*357683* EXHAUST BACK PRESSURE KIT - P/N SAFETY INFORMATION DANGER WARNING CAUTION NOTICE. Outboard Engines

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1 Outboard Engines EXHAUST BACK PRESSURE KIT - P/N Use this kit on Evinrude E-TEC 115 HP V4 (1.7 L) outboards with 2-piece exhaust. Do NOT install on any other outboards SAFETY INFORMATION The following symbols and/or signal words may be used in this document: DANGER avoided, will result in death or serious injury. WARNING avoided, could result in death or serious injury CAUTION avoided, could result in minor or moderate personal injury. NOTICE Indicates an instruction which, if not followed, could severely damage engine components or other property. These safety alert signal words mean: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! For safety reasons, this kit must be installed by an authorized Evinrude/Johnson dealer. This instruction sheet is not a substitute for work experience. Additional helpful information may be found in other service literature. DO NOT perform any work until you have read and understood these instructions completely. Torque wrench tightening specifications must strictly be adhered to. Should removal of any locking fastener (lock tabs, locknuts, or patch screws) be required, always replace with a new one. When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Use of substandard parts could result in injury or product malfunction. Always wear EYE PROTECTION AND APPRO- PRIATE GLOVES when using power tools. Unless otherwise specified, engine must be OFF (not running) when performing this work. Always be aware of parts that can move, such as flywheels, propellers, etc. Some components may be HOT. Always wait for engine to cool down before performing work. If you use procedures or service tools that are not recommended in this instruction sheet, YOU ALONE must decide if your actions might injure people or damage the outboard. This instruction sheet may be translated into other languages. In the event of any discrepancy, the English version shall prevail. TO THE INSTALLER: Give this sheet and the operating instructions to the owner. Advise the owner of any special operation or maintenance information contained in the instructions. TO THE OWNER: Save these instructions in your owner s kit. This sheet contains information important for the use and maintenance of your engine. Printed in the United States BRP US Inc. All rights reserved. TM, and the BRP logo are registered trademarks of Bombardier Recreational Products Inc. or its affiliates. *357683* 1 of 5

2 KIT CONTENTS Part Number Description QTY EXHAUST BACK PRESSURE KIT 1 HOUSING ASSEMBLY, Inner Exhaust 1 FITTINGS CLAMP, 25.6 mm GASKET (not shown) PROCEDURE Refer to the correct service manual. Remove the engine covers. Remove the exhaust valve actuator. Remove the powerhead. INSTALLATION 1) Center the drill template over the rear of the outer exhaust housing as shown. Use a punch to mark the drill locations. If the template is not available: From the exhaust housing centerline measure out 1-1/8 inch. From the top of the exhaust housing measure down 2-11/16 inch. Drill two 1/8 inch (3.0 mm) pilot holes in the outer exhaust housing at the locations shown. Drill Template of 5

3 2) Enlarge the pilot holes to 9/16 inch (14 mm). Use a 3/8-18 NPT tap to thread the holes. IMPORTANT: Refer to the correct service manual for: the installation of the water tube application of Gel-Seal II orientation of exhaust valve linkage tightening torque values 5) Place hose clamps over each hose. Position the clamps as shown. Install the new inner exhaust assembly into the outer exhaust housing ) Apply PST Thread Sealant, P/N , to the threads of the fittings. Install the fittings as shown ) Assemble the hose onto the fittings of the outer exhaust housing. Position the two clamps as shown. Use Oetiker pincers to secure the clamps ) Install the two hoses onto the fittings of the new inner exhaust housing. Position the two clamps as shown. Use Oetiker pincers to secure the clamps Refer to the correct service manual. Install the powerhead, exhaust valve actuator and engine covers. Run the outboard and inspect for leaks of 5

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5 DRILL TEMPLATE Use the drill template to mark the drill locations on the rear of the outer exhaust housing. IMPORTANT: If printing this document from an electronic file MAKE SURE the print options are set to Actual Size. Do NOT change the scale or the drilled holes will be in the wrong location. Drill Template IMPORTANT: Do NOT scale this document when printing! 5 of 5

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