2003 Johnson Evinrude 75HP 90HP 115HP Parts Catalog Manual DOWNLOAD

E75FPLSTA E90FPLSTB E90FSLSTB E115FPLSTB E115FPXSTB E115FSLSTB

75, 90, 115 60° V4

75, 90, 115HP MODELS

ABOUT THIS CATALOG Bombardier reserves the right to make changes at any time, without notice, to features, specifications, and model availability. The right is also reserved to change any specification or part, at any time, without incurring any obligation to update older models. The information in this catalog is based on the latest specifications available at the time of publication.

Illustrations are for reference only and might not depict the actual equipment described. Specifications and recommendations are based on the latest information available at the time of publication. The continuing accuracy of this booklet cannot be guaranteed.

Certain features or equipment shown in this catalog might not be found on all models in all marketing areas.

IMPORTANT: This catalog is a part reference. Refer to the appropriate Service Manual for exact service and maintenance information.

FEATURES

Indented part names indicate that the parts are included in the preceding assembly.

1 2 3 4 5 6

582365 581027 510231 580339 510231 328701

LEAD As s y, Spark Plug *COVER & TERMINAL As s y **TERMINAL, Spring *COVER & TERMINAL As s y **TERMINAL, Spring LOCK WASHER, COIL & s top s w. grd

Use exact engine model number, including any suffix letter, when indentifying parts in this catalog.

WARNING When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength, and material.

Using substandard parts could result in injury or product malfunction.

TABLE OF CONTENTS DECALS - “WHITE” MODELS ....................................................................................................... 2 DECALS - “BLUE” MODELS ......................................................................................................... 3 ENGINE COVER ........................................................................................................................ 4-5 LOWER ENGINE COVER .......................................................................................................... 6-7 ENGINE ELECTRICAL HARNESS ASSEMBLY ........................................................................ 8-9 ELECTRICAL SYSTEM .......................................................................................................... 10-11 FUEL COMPONENTS ............................................................................................................ 12-13 OIL COMPONENTS ............................................................................................................... 14-15 INTAKE MANIFOLD ............................................................................................................... 16-17 ELECTRIC STARTER ................................................................................................................. 18 CRANKSHAFT AND PISTONS ................................................................................................... 19 CYLINDER AND CRANKCASE ............................................................................................. 20-21 EXHAUST HOUSING .................................................................................................................. 22 POWER TRIM/TILT HYDRAULIC ASSEMBLY ........................................................................... 23 MIDSECTION ......................................................................................................................... 24-25 GEARCASE - FPL, FSL MODELS ......................................................................................... 26-27 GEARCASE - FPX MODELS ................................................................................................. 28-29 STEERING LINK ......................................................................................................................... 30 DUAL STEERING CONNECTOR KIT ......................................................................................... 30

5005259 5005058 215420 215421 215422 215423

SERVICE MANUAL – ENGLISH ENGINE DIAGNOSTIC SOFTWARE OPERATOR’S GUIDE – ENGLISH OPERATOR’S GUIDE – FRENCH OPERATOR’S GUIDE – SPANISH OPERATOR’S GUIDE – PORTUGUESE

PAINT COLOR NAME PRIMER BLACK 3 BLUE WHITE CLEARCOAT

SPRAY CAN

PPG # 1

PPG # 2

771227 771234 771230 771226 772414

DP40401 9696 18319 90538 –

– – 18320 – –

1. BASE COAT PLUS CLEARCOAT FOR UPPER & LOWER ENGINE COVERS 2. ONE COAT FINISH FOR MIDSECTION & GEARCASE 3. USED ON ENGINE CRANKCASE ASSEMBLY.

1

75, 90, 115 60° V4

LITERATURE

DECALS - “WHITE” MODELS

2 1

3

4

5

6

8

7

EPC3675 Ref 1 2 3 4

P/N 215288 215290 215289 215276

Name of Part *DECAL, "EVINRUDE " Port/Stbd *DECAL, Stripe, Port *DECAL, Stripe, Stbd *DECAL, "FICHT " Port/Stbd

A A A A

Ref 5 6 7 8

Qty 2 1 1 2

A Included with "ENGINE COVER Assy"

2

P/N 215279 215287 215343 215293

Name of Part *DECAL, "EVINRUDE " F/R *DECAL, "BOMBARDIER " F/R DECAL 90HP F/R DECAL 115 HP F/R

A A

Qty 2 1 2 2

DECALS - “BLUE” MODELS

2 1

3

75, 90, 115 60° V4

4

6 5

7

8

9

EPC3676 Ref 1 2 3 4 5

P/N 215270 215245 215246 215240 215243

Name of Part *DECAL, "EVINRUDE" Port/Stbd *DECAL, Stripe, Port *DECAL, Stripe, Stbd *DECAL, "FICHT " Port/Stbd *DECAL, "EVINRUDE " F/R

A A A A A

Ref 6 7 8 9

Qty 2 1 1 2 2

A Included with "ENGINE COVER Assy"

3

P/N 215238 215223 215224 215225

Name of Part *DECAL, "BOMBARDIER " F/R DECAL 75 HP F/R DECAL 90HP F/R DECAL 115 HP F/R

A

Qty 2 2 2 2

ENGINE COVER

5

6 7

3 2 1 1 3 4

4

4

ENGINE COVER EPC3000 Ref

1 2 3

P/N 5004953 285600 328744 344387 346780

Name of Part ENGINE COVER Assy ENGINE COVER Assy *SCREW *SEAL *LATCH BRACKET

Qty A,C 1 B,C 1 4 1 2

Ref 4 5 6 7

P/N 5001931 348857 348856 431929

Name of Part *HOOK Assy *SOUND BLANKET, Port *SOUND BLANKET, Stbd ADHESIVE KIT, Locating brackets

Qty 2 1 1 2

75, 90, 115 60° V4

A BLUE - Engine Cover B WHITE - Engine Cover C IMPORTANT: When ordering "ENGINE COVER Assy" also order appropriate "HP" decals.

5

LOWER ENGINE COVER 2 3 4 5

18 7

8

42

6

42

44

1

9

42

17 10

16

11

16

34

16

41 40

24

43

25 23

28 29

26 22

23

27

15 34

14 13 12 10

34

30 31

36

32 33 34

21

38 42

20

35

19

37

6

39

LOWER ENGINE COVER EPC3001

A B C D

P/N 5004969 5005012 586074 514679 514686 514682 334656 339575 328735 309485 308532 435026 330234 343578 342191 335499

Name of Part COVER Assy, Lower - Port COVER Assy, Lower - Port *SWITCH Assy, Trim & tilt **TERMINAL, Pin **CONNECTOR, 3-pin **LOCK WEDGE *NUT, Switch *SCREW, Ball joint *WASHER, Screw, ball joint *NUT, Screw, ball joint *BUSHING, Latch lever *LATCH HANDLE *SPRING WASHER, Latch handle *HOOK, Front & rear *SCREW, Handle to latch *SEAL, Port *SEAL, Engine cover 5004576 *VALVE Assy 307256 *LUBRICATION FITTING 5004970 COVER Assy, Lower - Stbd 5005014 COVER Assy, Lower - Stbd 315656 *SCREW, Access panel 438604 *ACCESS PANEL 435026 *LATCH HANDLE

Ref 23 24 25 26 27 28 29 30 31 32 33 34 35 35 36 37 38 39 40 41 42 43 44

Qty 1 1 1 3 1 1 1 1 1 1 2 1 1 1 1 D 1 C 1 1 A 1 B 1 2 1 1 A B

P/N 308532 307256 330234 436048 202893 343578 342191 335500 309485 328735 339575

Name of Part Qty *BUSHING, Latch lever 2 *LUBRICATION FITTING 1 *SPRING WASHER, Latch handle 1 1 *CHECK VALVE Assy, Drain *O-RING 1 *HOOK, Front & rear 1 *SCREW, Handle to latch 1 *SEAL, Stbd D 1 *NUT, Screw, ball joint 1 *WASHER, Screw, ball joint 1 1 *SCREW, Ball joint *SEAL, Engine cover C 350040 *COVER, Cable entry A 1 350206 *COVER, Cable entry B 1 1 5004576 *VALVE Assy 343505 SCREW, Cover 3 348811 GROMMET, Cable entry 1 343912 SLEEVE, Fuel & electrical 1 349556 WASHER, Mount 4 349557 MOUNT, Lower cover 4 325115 SCREW, Lower cover 1 3/4 in. (44.5mm) 4 333676 SCREW, Lower cover 1 1/4 in. (31.8mm) 1 317972 SCREW, Lower cover 4 1/4 in. (107.9mm) 1

Painted BLUE Painted WHITE Cut to length from P/N 331018 Included in POWERHEAD GASKET SET

75, 90, 115 60° V4

Ref 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19 20 21 22

7

ENGINE ELECTRICAL HARNESS ASSEMBLY PDP GROUND

STARTER SOLENOID SAC CIRCUIT

6 3

OIL PRESSURE SWITCH

26,37,38

9

WATER IN FUEL SENSOR

1,2,27

STARTER SOLENOID BAT + STARTER SOLENOID GROUND

OIL INJECTOR

1,2,27

(36 in position "A","C")

47

DIAGNOSTIC PLUG COVER

STARTER SOLENOID START DELAY CIRCUIT

PDP

1,2,27

(55 in position "P") 20 AIR TEMP SENSOR

26,29, 33

9

TILT LIMIT SWITCH

50,51 40,41,49

8 EMM GROUND

1,2,27 CRANKSHAFT POSITION SENSOR

27,28,32

24

(43, position in 19,20) 39,42

TRIM SENDER

FUSE

13 27,28,32

EMM

TRIM AND TILT SWITCH

15,45 WATER TEMP SWITCH

THROTTLE POSITION SENSOR

21,22,25

DIODE

(43, in position 2,5,8,11)

10 IGNITION COILS

47

GROUND, FUEL INJECTORS

47

7,27,57

GROUND, IGNITION COILS

47

FUEL INJECTOR #1

1,2,27

23

39,42 FUEL INJECTOR #3

27,28,32

1,2,27

DIAGNOSTIC DIODE

10

EMM

START DELAY RELAY CONNECTOR

19,48,56

23 16,17,18 EMM

11

1,2,27

START DELAY RELAY

FILTER MODULE

26,31,35

12

SYSTEM CHECK

4,5,14

27,30,34

CAPACITOR ASSY

KEY SWITCH

46

26,29,33

26,37,38

TRIM AND TILT

OIL TANK

70 AMP RELAY

52,53,54 70 AMP RELAY CONNECTOR

1,2,27 FUEL INJECTOR #4

44 CAPACITOR COVER

1,2,27 FUEL PUMP

50,51 WATER TEMP SENSOR

FUEL INJECTOR #2

8

1,2,27

ENGINE ELECTRICAL HARNESS ASSEMBLY EPC3002

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 A B C D

P/N 586716 127287 176295 204053 327283 332067 204363 176529 510818 511829 583898 586224 586397 320107 512550 513356 513664 513665 513667 511866 513439 513773 514485 514768 514591 514679 514680 514681

Name of Part ENGINE HARNESS Assy *LOCKWEDGE - 2 Socket *CONNECTOR - 2 Socket A *TERMINAL, Ring, Solenoid Bat + *WASHER, Lock, Capacitor screw *SCREW, Capacitor leads *TERMINAL, Ring, PDP Ground *CONNECTOR, 4 Socket B *TERMINAL, Ring, EMM ground *TERMINAL, Ring, SAC Circuit *DIODE KIT *RELAY, Start Delay *RELAY, 70 AMP *TIE STRAP, Harness to cyl assy, stbd *TERMINAL, Ring, Capacitor *CONNECTOR - 1 Socket, Water temp *CONNECTOR - 2 Connector, EMM C *PLUG, Connector seal *TERMINAL, Receptacle *CONNECTOR - 5 Terminal male *TERMINAL, Socket *TERMINAL, Pin **SEAL *TUBING, Convoluted D *FUSE, 20 AMP *CONNECTOR - 3 Pin E *TERMINAL, Pin *TERMINAL, Socket *LOCK WEDGE - 3 Socket

Qty 1 10 10 1 4 2 1 1 1 2 3 1 1 1 2 1 1 1 2 1 13 3 3

Ref 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

1 1 14 38 3

Includes P/N 514788 Seal Includes P/N 514769 Seal Includes P/N 911729 O-Ring Cut to length from P/N 3010608

P/N 514682 514683 514684 514685 514686 514687 514688 514690 514696 514697 514740 514823 514824 514856 514858 514889 581656 3010206 600138 513166 3010023 3010124 3010125 3010126 3010128 3010129 914672 513167 127484

Name of Part *LOCK WEDGE - 3 Pin *LOCK WEDGE - 6 Socket *LOCK WEDGE - 6 Pin *CONNECTOR - 3 Socket *CONNECTOR - 3 Pin *CONNECTOR - 6 Socket *CONNECTOR - 6 Pin *PLUG, Sealing *CONNECTOR - 2 Pin *LOCK, WEDGE - 2 Pin *CONNECTOR - 24 Socket *TERMINAL *CONNECTOR - 4 Socket *TERMINAL *PLUG, Sealing *COVER, Capacitor *TERMINAL Assy, Socket *CAPACITOR *TERMINAL, Ring, Ground *TERMINAL, Receptacle *SEAL, Terminal *CONNECTOR, 2 Pin *TERMINAL Socket *CONNECTOR, Relay *TERMINAL, Receptacle *TERMINAL, Receptacle *PLUG *TERMINAL, Receptacle *LOCK,WEDGE - 4 Socket

E Includes P/N 3010398 Seal F Includes P/N 514789 Seal G Includes P/N 514790 Seal

9

Qty 2 1 1 F 3 2 G 1 1 2 2 2 2 4 1 41 6 1 1 1 4 2 4 2 4 1 2 2 1 2 1

75, 90, 115 60° V4

Ref

ELECTRICAL SYSTEM 25

102 100 101

99 31

11 18 46

13

39 41

38

95

50 31

31 14

51

2

16 30

48

40

19

20

10

37 15

24

21

4 97 96

52

99

98

31

49

71 70

12

5 67

103

7

104

72

45

8 9 29

31

68 69 66

1

87 65

42

23

76

79 74

43

45 89

77

80 88

73 93

94

55 45

90 91

84 85

83

36 56

57

63

92

53

60

47

54

34 32 17

30

86

79

3

27 28

82 85

75

78

26

6

81 44

55

62 57 58 45

36

31

22 64 61

45 33

35

59

10

31

ELECTRICAL SYSTEM

Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

P/N 586526 336135 328703 5004519 341613 343525 328703 333040 338558 329518 332226 324814 514891 909533 328735 344789 331025 332226 343468 344776 315656 328724 350056 330151 344794 176509 514796 127468 335328 317893 320107 328703 328724 514766 586224 328700 315656 586523 514679 514696 514697 5004960 350071

Name of Part Qty FLYWHEEL Assy 1 SCREW, Flywheel 5 WASHER, Flat 1 1 COVER Assy, Flywheel *BUSHING, Pinion & shaft to cover 1 SCREW, Stator mounting 6 WASHER, Flat 2 ISOLATOR/MOUNT, EMM, rear 2 FLANGED SPACER, EMM, rear 2 GROMMET, EMM mounting, front 1 SCREW, Capacitor clamp 1 SCREW, EMM Mount 2 CLAMP, Capacitor mounting 1 SCREW, Flywheel cover 11 WASHER, Sensor cover 2 HOSE, Water out EMM 1 SCREW, Coil mounting 4 SCREW, EMM mount to cover 1 COVER, Sensor 1 TIMING POINTER 1 SCREW, Timing pointer 1 SCREW, Auxiliary battery lead 1 1 RETAINER, High Tension Lead CLAMP, Vent hose and leads, Port 1 HOSE, Water to EMM from vapor sep 1 CONNECTOR, 4 Pin 1 *SEAL, 4 Pin connector 1 LOCKWEDGE, 4 Pin Connector 1 SPACER, EMM mount 2 TIE STRAP 7 TIE STRAP 7 FLAT WASHER, Coil mounting 4 1 SCREW, Battery cable ground FUSE, 10 AMP 7 RELAY Assy 4 2 WASHER, Bracket to block SCREW, Cover, sensor 2 SENSOR Assy, Crank position 1 *TERMINAL, Pin 2 *CONNECTOR 1 *LOCK WEDGE 1 LEAD Assy, Ignition coil 4 RETAINER, High Tension leads 4 (Clip to injector 1 and 2 screw sleeves)

44 350357 GASKET, Base plate A 45 328701 LOCK WASHER 46 336316 WASHER, EMM to cover 47 328701 LOCK WASHER, Coils 48 5001301 DIAPHRAGM & HOSE Assy, Exhaust 49 *HOSE, Exhaust pressure inlet E 50 *HOSE, Exhaust pressure to EMM F 51 346930 *CLAMP, 9.5mm 52 346931 *CLAMP, 14mm

1 9 1 4 1 1 1 1 1

Ref 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104

A Included in POWERHEAD GASKET SET B Cut to length from P/N 3011044 C Models using a steel fitting, use kit P/N 5005269

D E F

11

P/N 514867 343598 329518 328649 328724 586754 345004 3853299 586300 514766 345005 344233 3010815 346547 346538 333040 338558 328703 328740 328695 329110 586546 514696 514679 514697 510818 328701 586514 176296 514791 3010885 3010888 514680 514690 127288 3010959 328744 5004964 307417 586738 514679

Name of Part Qty BRACKET, Power distribution panel 1 BUMPER, Bracket to block 1 GROMMET, Bracket to block 2 SCREW, Fuse & relay to bracket 5 SCREW, Bracket to block 2 POWER DISTRIBUTION PANEL Assy 1 *SEAL, Cover 1 *GASKET, Connector 1 *COVER Assy 1 **FUSE, 10 AMP, spare 2 **FUSE, Puller 1 **SCREW 2 BASE PLATE 1 BOLT, Double-ended 3 BRACKET, Capacitor mounting 1 ISOLATOR, Mounting bracket 3 SPACER 3 WASHER 3 NUT 3 SCREW, Bracket to block 1 SCREW, Filter to base 2 FILTER Assy 1 *CONNECTOR 1 *TERMINAL, Pin 2 *WEDGE 1 *TERMINAL, Ring 1 LOCK WASHER, Filter Assy 2 1 STATOR Assy *CONNECTOR, 8-socket 1 **SEAL 1 *CONNECTOR, 12-pin 1 **SEAL 1 *TERMINAL, Socket 18 *PLUG, Vacant hole 2 *LOCK WEDGE 1 *LOCK WEDGE 1 SCREW, Coil bracket to cylinder assy 4 COIL, Bracket 2 *GROMMET, Ignition primary lead 2 COIL ASSY, Dual 2 *TERMINAL, Pin 4 *TUBING,Sleeve-ignition primary B EMM D 1 513663 *CONNECTOR, 2 Terminal 1 513665 *SEAL 1 513666 *TERMINAL 2 330272 *FITTING, water C 2 204363 *TERMINAL, Ring, Ground 1 316245 *CLAMP, EMM leads 1 328714 *SCREW, EMM leads clamp 1 5004456 *FUSIBLE LINK KIT, AUX BATTERY 1 514158 **TERMINAL, Ring 1

Call Dealer Support Services Cut to length from P/N 772572 Cut to length from P/N 772571

75, 90, 115 60° V4

EPC3003

FUEL COMPONENTS 28

44 45

54 29

46

51

43 47

33

42 48

30

49 5

50

31

52

7 53

8

6

53

27 2 1

19 26

8 4

52 22

52

52

23

11

34

24 14 19 18 17 16

34 52

52

13

25

9 20

3

12

10

15

35 35

36

14 37

21 38

55 35 39 40

12

FUEL COMPONENTS EPC3004 Ref 27 28 29 30 31 33 34 35 36 37 38 39 40 42 43 44 45 46 47 48 49 50 51 52 53 54 55

Qty 1 1 1 1 1 1 1 4 1 1 1 1 2 3 3 3 3 3 5 1 1 2 1 1 1 3

A Quantity of one is included in P/N 5004459 B Cut to length from P/N 3010592 C Cut to length from P/N 327228

P/N 335328 5000203 344828 5005404 343585 345702 346150 345701 348838 348790 348939 5005195 346064 349870 348224 5001718 348107 5001901 348496 5001911 318322 320107 317893 907833

Name of Part SPACER, Vapor separator FUEL MANIFOLD Assy, Supply *O-RING FUEL MANIFOLD Assy, Return *O-RING TUBING, Convoluted NIPPLE, Pulse CLAMP, 18.5 mm TEE, Fuel CLAMP, 10.5mm HOSE, Oil to check valve HOSE, Fuel inlet to tee CONNECTOR, Fuel line FUEL INJECTOR *VIBRATION DAMPENER SCREW, Injector to head WASHER, Injector CAP, SLEEVE & O-RING *O-RING *SPRING & BUTTON Assy *O-RING, Spring SPRING, BUTTON & O-RING Assy TIE STRAP, Manifolds TIE STRAP TIE STRAP, Vent hose TIE STRAP, Manifolds TUBING, Convoluted

D Includes Ref # 47 & 50 E Cut to length from P/N 3010591

13

Qty 3 1 8 1 8 B 2 3 1 1 C

D

1 1 4 1 8 16 4 4 4 4 4 1 6 2 3

E

75, 90, 115 60° V4

Ref P/N Name of Part 1 5004428 VAPOR SEPARATOR/FUEL PUMP 2 439821 FUEL SUPPLY TUBE Assy, Filter to vapor separator 3 333381 HOSE, Water, block to vapor separator 4 344794 HOSE, Water, vapor separator to EMM 5 345529 HOSE, Vapor separator to intake, Port 6 344848 STUD, Vapor separator to block 7 510487 RETAINING RING 8 328700 WASHER, Vapor separator mounting 9 5004459 FUEL, Lift Pump Assy 10 334132 *HOSE, Fuel tee to pump 11 336224 *HOSE, pulse - upper case fitting 12 346160 *HOSE, pulse - lower case fitting 13 346786 *CLAMP, 15.7mm 14 348839 *CLAMP, 17mm 15 124341 SCREW, Bracket to pump 16 338558 SPACER, Fuel bracket A 17 333040 ISOLATOR, Bracket mounting A 18 328703 WASHER 19 333710 SCREW, 20 5001252 HOUSING Assy 21 502906 *FILTER Assy, Fuel 22 336481 *SCREW 23 344609 *RETAINER 24 5001502 **SENSOR, Water 25 3850819 ***O-RING, Water sensor 26 329518 GROMMET, Vapor separator mount

OIL COMPONENTS 1

6

9 38 28

9

7 46 43

41 29 8

31

5

16 4

45

45 10

39 17

18 19 20

47

22 2

44 45 30

34

45 23

48

24 45

42 44

14

21

33

11 32

15

49

12 4

28

41

40

4 3 13

37 44

44

25

36

35

45 45

26 27

EPC3005 Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 A B C D

P/N 5000836 332026 308743 313022 350014 349898 5001110

5001221 344631 5000911 344828 5000912 343585 345468 5001234 127287 176295 514788 514680 346889 333407 5001054 349057

Name of Part INJECTOR-MANIFOLD Assy, Oil *SCREW Oil Brkt to Fuel Brkt *SCREW, Injector to Manifold *NUT, Lock *OIL PUMP BRACKET *HOSE, Support *CHECK VALVE *HOSE, Oil to fuel tee *HOSE, Oil - translucent blue OIL LIFT PUMP Assy *SCREW, Oil lift pump housing FITTING, Oil injector inlet O-RING, Inlet fitting, black FITTING, Oil injector outlet O-RING, Outlet fitting, brown RETAINER, Fitting PRESSURE SWITCH *LOCK WEDGE *CONNECTOR 2 Socket *SEAL *TERMINAL, Socket RETAINER, Switch HOSE, Oil injector to regulator PRESSURE REGULATOR HOSE, Regulator to fitting

Qty 1 2 2 4 1 5 1 A B

D D

D D

1 4 1 2 1 2 2 1 1 1 1 2 1 1 1 1

Ref 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

P/N 348841 315391 345702 344801 333407 333724 350067 350023 5004958 350068 349008 328074 345701 336269 317893 320107 346785 349516 346785 346786 348838 330151

Name of Part Qty CONNECTOR, Oil return 1 CAP, Oil return 1 NIPPLE, Pulse hose 2 1 HOSE, Oil pump pulse, Port 1 HOSE, Oil pump pulse, Stbd SCREW, Oil pump to bracket 4 1 HOSE, Oil inlet filter to oil lift pump HOSE, Pump to injector 1 FILTER, Oil inline supply 1 HOSE, Inlet to filter 1 CONNECTOR, Oil supply 1 CAP Oil supply 1 FUEL,Tee 1 SLEEVE, Oil hose-5/8 in. x 12 in. (304.8mm) 2 TIE STRAP 4 TIE STRAP 2 CLAMP, 14.5mm 1 CLAMP, 11.3mm 1 CLAMP, 14.5mm 4 CLAMP, 15.7mm 7 CLAMP, 10.5mm 1 CLAMP, Oil Return Hose 1 TUBING, Convoluted C 350323 SLEEVE, Oil hose-3/16 in. x 21 in. (533.4mm) 4

Cut to length from P/N 327228 Cut to length from P/N 344249 ( IMPORTANT - See service manual for proper installation.)

Cut to length from P/N 3010591

Included with P/N 5001221

14

THROTTLE LINKAGE 6 7

10 8 5 9

12

4 10 17 14

16 15

3

1

2 11

EPC3006 Ref 1 2 2 3 4 5 6 7 8

P/N 328702 346838 348503 335544 343749 343086 343877 5001793 344191

Name of Part WASHER, Clip CAM, Throttle CAM, Throttle SHAFT, Roller arm LEVER, Throttle arm RETAINER, Throttle sensor SCREW, Throttle sensor SENSOR, Throttle *CAP, Throttle sensor

Qty 1 A 1 B 1 1 1 1 2 1 1

Ref 9 10 11 12 13 14 15 16 17

A 90, 115 HP Models B 75 HP Models

15

P/N 335595 315656 5001722 438255 335815 335717 333774 5004519 330151

Name of Part Qty LINK, Throttle 1 SCREW, Clamp linkage 4 THROTTLE ARM & PIN 1 THROTTLE LEVER 1 SHAFT, Throttle arm 1 1 RETAINER, Linkage to cover CLIP, Throttle cable 1 FLYWHEEL, Cover 1 CLAMP, Hose and leads to cover, Port 1

75, 90, 115 60° V4

13

INTAKE MANIFOLD 14

7

6 11

17

15 9

4

18 31

32

1

33 19 24 13 12 8

26 29

27 9 16

3

17 28

10

30

25

24

23

2 5

20

21 22

16

INTAKE MANIFOLD EPC3007 Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

P/N 439158 5004325 348934 328765 344031 328714 345044 345045 318165 326467 346460 5001055 348947 437591 348934 347094 328735

Name of Part Qty THROTTLE BODY Assy, Port 1 THROTTLE BODY Assy, Stbd 1 1 *SCREW, Adjustment *CLIP 1 *SEAL, Air silencer 2 *SCREW, Shaft 1 GASKET, Manifold to block - Port A 1 GASKET, Manifold to block - Stbd A 1 RETAINER, Link 2 NIPPLE, Intake manifold, Stbd 1 INTAKE MANIFOLD Assy, Port 1 1 INTAKE MANIFOLD Assy, Stbd LINK, Throttle body 1 4 LEAF PLATE Assy SCREW, Adjustment 1 ROLLER, Cam follower 1 WASHER 1

Ref 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

P/N 335257 328744 5005368 337574 511421 340840 344526 317893 324678 344038 323626 303630 3010673 349182 330151 333677

Name of Part Qty LEVER, Linkage adjustment 1 SCREW, Manifold to crankcase 10 AIR SILENCER Assy 1 *SCREW, Air Silencer 2 *WASHER, Air silencer screw 2 *SEAL 2 GASKET, Manifold to throttle assy A 2 TIE STRAP, Oil hoses & elec harness 1 O-RING, Roller & sleeve 1 SCREW, Intake manifold 4 SCREW, Throttle body to manifold 12 WASHER, Fiber 2 SENSOR Assy, Air temperature 1 NIPPLE, Intake manifold, Port 1 CLAMP, Vent & oil hose 2 SCREW, Reed box to manifold 8

75, 90, 115 60° V4

A Included in POWERHEAD GASKET SET

17

ELECTRIC STARTER 2

1

14

11

6

3

6

6

25 12 9

8

4

26

6

28

15 20

16 18 21

13 5

19 20

27 22 24

24 7

10 21 17

23

EPC3008 Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14

P/N 586287 5001579 335856 433849 433852 335857 433850 335778 342881 342880 306556 5004518 513398 322000 435294

Name of Part STARTER MOTOR Assy *CAP Assy, Drive end *SEAL, Shaft *ARMATURE Assy *CAP ASSY, Commutator *BOLT & LOCK WASHER *BRUSH & SPRING SET NUT, Starter cable GEAR, Drive, starter GEAR, Pinion & shaft NUT, Terminal, Yel/Blue lead PINION & SHAFT Assy RETAINING RING, Drive gear SCREW, Starter to crankcase PINION HARDWARE KIT Assy

Qty 1 1 1 1 1 2 1 1 1 1 1 1 1 3 1

Ref 15 16 17 18 19 20 21 22 23 24 25 26 27 28

18

P/N 321472 341613 586730 306556 321472 331259 327283 328724 586149 328701 584348 349767 328724 310947

Name of Part NUT, Positive lead to starter BUSHING, Shaft to cylinder block SOLENOID Assy NUT, Terminal, Pink/White lead NUT, Positive lead from battery LOCK WASHER LOCK WASHER, Small SCREW, Starter solenoid to bracket CABLE Assy, Solenoid to starter WASHER BATTERY CABLE WASHER, Thrust SCREW, Clamp CLAMP, Positive battery cable

Qty 1 2 1 1 2 3 2 2 1 4 1 1 1 1

CRANKSHAFT AND PISTONS 7 13 2 4

16 17

3

20 21 11 15

20 14

10

6 5

16

19

1 8 9

EPC3009 Ref 1 2 3 4 5 6 7 8 9 10 11 12 13

P/N 340559 336232 327861 439568 326047 433503 306972 337087 337030 392591 308186 387787 335825

Name of Part HOUSING, Seal, lower bearing SEAL, Upper WRIST PIN CRANKSHAFT Assy *RING, Retaining *BEARING Assy, Ball *ROLL PIN, Flywheel *O-RING, Sleeve *SLEEVE CONNECTING ROD Assy *SCREW, Rod cap NEEDLE & RETAINER SET SPLIT LINER, Bearing

Qty 1 A 1 4 1 1 1 1 A 1 1 4 2 4 2

Ref 14 14 14 14 15 15 16 17 18 19 20 21

A Included in POWERHEAD GASKET SET

19

P/N 5000812 5000813 5000814 5000815 5000819 5000820 317831 387041 338518 337085 395627 319244

Name of Part Qty PISTON & RINGS, Std., Port 2 PISTON & RINGS, Std., Stbd.

2 PISTON & RINGS, 0.030" O.S, Port 2 PISTON & RINGS, 0.030" O.S, Stbd 2 *RING SET, Std. 4 *RING SET, 0.030" O.S. 4 *RETAINING RING 8 RETAINER & NEEDLE SET, Main 2 O-RING, Housing A 1 SEAL, Lower housing A 1 BEARINGS and RETAINERS 4 SEAL RING 6

75, 90, 115 60° V4

18

CYLINDER AND CRANKCASE 33 13

73

11

65 69 17

8

7 7

16 1

22

79 49

50

31

78

3 14

70

76 80

87

15

9

57

19 21 18 56

81

20

5

83

27

23

63

14

4

26

10

66

84 38

24 74

77

32 85 75

4

44

52

52 43

42 43

55 29

45

72 6 68

47 30

35 43 52

20

59 62

37 36

51

60

58 41

48 46

39

34

28 25

61 54 82

86

12

2

40 71

67

86

53

64

CYLINDER AND CRANKCASE EPC3010 P/N 5004929 304178 305070 336630 336166 335611 335369 343929 437773 345702 332135 345702 3010674

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

350458 330935 328725 5001211 433817 5004323 348449 5001560 5000477 335523 330933 343118 328725 306012 336136 311015 328701 202026 436902 328702 349060 340734

317893 344789 338632 585038 511469 329562 513357 331188

Name of Part Qty CYLINDER & CRANKCASE Assy 1 2 *DOWEL PIN, Bearing *PIN, Taper 1 *PIN, Roll 4 4 *SCREW, Cyl to case, short 2 *SCREW, Cyl to case, long 2 *NIPPLE, Upper main *SCREW, Plug - Emission 2 2 *CHECK VALVE, #2 main brg & #4 cyl *NIPPLE, Water from EMM 1 1 *PLUG, Water pressure *NIPPLE, Pulse hose 4 TEMPERATURE SENSOR, Port 1 HOSE, Oil - (Secure with #15) F TIE STRAP 8 HOSE, EMM water out - (Secure with #57) 1 COVER, Thermostat 2 TEMPERATURE SWITCH, Stbd 1 *TERMINAL, Pin 1 *COVER 1 *CONNECTOR 1 O-RING, Thermostat cover A 2 HOSE, Tee to block, 2 in. (50mm) E (Connect to #10 - Secure with #57) SCREW, Cylinder to crankcase 12 BUSHING, Shift lever 1 SCREW, Shift rod lever 1 SPARK PLUG, XC12PEPB B 4 LEVER ASSY, Shift rod 1 1 MOUNT, Kit upper *SCREW, Upper mount 2 CYLINDER HEAD, Stbd 1 NIPPLE CHECK VALVE, Recirculation 2 O-RING, Cylinder head A 4 1 SCREW, Shift arm to block LINK, Shift lever to shift arm 1 SCREW, Cover, trunnion 1 SPRING WASHER, Shift shaft 1 CLAMP, Grommet, water 2 BUSHING, Shift lever 1 LOCK WASHER, Ground 1 WASHER, Shift arm 1 SHIFT LEVER 1 WASHER, Link to shift arm 3 COVER, Trunnion 1 BUSHING, Shift shaft assy 1

A Included in POWERHEAD GASKET SET B Refer to Emissions Control Information Label C Cut to length from P/N 340848

Ref 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69

P/N 330941 5000470 349061 435491 338174 328733 333774 439953 328744 335316 436857 320107 335521 343881 324677 310947 329513 301967 5001559 339066 349557 349556 330263

Name of Part Qty PIN, Shift arm 1 SHIFT SHAFT & ARM Assy 1 TRUNNION BLOCK 1 2 THERMOSTAT Assy SPRING, Thermostat 2 SPRING WASHER, Shift lever 1 CLIP, Shift lever, shift arm 3 GROMMET & INSERT, Exhaust relief 1 SCREW, Trunnion to block 2 SEAL, Shift rod 1 PLUG & NOZZLE, Overboard indicator 1 TIE STRAP 11 BUSHING, Shift lever to block 1 NIPPLE, Lower drain 1 O-RING, Nipple, lower drain 1 CLAMP, Oil hose 1 SCREW, Nipple 1 O-RING, Overboard indicator 1 CYLINDER HEAD, Port 1 28 SCREW, Cylinder head MOUNT 4 WASHER, Mount 4 SCREW, Upper mount limiter 1 HOSE, Cylinder block vent to tee, D 16 in. (406mm) (Secure with #57) 70 330474 30° TEE, Water return hoses 1 71 328724 SCREW, Motor cable, ground 1 72 340418 RETAINER, Upper mount limiter 1 73 787129 POWERHEAD GASKET SET 1 74 319126 SCREW, Powerhead to exhaust hsg 4 75 123199 NIPPLE, Water to vapor separator 1 76 HOSE, Upper bearing vent to C check valve, 6 in. (152mm) 77 343398 HOSE, Exhaust grommet to block 1 78 335981 SEAL, Thermostat A 2 79 HOSE, Upper Stbd brg vent to C Stbd intake mfld, 9 in. (229mm) 80 434927 CHECK VALVE 1 81 HOSE, Lower bearing vent to D check valve, 4 1/2 in. (114mm) 82 345537 CLAMP, Fuel tube assy 1 83 5001769 CHECK VALVE, Transfer drain - Port 2 1 84 5001551 FITTING, Exhaust pressure 1 85 346527 GASKET, Exhaust fitting 86 349729 CLAMP, Exhaust relief - 41.0mm 2

D Cut to length from P/N 327228 E Cut to length from P/N 333341 F Cut to length from P/N 344249

21

75, 90, 115 60° V4

Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

EXHAUST HOUSING

16

EPC3011 Ref 1 2 3 3 4 5 6 7 7 8 9 10 11 11

P/N 341910 317624 350964 350965 911042 301161 434632 335520 335519 314008 328725 344386 341197 338664

Name of Part Qty COVER, Mount bracket lower 2 SCREW, Cover 8 EXHAUST HOUSING, Outer B,N 1 EXHAUST HOUSING, Outer C,N 1 6 SCREW, Exhaust housing 6 WASHER, Exhaust housing RUBBER MOUNT, Lower 2 WATER TUBE B 1 WATER TUBE C 1 GROMMET, Water tube 1 5 SCREW, Inner to outer hsg/block GASKET, Hsg to powerhead A 1 EXHAUST HOUSING, Inner, lower B 1 EXHAUST HOUSING, Inner, lower C 1

A Included in POWERHEAD GASKET SET B FPL, FSL Models C FPX Models

Ref 12 13 14 15 16 17 18 19 20 21 22 23 24 25

P/N 344945 320936 320961 340215 319126 301250 336301 342979 341191 345776 910736 910741 301250 911201

Name of Part Qty EXHAUST HOUSING, Inner, upper 1 1 SEAL, Exhaust housing, lower 1 SEAL, Gearcase to inner housing 1 SEAL, Exhaust housing SCREW, Housing to block, outer 4 WASHER, Screw, mount 8 1 ROLL PIN, Housing to block SPACER, Lower cover to exh hsg 1 SEAL, Water tube B 1 SPRAY DEFLECTOR C 1 SCREW, Plate & deflector C 2 SCREW, Spray plate C 2 WASHER, Spray deflector C 2 WASHER, Spray plate C 2

N New P/N for 2003

22

POWER TRIM/TILT HYDRAULIC ASSEMBLY

31 33

34

10 11

35

32 37 38

39

EPC3012 Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

P/N Name of Part 5005114 HYDRAULIC Assy 435260 *MANUAL RELEASE VALVE & SEAL Assy 337494 *SCREW, Motor to manifold 435341 *RESERVOIR & CAP Assy 435342 **CAP & O-RING Assy 336746 *SCREW, Reservoir to manifold 435343 *VALVE BODY Assy 337495 *SCREW, Valve body, long 337517 *SCREW, Valve body, short 337530 *PLUG & SCREEN 337496 *THRUST PAD 435345 *TRIM ROD END CAP & SEAL Assy 337497 *FILTER Assy 439937 *MOTOR & O-RING Assy 321163 **O-RING 914053 **DRIVE, Pump 3010063 **SEAL, Wire 514823 **TERMINAL 324385 *WASHER 435261 *CLAMP & SCREW Assy

Ref 20 21 22 23 24 25 26

Name of Part *RETAINING RING *CAP Assy *TRIM ROD *ROD AND EYE *PISTON Assy *NUT SLEEVE, Trim motor & sending unit leads 27 335479 BUSHING, Upper & lower mount 28 336534 RETAINING RING 29 512258 SLEEVE, Motor leads 30 3010049 CONNECTOR, Motor 31 335480 PIN, Tilt cylinder 32 335463 ROD, Lower mount 33 585229 BRUSH & SEAL KIT, Trim motor 34 434519 O-RING & SEAL KIT 35 586074 SWITCH Assy, Trim & tilt lower cvr 36 514686 *CONNECTOR, 3-pin 37 514679 *TERMINAL, Pin 38 514682 *LOCK WEDGE 39 334656 NUT, Switch

Qty 1 1 4 1 1 3 1 1 2 1 2 2 1 1 1 1 2 2 1 1

23

P/N 914069 390006 436389 436390 435262 324390 513816

Qty 1 1 2 1 1 1 1 4 4 1 1 1 1 1 1 1 1 3 1 1

75, 90, 115 60° V4

36

MIDSECTION 78

73

46 60

71

66 39

65

72 69 68

51

70

43 67 56

77 79 76

42

61

47

50

75 45

37

38

36

28

43 44 33

34

35

26

49

62

63

40

80 41

74 57

59

55

54 52

53

64

81 32 48

52

54

58

82

57

24

MIDSECTION EPC3013 P/N 434691 434724 313607 320962 335686 337579 336819 910992 327696 336210 328724 328724 328724 340006 338744 320746 335814 342191 319886 336230 334936 5001766 5001825 514686 335474 335475 320866 336172 335481 337586 335486 513817 335701 336529 433580 335554 337592 336853 335470 334241 335485 348449 336467 328724 584136 337580 336506

Name of Part SWIVEL BRACKET SWIVEL BRACKET *LUBRICATION FITTING *BUSHING, Upper *SEAL *BUSHING, Tilt tube *BUSHING, Lower pivot shaft *WASHER, Tilt tube KEEPER, Pivot shaft SPRING, Trail lock to bracket SCREW, Ground lead SCREW SCREW, Tilt limit switch MOUNT BRACKET MOUNT BRACKET NUT, Mount bracket RETAINER, Trail lock spring SCREW, Retainer to bracket SCREW SPRING, Detent, tilt lock SCREW, Mount STEERING ARM Assy STEERING ARM Assy CONNECTOR, Sending unit, 3-pin COVER, Stern bracket, Stbd COVER, Stern bracket, Port THRUST WASHER, Pivot shaft RETAINER, Trail arm SCREW, Tilt lever to bracket WIPER, Tilt tube BUSHING, Tilt lever SLEEVE, Lead BUSHING, Trail arm RETAINING RING, Trim rod ANODE, Stern bracket NUT, Tilt tube COLLAR, Upper, tilt limit CLIP, Screw, retainer ARM, Trail lock GUIDE, Ball detent, tilt lock LEVER, Tilt lock SCREW, Upper Mount SUPPORT SCREW, Support LEAD ASSY, Ground SCREW, Cover to stern bracket STERN BRACKET, Stbd

A B

A B

A B

Ref 45 46 47 48 49 50 51 52 53 54 55 56 57

Name of Part Qty BALL, Detent, tilt lock 1 TILT TUBE Assy 1 BRACKET, Tilt limit switch 1 SCREW, Anode 2 COLLAR, Lower, tilt limit switch 1 CAM, Tilt limit switch 1 ROD, Trim limiter 1 NUT, Stern bracket screw 4 WASHER 2 WASHER, Nut 4 SCREW, Trail arm to bracket 2 2 SCREW, Sending unit SCREW, Bracket to transom, 3 in.

4 (76mm) 57 318573 SCREW, Bracket to transom 3 1/2 in. 4 (89mm) 57 336676 SCREW, Bracket to transom, 4 1/2 in. 4 (114mm) 57 331578 SCREW, Bracket to transom, 5 in.

4 (127mm) 57 321577 SCREW, Bracket to transom, 6 in.

4 (152mm) 58 318272 PLATE 2 59 318572 CAP 4 60 336505 STERN BRACKET, Port 1 61 513787 RETAINER, Limit switch 1 62 335949 THRUST ROLLER 2 63 317894 CAP, Tilt tube 1 64 318273 RETAINER 2 1 65 586160 SENDING UNIT Assy 1 66 513871 *TERMINAL, Ring 67 511527 *RETAINER 1 68 511528 *SPRING 1 69 320689 *NUT 1 70 342386 *ARM 1 71 514679 *TERMINAL, Pin 3 72 3854047 *TERMINAL, Ring 1 73 514682 LOCK WEDGE, 3-pin 1 74 328702 WASHER, Clip 1 75 586156 SWITCH Assy, Tilt limit 1 76 514679 *TERMINAL, Pin 2 77 514697 LOCK WEDGE 1 78 123692 CONNECTOR, Speedometer hose 1 79 514696 CONNECTOR, 2-pin 1 80 335487 SCREW, Thrust roller, swivel bracket 2 81 912233 RETAINER, Pivot shaft seal B 1 82 911312 SEAL, Pivot shaft B 1

Qty 1 1 3 1 2 2 1 2 1 1 2 4 1 1 1 1 2 1 4 1 4 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 2 1 1 1 2 1 2 1 4 1

A FPL, FSL Models B FPX Models

25

P/N 336209 435007 336171 324816 337593 337591 336525 313623 307238 320248 335487 328744 327053

75, 90, 115 60° V4

Ref 1 1 2 3 4 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 19 20 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

GEARCASE - FPL, FSL MODELS

87

89

WATER PUMP REPAIR KIT

11 12 14 10 88

54 51 92

49

57

93

40 39

78

60

CHROME CUP & PLATE KIT

35

86 85

77

1

29 52

61

8 9

83 90 26

80

7

68

82

27

81

64 65

6

48

5

79

47

91

58 2

84

GEARCASE SEAL KIT

38

37

45 25

24 34

41

59

62

69

33

4

67

66

28

3

91

50

48 47 20

46

55 19

44

42

94

15

31

21

23

22 17 18

32 16

30 70 74

72

56 53

36

13 43

63

73

76 75

71

26

GEARCASE - FPL, FSL MODELS EPC3014

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 49 49

P/N 5004632 5004767 384195 336535 305749 341219 436745 307161 341220 437330 439476 329922 329923 382408 317624 391365 331880 327345 911961 334163 324037 322941 320145 313446 436834 385043 338504 311538 346004 324670 5000440 382407 379504 330137 350271 314728 314731 314730 436746 387656 327656 328743 333957 345992 323664 313448 324369 318544 311598 323362 323361 314745

Name of Part GEARCASE Assy, Complete *GEARCASE & BEARING Assy **BEARING, Pinion **NIPPLE, Pitot tube **CAP, Pitot tube fitting **SCREW, Anode **ANODE, Gearcase **LOCK WASHER, Anode **SCREW, Pitot seal **WASHER & SEAL, Pitot tube *BEARING HSG Assy, Drive Shaft **SEAL, Upper A **SEAL, Lower A *THRUST BEARING, Reverse gear *SCREW, Housing to gearcase *BEARING HSG Assy, Fwd Gear **PIN, Housing **BALL, Detent **SPRING, Detent *CRADLE, Shifter *LEVER, Shift *SHAFT, Shift *PIN, Shift lever *O-RING, Propeller shaft housing A *PROPELLER SHAFT *THRUST BRG, Fwd. gear *RETAINER, Driveshaft *ROLL PIN, Driveshaft *DRIVESHAFT, Lower *GASKET, Shift rod cover A *BEARING HSG Assy, Prop Shaft **NEEDLE BEARING Assy, front **NEEDLE BEARING Assy, rear **SEAL, Propshaft A *SCREW, Retainer tab *O-RING, Driveshaft bearing hsg A *THRUST WASHER, Reverse gear *NUT, Pinion to driveshaft *GEAR SET, Pinion & fwd gear *THRUST BEARING, Driveshaft *THRUST WASHER, Driveshaft *WASHER, Tab screw *TAB, Retainer *GEAR, Reverse *SHIFTER, Clutch dog *PIN, Clutch dog *SPRING, Clutch dog pin *SCREW, Fill & drain A **SEAL, Fill & drain screw *SHIM, 0.003 in. (0.07mm) *SHIM, 0.004 in. (0.10mm) *SHIM, 0.005 in. (0.12mm)

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 2 2 1 1 1 1 2 1 AR AR AR

Ref 50 51 52 53 54 55 56 57 58 59 60 61

Name of Part Qty *THRUST WASHER, Forward gear 1 *COVER & SEAL Assy, Shift rod 1 1 **O-RING, Shift rod A *SCREW, Anode 2 *SCREW, Shift rod cover 6 *DETENT, Shifter 1 1 *ANODE, Bearing housing * WASHER, Shift rod cover screw 6 *SCREW, Water intake screens 2 *SCREEN, Water intake 2 SHIFT ROD 1 DRIVESHAFT Assy, Upper 1 (Includes # 26 & 27) 62 338742 TRIM TAB 1 63 314502 COTTER PIN, Propeller nut 1 64 330265 WASHER, Mounting, 3/8 in.

1 65 331998 SCREW, Mounting, 7/16 in. X 3.50 in. 1 1 66 331999 SCREW, Mounting, 3/8 in. X 1.75 in.

67 331999 SCREW, Mounting, 3/8 in. X 1.7 5in.

4 5 68 330266 WASHER, Mounting, 3/8 in.

69 313715 SCREW, Trim tab 1 1 70 315810 SPACER, Propeller nut, 3-blade 1 70 176563 SPACER, Propeller nut, 4-blade 71 127084 THRUST BUSHING, 3-blade (std) 1 71 127212 THRUST BUSHING, 4-blade 1 72 314503 NUT, Propeller 1 73 PROPELLER B AR 74 332393 *CONVERGING RING, Propeller 1 1 75 384977 *BUSHING Assy, Prop, 3-blade 75 176228 *BUSHING Assy, Prop, 4-blade 1 76 313926 *SLEEVE, Propeller bushing 1 77 5001595 WATER PUMP REPAIR KIT 1 78 435959 *IMPELLER HOUSING 1 79 331353 *SEAL, Impeller housing plate 1 1 80 5001593 *IMPELLER Assy 81 331107 *KEY, Impeller 1 82 302035 *O-RING, Impeller to plate 1 1 83 331188 *O-RING, Cup to housing 84 338484 *GASKET, Impeller plate 1 A 85 314008 *GROMMET, Water tube to cover 1 86 338893 *COVER, Impeller housing 1 87 320943 *GROMMET, Pump to exh hsg 1 4 88 302325 *SCREW, Impeller housing 2 89 306643 *SCREW, Cover to impeller hsg 90 338486 *CUP, Impeller-(Stainless) 1 91 338485 *PLATE, Impeller-(Stainless) 1 92 321008 GROMMET, Exh. hsg. to shift rod 1 93 435526 CHROME CUP & PLATE KIT 1 1 338551 *CUP, Impeller-(Chrome) C 338552 *PLATE, Impeller-(Chrome) 1 C 94 5000411 GEARCASE SEAL KIT 1

A Contents of GEARCASE SEAL KIT B Refer to EVINRUDE / JOHNSON Genuine Parts Propeller Chart C Not shown

27

P/N 324766 5004598 318372 908158 302325 915954 431708 328702 340665 340495 342994 5000615

75, 90, 115 60° V4

Ref

GEARCASE - FPX MODELS

WATER SCREEN KIT HIGH FLOW

97

WATER SCREEN KIT HIGH PERFORMANCE

66

58

70

99 83 59 93

85 95

19

72

57

46

18 53

91

73 61 17 55

1 10

94

45 44

92

34

7 8

56

84 81 77 71 74

63

87 89

9

75

60

3

68 67 69

51 80

2 62

76

47

42 13

81 52

89 88 12 90 96

15

5 6

78 11 4 79

52 51

43 49 48

25

31

65

54

14 28 29 64 38 32

50

24

20

35

27 16 23

36 39

37

26 21 22

107

108

104

40 41

33

109 30

106

43

100 CHROME CUP & PLATE KIT

102 105 103

101

28

GEARCASE SEAL KIT

82 WATER PUMP REPAIR KIT

GEARCASE - FPX MODELS

Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 53 53 54 55 56

P/N 5001603 5001589 387817 324852 332584 305749 336535 341220 437330 341219 436745 307161 346462 345998 349001 916070 160084 328702 314728 317624 5001601 389039 331880 911962 334163 322938 348483 317274 350271 5004765 389042 389042 333957 349193 324670 5001587 382407 436752 334950 326849 431708 908158 314730 5001598 387656 327656 321008 350038 337774 313448 324369 318544 311598 323362 323361 314745 327669 5004598 318372

Name of Part GEARCASE Assy, Complete *GEARCASE & BEARING Assy **BEARING, Pinion **SCREW, Pinion bearing ***SEAL, Pinion brg screw **CAP, Pitot tube fitting **NIPPLE, Pitot tube **SCREW, Pitot seal **WASHER & SEAL Assy, Pitot A **SCREW, Anode **ANODE, Gearcase **LOCK WASHER, Anode *RING, Propeller seal *WASHER, Wedge screw *WEDGE, Propshaft hsg to GC *SCREW, Wedge *BALL, Detent *WASHER, Shift rod cover screw *O-RING, Driveshaft bearing hsg A *SCREW, Housing to gearcase *BEARING HSG Assy, Fwd Gear ** BEARING, Fwd Gear **PIN, Housing *SPRING, Detent *CRADLE, Shifter *LEVER, Shift *SHAFT, Shift *PIN, Shift lever *SCREW, Retainer tab *PROPELLER SHAFT *THRUST BEARING, Reverse gear *THRUST BEARING, Fwd gear *TAB, Retainer *THRUST WASHER, Reverse gear *GASKET, Shift rod cover A *BEARING HSG Assy, Propshaft **NEEDLE BEARING Assy, Front **NEEDLE BEARING Assy, Rear **SEAL, Propshaft A ** O-RING, Propshaft housing A **ANODE, Bearing housing **SCREW, Anode *NUT, Pinion to driveshaft *GEAR SET, Fwd, Rev, Pinion *THRUST BEARING, Driveshaft *THRUST WASHER, Driveshaft *GROMMET, Exh hsg to shift rod *WASHER, Pinion nut *SHIFTER, Clutch dog *PIN, Clutch dog *SPRING, Clutch dog pin *SCREW, Fill & drain A **SEAL, Fill & drain screw *SHIM, 0.003 in. (0.07mm) *SHIM, 0.004 in. (0.10mm) *SHIM, 0.005 in. (0.12mm) *THRUST WASHER, Forward gear *COVER & SEAL Assy, Shift rod **O-RING, Shift rod A

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 1 4 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 2 2 AR AR AR 1 1

Ref P/N Name of Part Qty 57 439476 *BEARING HSG Assy, Driveshaft 1 58 329922 **SEAL, Upper A 1 59 329923 **SEAL, Lower A 1 60 345905 *DRIVESHAFT, Lower 1 61 302325 *SCREW, Shift rod cover 6 62 338504 *RETAINER, Driveshaft 1 1 63 311538 *ROLL PIN, Driveshaft 64 328743 *WASHER, Tab screw 2 65 347377 *DETENT, Shifter 1 66 5005063 *WATER SCREEN KIT, High flow 1 67 337061 **SCREW, Water intake screens 2 68 350264 **SCREEN, Wtr intake-high flow, Port 1 69 350265 **SCREEN, Wtr intake-high flow, Stbd 1 70 5005124 WATER SCREEN KIT, High Perf 1 337061 *SCREW, Water intake screens B 2 348479 *SCREEN, Wtr intake-high perf, Port B 1 348480 *SCREEN, Wtr intake-high perf, Stbd B 1 71 5000624 DRIVESHAFT Assy, Upper 1 72 349591 SHIFT ROD 1 73 321122 SPACER, Shift rod cover 1 74 331409 SEAL, Trim tab 1 75 338742 TRIM TAB 1 76 313715 SCREW, Trim tab 1 77 330263 SCREW, Mounting, 3/8 in. X 3.50 in.

1 78 330265 WASHER, Mounting screw, 7/16 in.

1 79 331998 SCREW, Mounting, 7/16 in. X 3.50 in. 1 4 80 331999 SCREW, Mounting, 3/8 in. X 1.75 in.

81 330266 WASHER, Mounting screw, 3/8 in.

5 82 5001595 WATER PUMP REPAIR KIT, 1 83 320943 *GROMMET, Pump to exh housing 1 84 338486 *CUP, Impeller-(Stainless ) 1 85 306643 *SCREW, Cover to impeller hsg 2 1 86 331353 *SEAL, Impeller housing plate 87 5001593 *IMPELLER Assy 1 88 331107 *KEY, Impeller 1 89 302035 *O-RING, Impeller to plate 1 90 338485 *PLATE, Impeller hsg-(Stainless) 1 91 314008 *GROMMET, Water tube to cover 1 92 435959 *IMPELLER HOUSING 1 93 302325 *SCREW, Impeller housing 4 94 331188 *O-RING, Cup to housing 1 95 338893 *COVER, Impeller housing 1 96 338484 *GASKET, Impeller plate A 1 97 338601 *GROMMET, Sleeve to exh hsg 1 99 338636 *SLEEVE, Pump cover extension 1 100 435526 CHROME CUP & PLATE KIT 1 338551 *CUP, Impeller-(Chrome) B 1 338552 *PLATE, Impeller hsg-(Chrome) B 1 101 126870 THRUST BUSHING, 3-blade (std) 1 101 126869 THRUST BUSHING, 4-blade 1 102 PROPELLER C AR 103 387157 *BUSHING, Alum. Propeller 1 1 103 175401 *BUSHING, S.S.propeller 104 332394 *CONVERGING RING, Prop (std) 1 105 313926 *SLEEVE, Propeller bushing 1 106 320570 SPACER, Propeller nut 1 107 398042 NUT & KEEPER, Propeller 1 108 306394 COTTER PIN, Propeller nut 1 109 5000411 GEARCASE SEAL KIT 1

A Contents of GEARCASE SEAL KIT B Not shown C Refer to EVINRUDE / JOHNSON Genuine Part s Propeller Chart

29

75, 90, 115 60° V4

EPC3015

STEERING LINK EPC3016 Ref 1 2 3

P/N 175125 315077 175110 319453

Name of Part STEERING LINK KIT *LOCKNUT *ROD Assy *WASHER

Qty 1 2 1 2

DUAL STEERING CONNECTOR KIT EPC3017 Ref 1 2 3 4 5 6 7 8 9 10 11

P/N 175322 123077 126296 123204 126299 315077 319453 328694 126617 319316 319253 337586

A Accessory

30

Name of Part DUAL CABLE STEERING KIT *SCREW, Cable to connector *BRACKET, Steering tube *NUT, Steering tube *CONNECTOR, Cables to rod *LOCKNUT *WASHER *SCREW, Bracket *STEERING TUBE *WASHER, Steering tube *LUBE FITTING, 45° *WIPER NUT

A

Qty 1 2 1 2 1 4 2 4 1 2 2 1

31

75, 90, 115 60° V4

32

33

75, 90, 115 60° V4