TABLE OF CONTENTS PREFACE... 3

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3 TABLE OF CONTENTS PREFACE EVINRUDE E-TEC ENGINES , 50, 60 EVINRUDE E-TEC , 50, 60 EVINRUDE E-TEC / 90 EVINRUDE E-TEC / 90 EVINRUDE E-TEC V4 EVINRUDE E-TEC V4 EVINRUDE E-TEC , 175, V6 EVINRUDE E-TEC , 175, V6 EVINRUDE E-TEC , 225, V6 (200 CU. IN. / 3.3 L) EVINRUDE E-TEC , 225, V6 (200 CU. IN. / 3.3 L) EVINRUDE E-TEC , V6 (210 CU. IN. / 3.4 L) EVINRUDE E-TEC , V6 (210 CU. IN. / 3.4 L) EVINRUDE E-TEC MISCELLANEOUS FLUID AND MISCELLANEOUS ADDITIONAL ALLOWANCE ACCESSORIES TABLE OF CONTENTS 2008 BRP US Inc. All rights reserved. TM, and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates. 1

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5 PREFACE This manual provides Warranty Flat Rate Allowances for 2008 outboard models. These manuals can also be useful in determining shop hours required to perform out-of-warranty service work. All flat rate times are based on the actual time required for a factory trained technician to complete the various operations using the appropriate hand tools and Evinrude/Johnson special tools. Flat rate times include an allowance for diagnosis as well as time for the removal and replacement of all components necessary to complete the repair. Where appropriate, the flat rate times also include time for performance tests with recommended test equipment. Notes Codes - Details for specific repair procedure 1 Must have authorization number 2 Includes return packaging 3 Contact dealer services for assistance 4 When servicing or replacing two or more injectors, call for prior authorization. Add 0.5 for lower pan removal when replacing injector assembly on cylinders 5 and 6 (only 90 ) 5 or replacing lower tube assembly. 6 Includes timing verification 7 Add 1.0 for Counter Rotation Models 8 Flat rate time includes removal of lower pans Flat rate time includes removal of oil reservoir. Add 0.5 for removing lower covers (H101) for bot 9 tom injector only. Do not use failing part number if the EMM software update is being performed as a 10 result of a specific warranty bulletin. Refer to applicable warranty bulletin for unique failing part numbers related to specific warranty campaigns. Flat rate times do not include time for painting or repainting. If the warranty repair includes painting, see flat rate codes Y for outboards. TABLE OF CONTENTS Flat rate times do not include the additional work required for removal of corroded screws. Dealers in salt water areas may add this time, when appropriate. See flat rate codes Y for outboards. Only one salt water allowance may be submitted for each repair. Any additional time required due to corrosion will be the responsibility of the customer. (See applicable Evinrude/Johnson Limited Warranty.) Flat rate times shown in this manual are the maximum times allowed for a given repair. Flat rate times are not cumulative. Use only the flat rate time for the longest operation. For example, when rebuilding an outboard gearcase requiring a forward gear, pinion gear, shifter and reverse gear, the longest operation is G111 Forward and Pinion Gear. The use of G107, Reverse Gear and G110, Propshaft or Shift Dog along with G111 is not acceptable as G111 includes time for G107 and G110. In such cases, Evinrude/Johnson After Sales Support will reduce the test time accordingly. Be aware of this when comparing flat rate hours claimed and those actually paid. If Flat Rate times overlap, this extra time will be cut from the claim without notification. If you diagnose an ignition system problem and find you have a fuel system problem instead, you cannot claim the ignition diagnostic time. However, in many cases, it may not be necessary for you to diagnose or test a problem, yet the flat rate time for that job will have test and diagnostic time in it. We believe the occasional loss of time will be more than made up this way. Consult the Warranty Procedures for detailed information on the Evinrude/Johnson warranty and instructions for the preparation, submission, and payment of warranty claims. 3

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7 EVINRUDE E-TEC ENGINES EVINRUDE E-TEC ENGINES 5

8 40, 50, 60 EVINRUDE E-TEC Powerhead Refer to page 3 for note codes Note Code Time Powerhead - Replace 1,2,6,8 P Cylinder Head and O-Ring Seal 8 P Thermostat/Pressure Relief Valve P Exhaust Cover or Gasket P Cylinder and Crankcase - Reseal 1,6,8 P Cylinder and Crankcase - Rebuild 1,6,8 P Crankshaft - Replace 1,6,8 P Upper Crankshaft Seal 1,6,8 P Lower Crankshaft Seal 6,8 P Upper Main Bearing 6,8 P Lower Main Bearing 6,8 P Upper Motor Mounts 8 P Gasket Powerhead to Adapter 8 P Grommet and Insert - Exhaust Relief 8 P Midsection Note Code Time Lower Engine Cover(s) 1 H Steering Arm Assembly H Steering Handle (Tiller) H Cable or Gear - Throttle Control - (Tiller) H Swivel Bracket 3 H Stern Brackets (One or Both) H Lower Mount Bracket H Shift Lever or Handle (Tiller) H Tilt Assist/Cylinder H Cable H Tilt Tube H Trail Lock Arm - Motor Support H Lever and Shaft Trail Lock H Tilt/Run Lever & Shaft or Linkage H Links, Levers or Springs - Reverse Lock H Lever - Tilt Lock H Upper Mounts H Exhaust Housing - Outer 1 H Exhaust Housing - Inner H Water Tube and/or Upper Grommet H Lower Thrust Mounts H Gearcase Note Code Time Gearcase Assembly 1,2 G Gearcase Assembly - Reseal G Gearcase Housing Only - Replace 1 G Pinion Bearing - Replace G Propshaft Bearing Housing - Replace G Propshaft Bearing Housing - Rebuild G Reverse Gear Only - Replace G Lower Driveshaft or Upper Bearing Housing Replace (requires shimming) G Shift Rod Cover/Bushing/O-Ring G Propshaft or Shifter Clutch Dog 1 G Forward and/or Pinion Gear 1 G Shift Housing and/or Forward Bearing Assembly 1 G Water Pump or Upper Bearing Housing Reseal 1 G

9 40, 50, 60 EVINRUDE E-TEC Electrical/Ignition Refer to page 3 for note codes Note Code Time Flywheel 6 E Flywheel Cover 6 E Stator 6 E Ignition Coil Assembly (One) E Ignition Coil Assembly (Each Additional) E Engine Wiring Harness 1,8 E Neutral Safety Switch (Engine Mounted) 8 E Electric Starter Motor - Replace 8 E Electric Starter Motor - Repair 8 E Starter Drive - Repair/Replace 6 E Solenoid - Electric Starter E Water Temperature Switch Sensor E EMM Assembly 1,3,6,8 E EMM Reprogram 10 EP Crank Sensor 6 E Fuse 10 Amp E Relay Assembly E Throttle Sensor E Air Temperature Sensor E Capacitor 8 E Fuel System/Oil System Note Code Time Intake Manifold/Reed Plate - Repair/Replace 8 F Fuel Lift Pump Assembly 8 F Fuel Filter Assembly F Vapor Separator and Electric Fuel Pump Assembly 8 F Oil Manifold and Pick-up Assembly/Grommet/Clamp F Oil Tank Replace F Fuel Manifold Assembly - Return 8 F Fuel Manifold Assembly - Supply 8 F Fuel Injector Assembly - Replace or Service 1,3,9 F Fuel Manifolds All/O-Rings 8 F Fuel Injector Assembly - Replace (Each Additional) 9 FX Throttle Body 8 F EVINRUDE E-TEC ENGINES Power Trim and Tilt Note Code Time Power Trim and Tilt - Replace 1,2 T Manifold - Rebuild/Replace T Motor and Cable - Replace T Motor and Cable - Rebuild T Oil Pump T Tilt Cylinder - Repair T Manual Release Valve T Internal Valves, Spring, O-Rings, Etc. T External Check Valves T Relay Assembly - (Both) T Switch TNT Lower Motor Cover T Sending Unit T

10 75 / 90 EVINRUDE E-TEC Powerhead Refer to page 3 for note codes Note Code Time Powerhead - Replace 1,2,6,8 P Cylinder Head and O-Ring Seal (One) 8 P Thermostat/Pressure Relief Valve (One) P Exhaust Cover or Gasket P Cylinder and Crankcase - Reseal 1,6,8 P Cylinder and Crankcase - Rebuild 1,6,8 P Crankshaft - Replace 1,6,8 P Upper Crankshaft Seal 1,6,8 P Lower Crankshaft Seal 1,6,8 P Upper Main Bearing 1,6,8 P Lower Main Bearing 1,6,8 P Upper Motor Mounts 8 P Gasket Powerhead to Adapter 8 P Grommet and Insert - Exhaust Relief 8 P Midsection Note Code Time Lower Engine Cover(s) 1 H Steering Arm Assembly - Pivot Shaft H Swivel Bracket 3 H Thrust Rollers or Pads Swivel Bracket (Both) H Stern Brackets (One or Both) H Lower Mount Bracket H Shift Lever H Tilt Tube H Trail Lock Arm - Motor Support H Lever and Shaft Trail Lock H Lever - Tilt Lock 1 H Exhaust Housing - Outer 1 H Exhaust Housing - Inner - Upper H Exhaust Housing - Inner - Lower H Water Tube and/or Upper Grommet H Lower Thrust Mounts H Gearcase Note Code Time Gearcase Assembly 1,2 G Gearcase Assembly - Reseal G Gearcase Housing Only - Replace 1 G Pinion Bearing - Replace G Propshaft Bearing Housing - Replace G Propshaft Bearing Housing - Rebuild G Reverse Gear Only - Replace G Lower Driveshaft or Upper Bearing Housing Replace (requires shimming) G Shift Rod Cover/Bushing/O-Ring G Propshaft or Shifter Clutch Dog 1 G Forward and/or Pinion Gear 1 G Shift Housing and/or Forward Bearing Assembly 1 G Water Pump or Upper Bearing Housing Reseal 1 G

11 75 / 90 EVINRUDE E-TEC Electrical/Ignition Refer to page 3 for note codes Note Code Time Flywheel 6 E Flywheel Cover 6 E Stator 6 E Ignition Coil Assembly (One) E Ignition Coil Assembly (Each Additional) E Engine Wiring Harness 1,8 E Neutral Safety Switch (Engine Mounted) 8 E Electric Starter Motor - Replace 8 E Electric Starter Motor - Repair 8 E Starter Drive - Repair/Replace 6 E Solenoid - Electric Starter E Water Temperature Switch Sensor E EMM Assembly 1,3,6,8 E EMM Reprogram 10 EP Crank Sensor 6 E Fuse 10 Amp E Relay Assembly E Throttle Sensor E Air Temperature Sensor E Capacitor 8 E Fuel System/Oil System Note Code Time Intake Manifold/Reed Plate - Repair/Replace 8 F Fuel Lift Pump Assembly 8 F Fuel Filter Assembly F Vapor Separator and Electric Fuel Pump Assembly 8 F Oil Manifold and Pick-up Assembly/Grommet/Clamp F Oil Tank Replace F Fuel Manifold Assembly - Return 8 F Fuel Manifold Assembly - Supply 8 F Fuel Injector Assembly - Replace or Service 1,3,9 F Fuel Manifolds All/O-Rings 8 F Fuel Injector Assembly - Replace (Each Additional) 9 FX Throttle Body 8 F EVINRUDE E-TEC ENGINES Power Trim and Tilt Note Code Time Power Trim and Tilt - Replace 1,2 T Manifold - Rebuild/Replace T Motor and Cable - Replace T Motor and Cable - Rebuild T Valve Body and Pump Assy. - Replace T Reservoir - Replace T Tilt Cylinder - Repair T Manual Release Valve T Internal Valves, Spring, O-Rings, Etc. T Relay Assembly - (Both) T Switch TNT Lower Motor Cover T Sending Unit T Trim Limit Switch T

12 V4 EVINRUDE E-TEC Powerhead Refer to page 3 for note codes Note Code Time Powerhead - Replace 1,2,6 P Cylinder Head and O-Ring Seal (One) P Cylinder Head and O-Ring Seal (Both) P Thermostat (One) P Thermostat (Both) P Cylinder and Crankcase - Reseal 1,6 P Cylinder and Crankcase - Rebuild 1,6 P Crankshaft - Replace 1,6 P Upper Crankshaft Seal 1,6 P Lower Crankshaft Seal 1,6 P Upper Main Bearing 1,6 P Lower Main Bearing 1,6 P Upper Motor Mounts P Gasket Powerhead to Adapter P Grommet - Exhaust Relief P Exhaust Backpressure Fitting P Water Pressure Valve Assembly P Midsection Note Code Time Lower Engine Cover(s) 1 H Steering Arm Assembly - Pivot Shaft H Swivel Bracket 3 H Thrust Rollers or Pads Swivel Bracket (Both) H Stern Brackets (One or Both) H Lower Mount Bracket H Shift Lever H Tilt Tube H Trail Lock Arm - Motor Support H Lever and Shaft Trail Lock H Lever - Tilt Lock H Exhaust Housing - Outer 1 H Exhaust Housing - Inner - Upper 1 H Exhaust Housing - Inner - Lower H Water Tube and/or Grommet H Lower Thrust Mounts H Exhaust valve and shaft H Gearcase Note Code Time Gearcase Assembly 1,2 G Gearcase Assembly - Reseal 1 G Gearcase Housing Only - Replace 1 G Pinion Bearing - Replace 1 G Propshaft Bearing Housing - Replace G Propshaft Bearing Housing - Rebuild G Reverse Gear Only - Replace 1 G Lower Driveshaft or Upper Bearing Housing Replace (requires shimming) 1 G Shift Rod Cover/Bushing/O-Ring 1 G Propshaft or Shifter Clutch Dog 1 G Forward and/or Pinion Gear 1 G Shift Housing and/or Forward Bearing Assembly 1 G Water Pump or Upper Bearing Housing Reseal 1 G

13 V4 EVINRUDE E-TEC Fuel System / Oil System Refer to page 3 for note codes Note Code Time Intake Manifold / Reed Plate - Repair/Replace 6 F Fuel Hose or Connectors - Repair/Replace F Oil Pick Up Assembly - Oil Tank F Fuel Lift Pump Assembly F Fuel Filter Assembly F Vapor Separator and Electric Fuel Pump Assembly F Oil Injector and Manifold Assembly F Rear oil distribution manifold F Oil Pressure Sensor F Fuel Injector Assembly - Replace 3,4,5 F Fuel Injector Assembly - Replace (Each Additional) 4 FX One or Both Fuel Manifolds or All O-Rings 5 F Throttle Body Assembly F Electrical / Ignition Note Code Time Flywheel 6 E Flywheel Cover - Lower 6 E Stator 6 E Ignition Coil Assembly (One) E Ignition Coil Assembly (Each Additional) E Engine Wiring Harness 1 E Shift Switch E Electric Starter Motor - Replace E Electric Starter Motor - Repair E Solenoid - Electric Starter E Temperature Sensor E EMM Assembly 1,3,6 E EMM Reprogram 10 EP Crank Sensor (CPS) 6 E Fuse 10 Amp E Throttle Sensor (TPS) E Air Temperature Sensor E Capacitor E Exhaust Valve Actuator E Exhaust Valve Control Module E EVINRUDE E-TEC ENGINES Power Trim and Tilt Note Code Time Power Trim and Tilt - Replace 1,2 T Manifold - Rebuild/Replace T Motor and Cable - Replace T Motor and Cable - Rebuild T Valve Body and Pump Assy. - Replace T Reservoir - Replace T Trim Cylinder - Repair (One) T Trim Cylinder - Repair (Both) T Tilt Cylinder - Repair T Manual Release Valve T Internal Valves, Spring, O-Rings, Etc. T Relay Assembly - (Both) T Switch TNT Lower Motor Cover T Sending Unit T Trim Limit Switch T

14 150, 175, V6 EVINRUDE E-TEC Powerhead Refer to page 3 for note codes Note Code Time Powerhead - Replace 1,2,6 P Cylinder Head and O-Ring Seal (One) P Cylinder Head and O-Ring Seal (Both) P Thermostat (One) P Thermostat (Both) P Cylinder and Crankcase - Reseal 1,6 P Cylinder and Crankcase - Rebuild 1,6 P Crankshaft - Replace 1,6 P Upper Crankshaft Seal 1,6 P Lower Crankshaft Seal 1,6 P Upper Main Bearing 1,6 P Lower Main Bearing 1,6 P Upper Motor Mounts P Gasket Powerhead to Adapter P Grommet - Exhaust Relief P Exhaust Pressure Fitting P Water Pressure Valve Assembly P Midsection Note Code Time Lower Engine Cover(s) 1 H Steering Arm Assembly - Pivot Shaft H Swivel Bracket 3 H Thrust Rollers or Pads Swivel Bracket (Both) H Stern Brackets (One or Both) H Lower Mount Bracket H Shift Lever H Tilt Tube H Trail Lock Arm - Motor Support H Lever and Shaft Trail Lock H Lever - Tilt Lock H Exhaust Housing - Outer 1 H Exhaust Housing - Inner - Upper 1 H Exhaust Housing - Inner - Lower H Water Tube and/or Grommet H Lower Thrust Mounts H Gearcase Note Code Time Gearcase Assembly 1,2 G Gearcase Assembly - Reseal 1 G Gearcase Housing Only - Replace 1 G Pinion Bearing - Replace 1 G Propshaft Bearing Housing - Replace G Propshaft Bearing Housing - Rebuild G Reverse Gear Only - Replace 1,7 G Lower Driveshaft or Upper Bearing Housing Replace (requires shimming) 1 G Shift Rod Cover/Bushing/O-Ring 1 G Propshaft or Shifter Clutch Dog 1 G Forward and/or Pinion Gear 1 G Shift Housing and/or Forward Bearing Assembly 1 G Water Pump or Upper Bearing Housing Reseal 1 G

15 150, 175, V6 EVINRUDE E-TEC Fuel System / Oil System Refer to page 3 for note codes Note Code Time Intake Manifold / Reed Plate - Repair/Replace(One) F Fuel Hose or Connectors - Repair/Replace F Oil Pick Up Assembly - Oil Tank F Fuel Lift Pump Assembly F Fuel Filter Assembly F Vapor Separator and Electric Fuel Pump Assembly F Oil Injector and Manifold Assembly F Rear oil distribution manifold F Oil Pressure Sensor F Fuel Injector Assembly - Replace 3,4,5 F Fuel Injector Assembly - Replace (Each Additional) 4 FX One or Both Fuel Rails or All O-Rings 5 F Throttle Body F Electrical/ Ignition Note Code Time Flywheel 6 E Flywheel Cover - Lower 6 E Stator 6 E Ignition Coil Assembly (One) E Ignition Coil Assembly (Each Additional) E Engine Wiring Harness 1 E Shift Switch E Electric Starter Motor - Replace E Electric Starter Motor - Repair E Solenoid - Electric Starter E Temperature Sensor E EMM Assembly 1,3,6 E EMM Reprogram 10 EP Crank Sensor (CPS) 6 E Fuse 10 Amp E Throttle Sensor (TPS) E Air Temperature Sensor E Capacitor E EVINRUDE E-TEC ENGINES Power Trim and Tilt Note Code Time Power Trim and Tilt - Replace 1,2 T Manifold - Rebuild/Replace T Motor and Cable - Replace T Motor and Cable - Rebuild T Valve Body and Pump Assy. - Replace T Reservoir - Replace T Trim Cylinder - Repair (One) T Trim Cylinder - Repair (Both) T Tilt Cylinder - Repair T Manual Release Valve T Internal Valves, Spring, O-Rings, Etc. T Relay Assembly - (Both) T Switch TNT Lower Motor Cover T Sending Unit T Trim Limit Switch T

16 200, 225, V6 (200 CU. IN. / 3.3 L) EVINRUDE E-TEC Powerhead Refer to page 3 for note codes Note Code Time Powerhead - Replace 1,2,6 P Cylinder Head and Gasket (One) P Cylinder Head and Gasket (Both) P Thermostat/Pressure Relief Valve (One) P Thermostat/Pressure Relief Valve (Both) P Cylinder and Crankcase - Reseal 1,6 P Cylinder and Crankcase - Rebuild 1,6 P Crankshaft - Replace 1,6 P Upper Crankshaft Seal 6 P Lower Crankshaft Seal P Upper Main Bearing 6 P Lower Main Bearing P Gasket Powerhead to Adapter P Water Pressure Valve Assembly P Midsection Note Code Time Lower Engine Cover(s) 1 H Steering Arm Assembly - Pivot Shaft H Swivel Bracket 3 H Thrust Rollers or Pads Swivel Bracket (Both) H Stern Brackets (One or Both) H Lower Mount Bracket H Shift Lever H Tilt Tube H Trail Lock Arm - Motor Support H Lever and Shaft Trail Lock H Adapter H Upper Mounts H Exhaust Housing - Outer 1 H Exhaust Housing - Inner - Upper 1 H Exhaust Housing - Inner - Lower H Water Tube and/or Upper Grommet H Lower Thrust Mounts H Exhaust Back Pressure Nipple H Gearcase Note Code Time Gearcase Assembly 1,2 G Gearcase Assembly - Reseal 1 G Gearcase Housing Only - Replace 1 G Pinion Bearing - Replace 1 G Propshaft Bearing Housing - Replace G Propshaft Bearing Housing - Rebuild 7 G Reverse Gear Only - Replace 1 G Lower Driveshaft or Upper Bearing Housing Replace (requires shimming) 1 G Shift Rod Cover/Bushing/O-Ring G Propshaft or Shifter Clutch Dog 1 G Forward and/or Pinion Gear 1 G Shift Housing and/or Forward Bearing Assembly 1 G Water Pump or Upper Bearing Housing Reseal 1 G Additional time for a pressed rear bearing gearcase GX

17 200, 225, V6 (200 CU. IN. / 3.3 L) EVINRUDE E-TEC Fuel System / Oil System Refer to page 3 for note codes Note Code Time Intake Manifold/Reed Plate - Repair/Replace 6 F Fuel Hoses or Connectors - Repair/Replace F Oil Pick Up Assembly - Oil Tank F Fuel Lift Pump Assembly F Fuel Filter Assembly F Water Sensor Assembly F Vapor Separator and Electric Fuel Pump Assembly F Oil Injector Assembly - Replace Manifold Assembly F Rear Oil distribution manifold F Oil Pressure Sensor F Fuel Injector Assembly - Replace or Service 4,5 F Fuel Injector Assembly - (Each Additional) 4 FX One or Both Fuel Rails or All O-Rings 5 F Throttle Body Assembly F Electrical / Ignition Note Code Time Flywheel 6 E Stator 6 E Ignition Coil Assembly (One) E Ignition Coil Assembly (Each Additional) E Engine Wiring Harness 1 E Shift Assist Switch E Electric Starter Motor - Replace E Electric Starter Motor - Repair E Solenoid - Electric Starter E Temperature Sensor E EMM Assembly 1,3,6 E EMM Reprogram 10 EP Crank Sensor Assembly (CPS) 6 E Fuse 10 Amp E Throttle Sensor (TPS) E Sensor Assembly Air Temperature (AT) E Capacitor E EVINRUDE E-TEC ENGINES Power Trim and Tilt Note Code Time Power Trim and Tilt - Replace 1,2 T Manifold - Rebuild/Replace T Motor and Cable - Replace T Motor and Cable - Rebuild T Valve Body and Pump Assy. - Replace T Reservoir - Replace T Trim Cylinder - Repair (One) T Trim Cylinder - Repair (Both) T Tilt Cylinder - Repair T Manual Release Valve T Internal Valves, Spring, O-Rings, Etc. T Relay Assembly - (Both) T Switch TNT Lower Motor Cover T Sending Unit T Trim Limit Switch T

18 250, V6 (210 CU. IN. / 3.4 L) EVINRUDE E-TEC Powerhead Refer to page 3 for note codes Note Code Time Powerhead - Replace 1,2,6 P Cylinder Head and Gasket (One) P Cylinder Head and Gasket (Both) P Thermostat/Pressure Relief Valve (One) P Thermostat/Pressure Relief Valve (Both) P Cylinder and Crankcase - Reseal 1,6 P Cylinder and Crankcase - Rebuild 1,6 P Crankshaft - Replace 1,6 P Upper Crankshaft Seal 6 P Lower Crankshaft Seal P Upper Main Bearing 6 P Lower Main Bearing P Gasket Powerhead to Adapter P Water Pressure Valve Assembly P Midsection Note Code Time Lower Engine Cover(s) 1 H Steering Arm Assembly - Pivot Shaft H Swivel Bracket 3 H Thrust Rollers or Pads Swivel Bracket (Both) H Stern Brackets (One or Both) H Lower Mount Bracket H Shift Lever H Tilt Tube H Trail Lock Arm - Motor Support H Lever and Shaft Trail Lock H Upper Mounts H Exhaust Housing - Outer 1 H Exhaust Housing - Inner - Upper 1 H Exhaust Housing - Inner - Lower H Water Tube and/or Upper Grommet H Lower Thrust Mounts H Exhaust Back Pressure Nipple H Gearcase Note Code Time Gearcase Assembly 1,2 G Gearcase Assembly - Reseal 1 G Gearcase Housing Only - Replace 1 G Pinion Bearing - Replace 1 G Propshaft Bearing Housing - Replace G Propshaft Bearing Housing - Rebuild 7 G Reverse Gear Only - Replace 1 G Lower Driveshaft or Upper Bearing Housing Replace (requires shimming) 1 G Shift Rod Cover/Bushing/O-Ring G Propshaft or Shifter Clutch Dog 1 G Forward and/or Pinion Gear 1 G Shift Housing and/or Forward Bearing Assembly 1 G Water Pump or Upper Bearing Housing Reseal 1 G

19 250, V6 (210 CU. IN. / 3.4 L) EVINRUDE E-TEC Fuel System / Oil System Refer to page 3 for note codes Note Code Time Intake Manifold/Reed Plate - Repair/Replace 6 F Fuel Hoses or Connectors - Repair/Replace F Oil Pick Up Assembly - Oil Tank F Fuel Lift Pump Assembly (One/Both) F Fuel Filter Assembly F Water Sensor Assembly F Vapor Separator and Electric Fuel Pump Assembly F Oil Injector Assembly - Replace Manifold Assembly F Rear Oil distribution manifold F Oil Pressure Sensor F Fuel Injector Assembly - Replace or Service 4,5 F Fuel Injector Assembly - (Each Additional) 4 FX One or Both Fuel Rails or All O-Rings 5 F Throttle Body Assembly F Electrical / Ignition Note Code Time Flywheel 6 E Stator 6 E Ignition Coil Assembly (One) E Ignition Coil Assembly (Each Additional) E Engine Wiring Harness 1 E Shift Assist Switch E Electric Starter Motor - Replace E Electric Starter Motor - Repair E Solenoid - Electric Starter E Temperature Sensor E EMM Assembly 1,3,6 E EMM Reprogram 10 EP Crank Sensor Assembly (CPS) 6 E Fuse 10 Amp E Throttle Sensor (TPS) E Sensor Assembly Air Temperature (AT) E Capacitor E EVINRUDE E-TEC ENGINES Power Trim and Tilt Note Code Time Power Trim and Tilt - Replace 1,2 T Manifold - Rebuild/Replace T Motor and Cable - Replace T Motor and Cable - Rebuild T Valve Body and Pump Assy. - Replace T Reservoir - Replace T Trim Cylinder - Repair (One) T Trim Cylinder - Repair (Both) T Tilt Cylinder - Repair T Manual Release Valve T Internal Valves, Spring, O-Rings, Etc. T Relay Assembly - (Both) T Switch TNT Lower Motor Cover T Sending Unit T Trim Limit Switch T

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21 MISCELLANEOUS MISCELLANEOUS 19

22 FLUID AND MISCELLANEOUS The following part numbers have been established to issue credit vouchers. These part numbers represent an average amount of gearcase lube, power trim and tilt fluid, and motor oil used when making warranty repairs. Select the correct part number from the following list and enter it in the List All Parts Used in Repair section of the warranty claim form. Part Number Category Dealer Net U.S. Dealer Net CA Outboard Gearcases HP Gearcases $1.20 $ HP 2 & 4 Stroke Gearcases $3.05 $ HP 2 & 4 Stroke Gearcases $6.40 $ V-4 Gearcases / 2 & 4 Stroke $8.50 $ V6 Gearcase $8.50 $11.48 IMPORTANT: Gearcase oil dollar amounts (Dealer Net) are based on a single gallon quantity at dealer cost, using Evinrude/Johnson Ultra-HPF. Part Number Category Dealer Net U.S. Dealer Net CA Motor Oil 4-Stroke Outboard Powerhead , 5, 6, 8 HP 4-Stroke Powerhead $ 2.50 $ /15 HP 4-Stroke Powerhead $ 2.50 $ /50 HP 4-Stroke Powerhead $ 6.25 $ /70 HP 4-Stroke Powerhead $12.00 $ /115/140 HP 4-Stroke Powerhead $15.00 $22.50 Part Number Category Dealer Net U.S. Dealer Net CA Miscellaneous Paint, Primer, Degreaser, or Marine Cleaner $4.25 $ Heli - Coil Insert $0.50 $ Trim & Tilt - Outboard $1.25 $ Rope Manual Start - Outboard $2.00 $ Fuel Hose - Outboard $1.00 $

23 ADDITIONAL ALLOWANCE Outboard Note Code All Others 3 Cyl. V4 V6 Saltwater Allowance for Major Repair 1 Y Priming and Painting Y Heli-Coil Repair (One) 2 Y NOTE: See Fluid and Miscellaneous section of this manual for part numbers for paint, Heli-Coils, etc. 1. Y102 Saltwater allowance may not be used on new motors. 2. May be used in conjunction with other flat rate codes that may be needed to expose the area to be repaired. ACCESSORIES Controls Note Code Time Remote Control Assy. - External Mount - Replace R Remote Control - External Mount - Repair 1 R Remote Control Assy. Binnacle Mount - Replace R Remote Control - Binnacle - Repair 1 R Remote Control Assy. - Concealed Mount - Replace R Remote Control - Concealed Mount - Repair 1 R Shift and Throttle Control Handle - Replace R Shift and Throttle Cable - Replace R Trim Switch (In Control Handle) R Horn-Clamped to Wiring Harness R Horn-Mounted Inside Control Box R Key Switch (In Dash) R Stop Switch (In Dash) R Wiring Harness (Engine to Dash) R Trim Switch (Tiller Handle) R Remote control repair includes the repair or replacement of any internal component such as switches, levers, cams, or electrical cables, etc. MISCELLANEOUS Gauges Note Code Time Replace Gauge - One GR1 0.5 Replace Gauge - Each Additional GR2 0.3 Instrument Panel GR3 1.0 Fuel System Note Code Time Fuel Tank - Manifold Repair or Replace (3 or 6 Gallons) F Accu-Mix - Repair F

24 CUSTOMER COMMENT CODES Evinrude/Johnson has revised the customer comment codes to assist our Quality Assurance Department. This change will help Evinrude/Johnson identify and correct any problem areas in a timely manner. New numbers have been assigned to these codes. We now have fewer codes, which will make your selection easier. These comment codes are to be used to describe the condition of the failing part number used on the claim. Choose the comment code from the list that is best suited for the failure. Cosmetics/Paint General Missing part on engine Wrong part on engine Chipped Grounded/Shorted Peeling/Flaking Open circuit Cracked Burned Scratched/Scraped High output Run/Sag No/Low output Blistered Warning malfunction Corrosion Erratic/Intermittent Shipping/Packaging Adjustment Foreign material Noisy Missing part in package Mismachined Wrong part in package Misassembled Damaged in shipment Tight/Sticking Kinked/Bent Seized/Scuffed Restricted Pinched Fractured/Broken Split Stripped Loose Leaking Cut Deformed/Warped Rounded Software Revision Field Campaign 22

25 REQUEST FOR REVIEW OF FLAT RATE TIME STANDARD Dealer Name: Dealer Code: Sender s Name: This Business Reply Form is for your convenience to request a review of a Flat Rate Time Standard. The information you provide will assist in our efforts to pay for warranty work fairly. Thank you for your help. Address: Phone: City, State, and Zip: Date: Engine Model # Serial # (Optional) Flat Rate Code: Time From Manual: What do you feel time allowed should be? Did the type of boat significantly affect repair time? If the above answer is yes, please give the following information: Make of Boat: Model: Year: Comments: MISCELLANEOUS To mail, fold this form in thirds and secure with tape In House use only: Model Years Affected Authorization 23

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