner
Evinrude ® ICON™ Triple-Guard ® Grease
Evinrude ® ICON II ™ HPF PRO™ Gearcase Lubricant
®
Evinrude ICON-Touch ™ DPL™ Lubricant
Evinrude ® i-Dock ™ Gel-Seal II™
Evinrude ® XD50™ Outboard Oil Nut Lock™
Evinrude ® XD100™ Outboard Oil Screw Lock™
I-Command™ Ultra Lock™
S.A.F.E.™ Moly Lube™
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Reference Information
Reference Information
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Table of Contents
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Abbreviations Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product Reference and Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Emission-Related Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Manufacturer’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dealer’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Owner’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EPA Emission Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EPA Internet Web Site: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Model Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Safety Notice
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This publication is written for qualified, factory- DO NOT perform any work until you have read
trained technicians who are already familiar with and understood these instructions completely.
the use of Evinrude Special Tools. The included
information is not a substitute for work experience. Torque wrench tightening specifications must
It is an organized guide for reference, repair, and/ strictly be adhered to.
or maintenance. Should removal of any locking fastener (lock tabs,
The following symbols and/or signal words locknuts, or patch screws) be required, always
may be used in this document: replace with a new one.
These safety alert signal words mean: This document may be translated into other lan-
guages. In the event of any discrepancy, the
ATTENTION! English version shall prevail.
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
IMPORTANT: Identifies information that controls
correct assembly and operation of the product.
ENVIRONMENTAL NOTE:
A note which provides tips and behaviors related
to protecting the environment.
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DANGER
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 propel-
ler 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.
WARNING
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. Defi-
nite resistance to tightening must be felt when reusing a locking fastener. If replacement is indi-
cated, use only authorized replacement or equivalent.
Reference Information
Abbreviations Used In This Manual
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Reference Information
Standard Torque Specifications
3/8 in. 216–240 18–20 24.5–27 All photographs and illustrations used in this man-
ual may not depict actual models or equipment,
7/16 in. 336–384 28–32 38–43.5 but are intended as representative views for refer-
ence only.
M3 15–22 1.25–1.83 1.7–2.5
M4 24–35 2–2.9 2.7–4.0 Certain features or systems discussed in this
manual might not be found on all models in all
M5 35–60 2.9–5 4.0–6.8 marketing areas.
M6 84–106 7–8.8 9.5–12 All service technicians must be familiar with nauti-
cal orientation. This manual often identifies parts
M8 177–204 14.7–17 20–23
and procedures using these terms.
M10 310–336 25.8–28 35–38
IMPORTANT: These values apply only when
a specific torque for a specific fastener is not list-
ed in the appropriate section. When tightening
two or more screws on the same part, DO NOT
tighten screws completely, one at a time.
WARNING
Torque wrench tightening specifications
must be strictly adhered to. Replace any lock-
ing fastener (locknut or patch screw) if its
locking feature becomes weak. Definite resis-
tance to turning must be felt when reusing a
locking fastener.
If replacement is specified or required
because the locking fastener has become
Nautical Orientation 006411
weak, use only authorized Evinrude Genuine
Parts.
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Reference Information
Emission-Related Installation Instructions
Emission-Related Installation
Instructions
Failing to follow these instructions when installing a certified engine in a vessel violates federal
law (40 CFR 1068.105 (b)), subject to fines or other penalties as described in the Clean Air Act.
A repair shop or person of the owner's choosing may maintain, replace, or repair emission control
devices and systems. These instructions do not require components or service by BRP or authorized
Evinrude dealers. Although an authorized Evinrude dealer has the in-depth technical knowledge and
tools to service Evinrude outboard engines, the emission-related warranty is not conditioned on the use
of an authorized Evinrude dealer or any other establishment with which BRP has a commercial relation-
ship.
For emission-related warranty claims, BRP is limiting the diagnosis and repair of emission-related parts
to authorized Evinrude dealers. For more information, please refer to the US EPA EMISSION-RELATED
WARRANTY contained in the Operator’s Guide. Proper maintenance is the owner's responsibility. A
warranty claim may be denied if, among other things, the owner or operator caused the problem through
improper maintenance or use.
You must follow the instructions for fuel requirements in the FUEL REQUIREMENTS section of this man-
ual. Even if gasoline containing greater than ten volume percent ethanol is readily available, the US EPA
has issued a prohibition against the use of gasoline containing greater than 10 vol% ethanol that applies
to this engine. The use of gasoline containing greater than 10 vol% ethanol with this engine may harm
the emission control system.
Manufacturer’s Responsibility
Beginning with 1999 model year outboards, manufacturers of marine outboards must determine the
exhaust emission levels for each outboard horsepower family and certify these outboards with the
United States of America Environmental Protection Agency (EPA). An emissions control information
label, showing emission levels and outboard specifications, must be placed on each outboard at the time
of manufacture.
Dealer’s Responsibility
When performing service on all 1999 and more recent Evinrude outboards that carry an emissions con-
trol information label, adjustments must be kept within published factory specifications.
Replacement or repair of any emission related component must be executed in a manner that maintains
emission levels within the prescribed certification standards.
Dealers are not to modify the outboard in any manner that would alter the horsepower or allow emission
levels to exceed their predetermined factory specifications.
Exceptions include manufacturer’s prescribed changes, such as altitude adjustments, for example.
Owner’s Responsibility
The owner/operator is required to have outboard maintenance performed to maintain emission levels
within prescribed certification standards.
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Reference Information
Emission-Related Installation Instructions
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 specifica-
tions. 1
Tampering with the fuel system to change horsepower or modify emission levels beyond factory settings
or specifications will void the product warranty.
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Reference Information
Model Designation
Model Designation
Engine Identification
DESIGN FEATURES: MODEL IDENTIFICATION
C Counter Rotation The first two characters identify
D Evinrude E-TEC Model Version:
G Graphite Paint AA A First major variant
H High Output AB A Second major variant
O Hydraulic Steering AF A Third major variant
(non-power assist) • follow the model identification shown
U 300 HP with Water Valve above.
PREFIX: • subsequent versions continue through the
A Alternate Feature* alphabet as AG, AH etc.
E Evinrude
• will not use letters from the word
INTRODUCES to identify models.
E 250 L HO AG B
HORSEPOWER SHAFT LENGTH: The third character identifies
L 20 in. Long Model Revision:
X 25 in. X-long AA A First revision
Z 30 in. XX-long AA B Second revision
Subsequent revisions continue
through the alphabet in order
(A through Z).
* An “A” prefix in the model number of an Evinrude E-TEC G2 indicates a Counter-Rotation model with Dynamic
Power Steering (DPS).
Model and serial numbers are located on the swivel bracket and on the powerhead.
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Reference Information
Models Covered
Models Covered
This service manual covers information on the following Evinrude E-TEC G2, 210 cubic inch (3.4 L), 1
74° V6, models, starting with serial numbers:
AB models, s/n 5410201
AF models, s/n 5421512
AG and newer models, s/n 5437485
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Reference Information
Service Specifications
Service Specifications
HP 200 225 250 250 H.O. 300
Engine
Piston Ring End Gap, Both 0.022 to 0.028 in. (0.57 to 0.72 mm)
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Service Specifications
Use unleaded regular gasoline. The use of unleaded gasoline containing alcohol
above the percentage specified by government regulations is not recommended. Do
Acceptable Fuel
NOT use Fuel labeled "E85." Use of fuel labeled E15 is prohibited by U.S. EPA Reg-
ulations.
Fuel Pressure (maximum) – Lift Pump 3 psi (21 kPa) @ 5500 RPM
–High Pressure Pump 34 to 40 psi (234 to 275 kPa) @ idle RPM
Electrical System
675 CCA (845 MCA); or 750 CCA (940 MCA) below 32°F (0°C) (Use a 107 amp-hr
Minimum Battery Requirements
battery for extreme applications.)
Cooling System
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Reference Information
Service Specifications
Ignition System
Gearcase
Capacity – Standard Rotation Gearcase only – 38.9 fl. oz. (1180 ml)
Gearcase, vent hose and oil reservoir 45.6 fl. oz. (1350 ml)
– Counter Rotation Gearcase only – 39 fl. oz. (1154 ml)
Gearcase, vent hose and oil reservoir 44.7 fl. oz. (1324 ml)
Steering System
Fluid Capacity
10 oz. (300 ml) (approximate)
(NOT including helm or hydraulic hoses)
Steering Range (lock to lock) –32° to +32°, 64° Total (see engine Profile Drawing)
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