PDF Service Manual 2007 Evinrude 115 150 175 200 HP Outboard - 4 MB
Keep your 2007 Evinrude outboard motor running like new with this complete factory service manual.
It covers the 115, 150, 175, and 200 horsepower models, providing step-by-step instructions for everything from basic maintenance to complete engine rebuilds.
Detailed diagrams, wiring schematics, and torque specifications are included to guide you through any repair or service procedure.
This is the same manual used by professional marine mechanics.
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--- Page 3 ---
INTRODUCTION
TYPICAL PAGE – B
TYPICAL PAGE – B
Section Title
INSTALLATION AND PREDELIVERY
OUTBOARD RIGGING PROCEDURE
Subsection
Section Title
Title
Cable, Hose, and Wire Routing If a water pressure gauge is to be used, install the
Route all hoses, control cables, and wiring water pressure hose fitting in the cylinder block.
through a protective sleeve or conduit into the Use Pipe Sealant with Teflon (P/N 910048) on the
boat and through the grommet. threads of the hose fitting. Refer to installation
instructions supplied with gauge.
Refer to the following diagram to ensure proper
positioning of rigging components in grommet. Route the water pressure hose through cover 2
grommet with oil tank sending unit harness. Route
hose along battery cables toward the back of the
powerhead. Use tie straps to fasten in place.
1
1. Fuel supply hose 000084
2. Oil return hose
3. Oil supply hose
4. Battery cables V4 Models DP0827
5. Main wire harness (MWS) 1. Water pressure fitting location: top, starboard side
6. Throttle cable of cylinder/crankcase assembly, below throttle
Model specific position sensor.
7. Shift cable
8. Oil tank sending unit harness illustrations
9. Water pressure hose designated with
10. Accessory charge wire image captions
Connect outboard main wire harness to boat main
wire harness. 1
Before installing electrical connectors, check that
the seal is in place. Clean off any dirt from con-
nectors. Apply a light coat of Electrical Grease™
to the seal. Push connectors together until
latched.
Products and
lubricants italicized V6 Models DP0828
1. Water pressure fitting location: rear of cylin-
der/crankcase assembly
If temperature gauge is to be used, route sending
unit wire through grommet with hose for water
pressure gauge. Follow the path of battery cables.
Provide adequate length to reach cylinder head.
1 Refer to installation instructions supplied with
gauge.
1. Seal DP0824
47
9
--- Page 4 ---
SERVICE SPECIFICATIONS AND SPECIAL TOOLS
TECHNICAL DATA
HP 115 150, 175, 200
675 CCA (845 MCA); or
1
ELECTRICAL
Minimum Battery
750 CCA (940 MCA) below 32°F (0°C)
Requirements
(Use a 107 amp-hr battery for extreme applications.)
Alternator Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation
Tachometer Setting 6 pulse (12 pole)
Charging Isolator Integral, Terminal on Engine Harness
Engine Fuses P/N 967545 – 10 A
Thermostat 143°F (62°C)
COOLING
Maximum Temperature 230°F (110°C) Below 3000 RPM and 194°F (90°C) Above 3000 RPM
Water pressure 21 psi minimum @ 3000 RPM
Type Capacitor Discharge
Firing Order 1-2-3-4 1-2-3-4-5-6
Ignition Features EMM Controlled
IGNITION
RPM Limit 6250
Crankshaft Position Sensor Air
Fixed
Gap
Refer to Emission Control Information Label
Spark Plug Champion † QC10PEPB @ 0.028 ± .003 in. (0.76 mm)
Refer to Emission Control Information Label
V4 “S” Type Gearcase: 13:26 (.500) (2:1)
V4 “O” Type Gearcase: 12:27 (.444) (2.25:1)
V6 “M” Type Gearcase: 13:24 (.542) (1.85:1)
Gear Ratio
V6 “O” Type Gearcase: 14:26 (.538) (1.86:1)
V6 “L” Type Gearcase: 14:26 (.538) (1.86:1)
Refer to GEARCASE TYPES on p. 305
Lubricant HPF XR Gearcase Lubricant
GEARCASE
“S” Type Gearcase: 31.6 fl. oz. (935 ml)
V4 “M” Type Gearcase: 43.0 fl. oz. (1270 ml)
V6 “M” Type Gearcase: 44.0 fl. oz. (1300 ml)
Capacity “M” Type – Counter Rotation: 41 fl. oz. (1220 ml)
“O” Type Gearcase: 33.1 fl. oz. (980 ml)
“L” Type Gearcase: 33.1 fl. oz. (980 ml)
Refer to GEARCASE TYPES on p. 305
20 in. (L) Models: 20.945 (532 mm) ± one-half turn
Shift Rod Height
25 in. (X) Models: 25.945 (659 mm) ± one-half turn
Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD
POWER TRIM/TILT
115 (Single Piston style): Evinrude/Johnson Biodegradeable TNT Fluid
Lubrication 115-200 (Three Piston style): Evinrude/Johnson Power Trim/Tilt & Power Steering
Fluid or GM Dextron † II Automatic Transmission Fluid
Fluid Capacity 21 fl. oz. (622ml)
Trim Range 0° to 21°
Tilt Range 22° to 75°
19
--- Page 5 ---
SERVICE SPECIFICATIONS AND SPECIAL TOOLS
SHOP AIDS
1
HI-VIS™ Gearcase Lube P/N 775605 Triple-Guard® Grease P/N 508298 Extreme Pressure Grease™
P/N 508303
Moly Lube P/N 175356 Needle Bearing Grease, P/N 378642 Starter Bendix Lube P/N 337016
Storage Fogging Oil Power Trim/Tilt and Power Steering Fluid Biodegradeable TNT Fluid
P/N 777186 P/N 775612 P/N 763439
Lubriplate† 777 P/N 317619 Black Neoprene Dip P/N 909570 Electrical Grease P/N 503243
29
--- Page 6 ---
INSTALLATION AND PREDELIVERY
BOAT RIGGING
Battery and Switch Wiring Diagrams
One outboard: Battery disconnect One outboard: One primary starting
battery; one secondary battery
2
S
S
BOTH
ON
1 2
OFF OFF
+ #1 + #1 + #2
PRIMARY PRIMARY SECONDARY
000135rev1
Two outboards: Two starting batteries for each outboard
#1 #2
S
S
BOTH BOTH
1 1 2 1 2 2
OFF OFF
+ + #1 + #2 + #2
#1
PRIMARY SECONDARY SECONDARY PRIMARY
Positive (+) Battery cables
Negative (–) Battery cables 000134N
Accessory charge wires, P/N 5006253
50 amp Fuse
39
--- Page 7 ---
INSTALLATION AND PREDELIVERY
BOAT RIGGING
Clamp Installation Clamp Removal
A constant stress should be applied to close the Method 1: Position Oetiker pincers across clamp
ear clamps. This method ensures a positive stress ear and cut clamp.
on the hose and does not result in excessive com-
pression or expansion of the band material.
IMPORTANT: Use only Oetiker recommended
2
tools to close Oetiker stepless clamps.
Oetiker pincers are available in the
Evinrude/Johnson Genuine Parts and Accesso-
ries Catalog (P/N 787145).
000108
Method 2: Lift end of stepless clamp with screw-
driver.
DP0886
• Position correct size clamp over hose.
• Install hose on fitting.
• Close clamp ear fully with Oetiker pincers (pli-
ers).
000090
Method 3: Use Oetiker pincers (pliers) to grip
clamp. Pull clamp off of connection and discard.
1 2
1. Open clamp 000092
2. Closed clamp
000091
49
--- Page 8 ---
INSTALLATION AND PREDELIVERY
OUTBOARD RIGGING
Refer to the following diagram to ensure proper
OUTBOARD RIGGING positioning of rigging components in grommet.
CAUTION
To prevent accidental starting while servic-
ing, disconnect the battery cables at the 10 6 11 2
battery. Twist and remove all spark plug 9 12
8
leads. 4
7
3
5
Cable, Hose, and Wire Routing 1 2
Remove two screws and bracket that fasten the
grommet to lower motor cover.
1. Fuel supply hose 000095c
2. Fuel supply hose--alternate location
3. Oil supply hose
4. Oil tank sending unit harness
5. Battery cables
1 6. Main wire harness (MWS)
7. Shift cable
8. Throttle cable
9. Accessory charge wires
10. CANbus harness
11. Water pressure hose
12. Speedometer hose
1. Grommet retaining bracket 003964 1
Route all hoses, control cables, and wiring
through a protective sleeve or conduit into the
boat and through the grommet.
The fuel hose may be routed through the protec-
tive sleeve or through an alternate hole in the
lower motor cover grommet.
1. Alternate fuel hose location 004946
To route the fuel hose outside the sleeve, trim the
material covering the alternate fuel hose slot in The main wiring harness, battery cables, oil tank
the grommet. sending unit harness, and any CANbus cables
should be routed along the same path to the star-
1
1. Alternate fuel hose location 003970
59
--- Page 9 ---
INSTALLATION AND PREDELIVERY
FUEL AND OIL PRIMING
Observe oil flow through the oil distribution hoses. Small bubbles are acceptable. Large bubbles
must be eliminated through a continued priming
process.
1
1
2
3 2
1. Oil distribution hose 004398
2. Small bubbles
3. Large bubbles
1. Oil distribution hoses (7) 004965
Make sure that oil flows through the rear oil distri- IMPORTANT: All clear “blue” oil distribution
bution manifold to the cylinder block fittings. hoses on the powerhead should fill with oil as the
air is purged from the lines.
Repair any fuel or oil leaks.
1 The oiling system can also be primed using the
Self-Winterizing feature if diagnostic software is
not available. Refer to STORAGE on p. 91.
1. Rear oil distribution manifold 005271
69
--- Page 10 ---
MAINTENANCE
MAINTENANCE
TABLE OF CONTENTS
INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
SACRIFICIAL ANODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
TESTING PROCEDURE – CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 3
METALLIC COMPONENT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
EXTERIOR FINISHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
WATER INTAKE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
ADDITIONAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
SWIVEL BRACKET AND TRAILERING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
THROTTLE AND SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
BATTERY AND BATTERY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
FUEL AND OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
OIL FILTERS AND OIL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
AIR SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
HOSES AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
EXHAUST PRESSURE FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
FUEL SYSTEM TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
INTERNAL ENGINE TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
ADDITIONAL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
PRE-SEASON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
OUTBOARD MOUNTING BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
BATTERY(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
POWER TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
SUBMERGED ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
ENGINE DROPPED OVERBOARD (NOT RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
ENGINE DROPPED OVERBOARD (RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
ENGINE DROPPED OVERBOARD (IN SALT WATER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
PROLONGED SUBMERSION (FRESH OR SALT WATER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
79
--- Page 11 ---
MAINTENANCE
SPARK PLUGS
Apply Triple-Guard grease to the gasket surface
SPARK PLUGS of the spark plugs. Install all spark plugs and
Spark plugs should be removed and examined tighten them to a torque of 15 ft. lbs. (20 N·m).
periodically. Replace worn, fouled or damaged
spark plugs. If the mark is in unshaded area do not tighten any-
more.
Use only recommended spark plugs with the cor-
rect gap setting.
Spark Plug, Champion 1 2
QC10PEPB @ 0.028 ± 0.003 in. (0.71 mm)
3
• Remove spark plugs and inspect condition.
• Set spark plug gap on new, replacement spark
plugs.
• Mark spark plugs for ground electrode orienta-
tion.
• Apply Electrical Grease to the ribbed portion of Spark Plug Indexing Diagram 004294
the spark plug ceramic and to the opening of 1. Unshaded area
2. Shaded area
the spark plug cover to prevent corrosion.
• Install spark plugs using “indexing” procedure. If the mark is in the shaded area, reset torque
wrench to 30 ft. lbs. (41 N·m) and continue to turn
Indexing until the mark is in the unshaded area.
Spark plug indexing positions the ground elec-
trode of the spark plug opposite the fuel injector If the mark does not reach the unshaded area
nozzle. before the torque of 30 ft. lbs. (41 N·m) is reached,
the spark plug cannot be indexed for that cylinder.
Put an ink mark on the ceramic of the spark plug Try another spark plug and repeat the steps
that is in line with the OPEN side of the ground above.
electrode. This mark will be used to orient the
spark plug with the OPEN side of the ground elec-
trode facing the fuel injector.
2 1
1. Ink mark 000758
2. Open side
89
--- Page 12 ---
ENGINE MANAGEMENT MODULE (EMM)
SENSORS AND FUNCTIONS
If EITHER cylinder head temperature exceeds Oil Pressure Sensor
248°F (120°C), the EMM The oil pressure sensor monitors oil pressure in
Activates SHUTDOWN the oil distribution manifold.
Stores a service code 31 If the sensor fails to indicate pressure in the oil
Flashes EMM NO OIL / OVERHEAT (LED 4) distribution manifold, the EMM:
Flashes SystemCheck TEMP/HOT light
Activates S.A.F.E.
Stores a service code 38
The outboard will not restart, after a temperature
Initiates EMM NO OIL / OVERHEAT (LED 4)
related SHUTDOWN, until the engine temperature
is BELOW 120°C (returns to normal. Refer to Initiates the SystemCheck NO OIL light
SHUTDOWN MODE on p. 103.
If sensor values are below -15°F (-26.1°C) or
If outboard has been run for more than 5 hours
with the existance of NO OIL faults (codes 34 &
4
above 331°F (166.5°C), the EMM: 38), the EMM
Stores a service code 41 Activates SHUTDOWN
Initiates EMM SENSOR FAULT (LED 3) Stores a service code 33
Flashes EMM NO OIL / OVERHEAT (LED 4)
If sensor values are below -4°F (-20°C), the EMM: Flashes SystemCheck NO OIL light
Stores a service code 42
(engine temperature below expected range) IMPORTANT: The outboard will restart for one
Initiates EMM SENSOR FAULT (LED 3) minute intervals until problem is resolved and
code is cleared. To clear code use the diagnostic
If engine does not reach operating temperature on software propram.
PORT cylinder head (122°F / 50°C below 2300 If the sensor circuit fails to indicate within a spe-
RPM) in 10 minutes, the EMM: cific range or fails, the EMM:
Stores a service code 58 Stores a service code 71
(engine not reaching operating temperature)
Initiates EMM SENSOR FAULT (LED 3)
Initiates EMM SENSOR FAULT (LED 3)
If the sensor circuit indicates below expected
If engine does not reach operating temperature on range (<.5 V), the EMM:
STARBOARD cylinder head (122°F / 50°C below
2300 RPM) in 10 minutes, the EMM: Stores a service code 72
Initiates EMM SENSOR FAULT (LED 3)
Stores a service code 59
(engine not reaching operating temperature)
Initiates EMM SENSOR FAULT (LED 3) If the sensor circuit indicates above expected
range (> 4.5 V), the EMM:
Stores a service code73
Initiates EMM SENSOR FAULT (LED 3)
99
--- Page 13 ---
ENGINE MANAGEMENT MODULE (EMM)
EMM DIAGNOSTICS
Oil Control IMPORTANT: Initiate Break-in programming for
rebuilt powerheads.
Oil Injection Ratio
(Used with XD100 oil only) Timing Verification
Evinrude E-TEC outboards can be programmed Use the Ignition Timing screen of the diagnostic
to run a reduced oiling rate. This feature should software to check and adjust EMM timing. EMM
only be used with Evinrude/Johnson XD100 oil. timing must be synchronized to crankshaft posi-
tion.
Refer to TIMING ADJUSTMENTS on p. 157.
1
4
1. Oil control setting 005140
CAUTION
Running an Evinrude E-TEC outboard on