,
,BRP US Inc.
Technical Publications
250 Sea Horse Drive
Waukegan, Illinois 60085 United States
† AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II
are registered trademarks of Tyco International, Ltd.
† Amphenol is a registered trademark of The Amphenol Corporation.
† Champion is a registered trademark of Federal-Mogul Corporation.
† Deutsch is a registered trademark of The Deutsch Company.
† Dexron is a registered trademark of The General Motors Corporation.
† Fluke is a registered trademark of The Fluke Corporation
† Frahm is a registered trademark of James G. Biddle Co.
† Gasoila is a registered trademark of The Federal Process Corporation.
† GE is a registered trademark of The General Electric Company.
† GM is a registered trademark of The General Motors Corporation.
† Locquic and Loctite are registered trademarks of The Henkel Group.
† Lubriplate is a registered trademark of Fiske Brothers Refining Company.
† NGK is a registered trademark of NGK Spark Plugs (U.S.A.) Inc.
† NMEA is a registered trademark of the National Marine Electronics Association.
† Oetiker is a registered trademark of Hans Oetiker AG Maschinen.
† Packard is a registered trademark of Delphi Automotive Systems.
† Permatex is a registered trademark of Permatex.
† Plastigage is a registered trademark of The Dana Corporation.
† STP is a registered trademark of STP Products Company.
† Snap-on is a registered trademark of Snap-on Technologies, Inc.
† ThreeBond is a registered trademark of Three Bond Co., Ltd.
Bombardier logo is a registered trademark of Bombardier, Inc., used under license.
The following trademarks are the property of BRP US Inc. or its affiliates:
Carbon Guard™ Nut Lock™
DPL™ Lubricant QuikStart™
Evinrude ® S.A.F.E.™
Evinrude ® E-TEC ® S.L.O.W.™
Evinrude ® / Johnson ® XD30™ Outboard Oil Screw Lock™
Evinrude ® / Johnson ® XD50™ Outboard Oil SystemCheck™
Evinrude ® / Johnson ® XD100™ Outboard Oil Triple-Guard ® Grease
FasTrak™ Twist-Grip™
Gel-Seal II™ 2+4 ® Fuel Conditioner
Hi-Vis™ Gearcase Lubricant Ultra™ 4-Stroke Outboard Oil
I-Command™ HPF XR™ Gearcase Lubricant
Johnson ® Ultra Lock™
Moly Lube™
Printed in the United States.
© 2006 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
, SAFETY INFORMATION
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This manual is written for qualified, factory-trained Always follow common shop safety practices. If
technicians who are already familiar with the use you have not had training related to common shop
of Evinrude®/Johnson® Special Tools. This man- safety practices, you should do so to protect your-
ual is not a substitute for work experience. It is an self, as well as the people around you.
organized guide for reference, repair, and mainte-
It is understood that this manual may be trans-
nance of the outboard(s).
lated into other languages. In the event of any dis-
This manual uses the following signal words iden- crepancy, the English version shall prevail.
tifying important safety messages.
To reduce the risk of personal injury, safety warn-
DANGER ings are provided at appropriate times throughout
the manual.
Indicates an imminently hazardous situa-
tion which, if not avoided, WILL result in DO NOT make any repairs until you have read the
death or serious injury. instructions and checked the pictures relating to
the repairs.
Be careful, and never rush or guess a service pro-
WARNING cedure. Human error is caused by many factors:
Indicates a potentially hazardous situation carelessness, fatigue, overload, preoccupation,
which, if not avoided, CAN result in severe unfamiliarity with the product, and drugs and alco-
injury or death. hol use, to name a few. Damage to a boat and
outboard can be fixed in a short period of time, but
injury or death has a lasting effect.
CAUTION When replacement parts are required, use
Evinrude/Johnson Genuine Parts or parts with
Indicates a potentially hazardous situation
equivalent characteristics, including type, strength
which, if not avoided, MAY result in minor
and material. Using substandard parts could
or moderate personal injury or property
result in injury or product malfunction.
damage. It also may be used to alert
against unsafe practices. Torque wrench tightening specifications must be
strictly followed. Replace any locking fastener
IMPORTANT: Identifies information that will (locknut or patch screw) if its locking feature
help prevent damage to machinery and appears becomes weak. Definite resistance to turning
next to information that controls correct assembly must be felt when reusing a locking fastener. If
and operation of the product. replacement is specified or required because the
locking fastener has become weak, use only
These safety alert signal words mean: authorized Evinrude/Johnson Genuine Parts.
ATTENTION! If you use procedures or service tools that are not
BECOME ALERT! recommended in this manual, YOU ALONE must
YOUR SAFETY IS INVOLVED! decide if your actions might injure people or dam-
age the outboard.
,BRP US Inc.
Technical Publications
250 Sea Horse Drive
Waukegan, Illinois 60085 United States
† AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II
are registered trademarks of Tyco International, Ltd.
† Amphenol is a registered trademark of The Amphenol Corporation.
† Champion is a registered trademark of Federal-Mogul Corporation.
† Deutsch is a registered trademark of The Deutsch Company.
† Dexron is a registered trademark of The General Motors Corporation.
† Fluke is a registered trademark of The Fluke Corporation
† Frahm is a registered trademark of James G. Biddle Co.
† Gasoila is a registered trademark of The Federal Process Corporation.
† GE is a registered trademark of The General Electric Company.
† GM is a registered trademark of The General Motors Corporation.
† Locquic and Loctite are registered trademarks of The Henkel Group.
† Lubriplate is a registered trademark of Fiske Brothers Refining Company.
† NGK is a registered trademark of NGK Spark Plugs (U.S.A.) Inc.
† NMEA is a registered trademark of the National Marine Electronics Association.
† Oetiker is a registered trademark of Hans Oetiker AG Maschinen.
† Packard is a registered trademark of Delphi Automotive Systems.
† Permatex is a registered trademark of Permatex.
† Plastigage is a registered trademark of The Dana Corporation.
† STP is a registered trademark of STP Products Company.
† Snap-on is a registered trademark of Snap-on Technologies, Inc.
† ThreeBond is a registered trademark of Three Bond Co., Ltd.
Bombardier logo is a registered trademark of Bombardier, Inc., used under license.
The following trademarks are the property of BRP US Inc. or its affiliates:
Carbon Guard™ Nut Lock™
DPL™ Lubricant QuikStart™
Evinrude ® S.A.F.E.™
Evinrude ® E-TEC ® S.L.O.W.™
Evinrude ® / Johnson ® XD30™ Outboard Oil Screw Lock™
Evinrude ® / Johnson ® XD50™ Outboard Oil SystemCheck™
Evinrude ® / Johnson ® XD100™ Outboard Oil Triple-Guard ® Grease
FasTrak™ Twist-Grip™
Gel-Seal II™ 2+4 ® Fuel Conditioner
Hi-Vis™ Gearcase Lubricant Ultra™ 4-Stroke Outboard Oil
I-Command™ HPF XR™ Gearcase Lubricant
Johnson ® Ultra Lock™
Moly Lube™
Printed in the United States.
© 2006 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
, SAFETY INFORMATION
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This manual is written for qualified, factory-trained Always follow common shop safety practices. If
technicians who are already familiar with the use you have not had training related to common shop
of Evinrude®/Johnson® Special Tools. This man- safety practices, you should do so to protect your-
ual is not a substitute for work experience. It is an self, as well as the people around you.
organized guide for reference, repair, and mainte-
It is understood that this manual may be trans-
nance of the outboard(s).
lated into other languages. In the event of any dis-
This manual uses the following signal words iden- crepancy, the English version shall prevail.
tifying important safety messages.
To reduce the risk of personal injury, safety warn-
DANGER ings are provided at appropriate times throughout
the manual.
Indicates an imminently hazardous situa-
tion which, if not avoided, WILL result in DO NOT make any repairs until you have read the
death or serious injury. instructions and checked the pictures relating to
the repairs.
Be careful, and never rush or guess a service pro-
WARNING cedure. Human error is caused by many factors:
Indicates a potentially hazardous situation carelessness, fatigue, overload, preoccupation,
which, if not avoided, CAN result in severe unfamiliarity with the product, and drugs and alco-
injury or death. hol use, to name a few. Damage to a boat and
outboard can be fixed in a short period of time, but
injury or death has a lasting effect.
CAUTION When replacement parts are required, use
Evinrude/Johnson Genuine Parts or parts with
Indicates a potentially hazardous situation
equivalent characteristics, including type, strength
which, if not avoided, MAY result in minor
and material. Using substandard parts could
or moderate personal injury or property
result in injury or product malfunction.
damage. It also may be used to alert
against unsafe practices. Torque wrench tightening specifications must be
strictly followed. Replace any locking fastener
IMPORTANT: Identifies information that will (locknut or patch screw) if its locking feature
help prevent damage to machinery and appears becomes weak. Definite resistance to turning
next to information that controls correct assembly must be felt when reusing a locking fastener. If
and operation of the product. replacement is specified or required because the
locking fastener has become weak, use only
These safety alert signal words mean: authorized Evinrude/Johnson Genuine Parts.
ATTENTION! If you use procedures or service tools that are not
BECOME ALERT! recommended in this manual, YOU ALONE must
YOUR SAFETY IS INVOLVED! decide if your actions might injure people or dam-
age the outboard.
