2004 Johnson Evinrude 150HP, 175HP V6 2-Stroke Parts Catalog Manual DOWNLOAD

J150PLSRB J150PXSRB J150CXSRM J150GLSRM J150MLSRC J150MXSRC

Printed in the United States © 2003 Bombardier Motor Corporation of America. All rights reserved.

TM, ® Trademarks are registered trademarks of Bombardier Motor Corporation of America or its affiliates.

J175PLSRB J175PXSRB J175CXSRB J175GLSRM J175MXSRC

150, 175 60° V6

150, 175HP 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.

LITERATURE 5005647 5005648 215519 215520 215521 215522

SERVICE MANUAL – ENGLISH SERVICE MANUAL – FRENCH OPERATOR’S GUIDE – ENGLISH OPERATOR’S GUIDE – FRENCH OPERATOR’S GUIDE – SPANISH OPERATOR’S GUIDE – PORTUGUESE

PAINT COLOR NAME PRIMER 3

BLACK GRAPHITE GREEN 4 WHITE CLEARCOAT

SPRAY CAN

PPG # 1

PPG # 2

771227 771234 771232 351061 771226 772414

DP40401 9696 35718

– – –

90538 –

– –

1. ONE COAT FINISH FOR MIDSECTION & GEARCASE 2. BASE COAT PLUS CLEARCOAT FOR UPPER & LOWER ENGINE COVERS 3. USED ON ENGINE CRANKCASE ASSEMBLY. 4. ML, MX MODELS

1

150, 175 60° V6

TABLE OF CONTENTS DECALS - “WHITE” MODELS ...................................................................................................... 2 DECALS - “GRAPHITE” MODELS ............................................................................................... 3 DECALS - ML, MX MODELS ....................................................................................................... 4 ENGINE COVER .......................................................................................................................... 5 LOWER ENGINE COVER ......................................................................................................... 6-7 ENGINE ELECTRICAL HARNESS ASSEMBLY ....................................................................... 8-9 ELECTRICAL SYSTEM ......................................................................................................... 10-11 FUEL COMPONENTS ............................................................................................................12-13 CARBURETOR & INTAKE MANIFOLD ................................................................................ 14-15 THROTTLE LINKAGE ................................................................................................................ 16 CRANKSHAFT & PISTONS ....................................................................................................... 17 CYLINDER & CRANKCASE .................................................................................................. 18-19 ELECTRIC STARTER ........................................................................................................... 20-21 MIDSECTION ........................................................................................................................ 22-23 POWER TRIM/TILT HYDRAULIC ASSEMBLY..................................................................... 24-25 POWER TRIM AND TILT ELECTRICAL ............................................................................... 26-27 GEARCASE - PL, GL MODELS ............................................................................................ 28-29 GEARCASE - ML, MX, PX MODELS .................................................................................... 30-31 GEARCASE - CX MODELS .................................................................................................. 32-33 STEERING LINK KIT .................................................................................................................. 34 DUAL STEERING CONNECTOR KIT ........................................................................................ 34

DECALS - “WHITE” MODELS

2 1

3

4

6

7

5

9

8 EPC3650 Ref 1 2 3 4 5 A

P/N 350165 350184 350188 350187 350189

Name of Part "BOMBARDIER" , F/R "JOHNSON ", Port/Stbd DECAL, Stbd DECAL, Port "JOHNSON ", Front/Rear

A A A A A

Ref 6 7 8 9

Qty 2 2 1 1 2

Included with "ENGINE COVER Assy"

N

2

P/N 350192 350193 351222 351237

Name of Part 150 HP, Front/Rear 175 HP, Front/Rear "SALTWATER ", Port "SALTWATER ", Stbd

New P/N for 2004

N N

Qty 2 2 1 1

DECALS - “GRAPHITE” MODELS

2

150, 175 60° V6

1

3

4 7

6

5

EPC3651 Ref 1 2 3 4 A

P/N 350231 350241 350233 350235

Name of Part DECAL, "BOMBARDIER" , F/R DECAL, "JOHNSON ", Port/Stbd DECAL, Stbd DECAL, Port

A A A A

Qty 2 2 1 1

Ref P/N Name of Part 5 350239 DECAL, 150 HP, Front/Rear 6 350240 DECAL, 175 HP, Front/Rear 7 350236 DECAL, "JOHNSON ", Front/Rear

Included with "ENGINE COVER Assy"

3

A

Qty 2 2 2

DECALS - ML, MX MODELS

2

1

5 4

3 EPC3652 Ref P/N Name of Part 1 350394 DECAL "JOHNSON" , Port 2 350395 DECAL "JOHNSON" , Stbd 3 350380 DECAL, "175" A

A A

Ref P/N Name of Part 4 350396 DECAL, "150" 5 350393 DECAL, "BOMBARDIER" , Rear

Qty 1 1 1

Included with "ENGINE COVER Assy"

4

A

Qty 1 1

ENGINE COVER

8

ADHESIVE KIT LOCATING BRACKETS

5 3

6 2

7

2

3

5

4

EPC3089 Ref 1 1 1 2 3 A B C

P/N 5005011 5005028 5005394 328744 5001931

Name of Part ENGINE COVER Assy ENGINE COVER Assy ENGINE COVER Assy *SCREW, Hook *HOOK

A,C B,C D,C

Qty 1 1 1 4 2

Ref 4 5 6 7 8

P/N 344387 346780 348219 348220 431929

Name of Part *SEAL, Engine cover *BRACKET, Front & Rear *SOUND BLANKET, Port *SOUND BLANKET, Stbd ADHESIVE KIT, Locating brackets

WHITE - Engine Cover D ML, MX Models only GRAPHITE - Engine Cover IMPORTANT: When ordering "ENGINE COVER Assy" also order appropriate "HP" decals.

5

Qty 1 2 1 1 1

150, 175 60° V6

1

LOWER ENGINE COVER 2 3 4 5 6

18 44 7

42

42

8

1

9

42 17 10

16

16 16

11

41 40 43

14 13 12 10

15 34

24

25 23

28 29

26 22

23

27

34

34

30 31

36

32 33 34

21 38 42

20

35

19

37

6

39

LOWER ENGINE COVER EPC3090

A B C

P/N 5005029 5005012 5005391 586074 514679 514686 514682 334656 339575 328735 309485 308532 435026 330234 343578 342191 335499 5004576 307256 5005031 5005014 5005393 315656 438604

Name of Part ENGINE COVER, Port ENGINE COVER, Port ENGINE COVER, 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 *VALVE Assy *LUBRICATION FITTING ENGINE COVER, Stbd ENGINE COVER, Stbd ENGINE COVER, Stbd *SCREW, Access panel *ACCESS PANEL

A B E

D C

A B E

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

Ref 22 23 24 25 26 27 28 29 30 31 32 33 34 35 35 35 36 37 38 39 40 41 42 43 44

Painted GRAPHITE Painted WHITE Cut to length from P/N 331018

D E

7

P/N 435026 308532 307256 330234 436048 202893 343578 342191 335500 309485 328735 339575 350242 350206 350857 5004576 343505 348811 343912 349556 349557 325115 333676 317972

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

Included in POWERHEAD GASKET SET ML, MX Models Only

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

150, 175 60° V6

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

ENGINE ELECTRICAL HARNESS ASSEMBLY

8

ENGINE ELECTRICAL HARNESS ASSEMBLY

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

P/N 586028 511469 513438 513185 512750 513186 511829 512876 330100 513423 513437 514021 513356 512947 583898 513357 581656 585078 514485

Name of Part ENGINE CABLE Assy *TERMINAL, Pin *CONNECTOR *SLEEVE *CONNECTOR, 4-pin *SLEEVE *TERMINAL, Ring *TERMINAL, Socket *TERMINAL, Ring *TERMINAL, Socket *SEAL, Wire to connector *FUSE, 20 Amp *CONNECTOR, 1-socket *TERMINAL, Bullet *DIODE KIT *CONNECTOR, 1-pin *TERMINAL, Socket *CONNECTOR & SEAL *SEAL, Wire to connector

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

Ref 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

9

P/N 514487 514680 514697 514696 514679 512745 176295 514788 127287 514684 514688 514683 514687 514790 514033 514035 514491 514022

Name of Part *TERMINAL, Socket *TERMINAL, Socket *LOCK WEDGE *CONNECTOR, 2-pin *TERMINAL, Pin *CONNECTOR, 2-socket *CONNECTOR, 2-socket **SEAL *LOCK WEDGE *LOCK WEDGE *CONNECTOR, 6-pin *LOCK WEDGE *CONNECTOR, 6-socket **SEAL *CONNECTOR, Fuse *TERMINAL *COVER *PLUG, Spare fuse

Qty 2 9 1 1 8 1 1 1 1 1 1 1 1 1 1 2 1 1

150, 175 60° V6

EPC3091

ELECTRICAL SYSTEM

29 21

16

15 26

20

57

27

23

55

22

56 54

28 12

44 18 19

33 13

35 24

34 41

30 41

17

39 40

42 48 47 49

36

31

42

50

38

32

52

24

37

51 25

45

46

53 14

10

43

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 A

P/N 584350 336135 584981 514374 513437 513424 513423 513664 513667 513665 317893 336732 315656 333430 316074 909533 328649 513584 331102 335428 315656 335204 315656 301551 342202 433581 341613 308995 336492 513818

Name of Part FLYWHEEL Assy SCREW, Flywheel STATOR Assy *SLEEVE *SEAL *CONNECTOR *TERMINAL *CONNECTOR *TERMINAL *PLUG, Seal *TIE STRAP GROMMET SCREW, Cover SCREW, Cable bracket to cyl head PLUG, Flywheel cover SCREW, Flywheel cover SCREW, Cover, power pack COVER, Power pack SCREW, Coil to block COVER, Sensor SCREW, Cover, sensor TIMING POINTER SCREW, Timing pointer LOCK WASHER, Ground BRACKET, Motor cable COVER Assy, Flywheel *BUSHING, Pinion & shaft to cover SCREW, Stator mounting VALVE, Flywheel cover COVER, Power pack to flywheel

Qty 1 5 1 2 6 1 6 1 2 1 2 1 4 2 2 17 4 1 6 1 3 1 1 12 1 1 1 4 3 1

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

ML, MX Models Only

11

P/N 328695 320107 328702 583740 584985 513439 513579 510818 513440 514754 512478 512256 317893 584919 584920 584921 586048 204053 514697 514679 513666 513663 513665 514696 350357 513917 350271 314099 336342 350957

Name of Part SCREW, Regulator TIE STRAP WASHER, Coil mounting COIL Assy, Dual POWER PACK *TERMINAL *SHIELD, Power pack *RING, Terminal *CONNECTOR, Sensor assy **SEAL, Connector *COVER *TERMINAL *TIE STRAP LEAD, Ignition coil 15½ in. (394mm) LEAD, Ignition coil 14½ in. (370mm) LEAD, Ignition coil 11 1/4 in. (286mm) RECTIFIER / REGULATOR *RING, Terminal *LOCK WEDGE *TERMINAL, Pin *TERMINAL, Blade *CONNECTOR *SEAL *CONNECTOR, 2-pin GASKET, Regulator to crankcase TIMING WHEEL SCREW, Timing wheel WASHER, Screw, timing wheel DECAL, Spark advance DECAL, Spark advance A

Qty 4 AR 6 3 1 5 1 1 1 1 6 6 3 2 2 2 1 1 2 2 2 1 1 1 1 1 1 1 1 1

150, 175 60° V6

EPC3092

FUEL COMPONENTS 56

37 32

79

55

33 35

80

49

50

47 54

34

19

41 89

71 75

46

43

36 66

42

44

37

67

48

45

77

51 76

25 77 37 86

84 40 39 52

78

69

53

38 23 24

59

61 60

82

72

63 31

65

85 74

30

83

93 88

6 10 20

68 11

80

13

28

26

70

13

27

62

18

2

58

17

64 73 90 81

15 16

12

4

14

91

21 57 21

12

10

9

83

5

3

7

83

8

6 92

22

FUEL COMPONENTS EPC3093 P/N 349009 5004558 512749 581656 435009 124549 125203 125212 340201 343172 345239 340200 335230 343852 124943 124378 512743 328649 332437

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

334132 349008 346150 348939 335229 328169 438081 909678 339277 333675 336316 336318 433352 338729 331307

37 38 39 40 41 42 43 44 45 46 47 48

320107 437232 512947 513185 511809 330121 332365 341297 333447 341071 175158 126341

A B C

Name of Part Qty HOSE, Connector to pump, oil 1 1 FUEL PUMP Assy 1 *CONNECTOR, 4 Socket *SOCKET 4 *PULSE LIMITER 1 2 *SCREW, Retainer *O-RING, Pulse fitting 1 *SCREW, Pulse fitting retainer 2 1 *RETAINER, Pulse fitting *RETAINER, Outlet fitting 1 1 *FITTING, Fuel outlet *FITTING, Pulse 1 *O-RING, Fuel outlet fitting 3 *FITTING, Fuel inlet 1 *CHECK VALVE, Fuel inlet 1 *O-RING, Fuel inlet fitting 1 RETAINER, connector 1 3 SCREW, Pump to bracket O-RING, Vapor pump to cover 1 HOSE, Vapor sep to vacuum switch, A 1 5½ in. (140mm) HOSE, Vapor sep to pump assy 1 CONNECTOR, Oil 1 CLAMP, 18.5mm 1 CONNECTOR, Fuel 1 SCREW, Vapor pump to cover 2 NUT, Vacuum switch 1 SWITCH, Vacuum 1 1 O-RING, Vacuum switch to brkt CLAMP, Wire, oil hose 1 SCREW, Bracket to c/c cover 4 4 WASHER, Screw, bracket to cover HOSE, Pulse, vapor pump to c/c cover 1 PUMP Assy, Vapor 1 1 *GASKET *DIAPHRAGM, Main 1 HOSE, Vapor pump to lower bearing B 1 vent nipple, 17 in. (432mm) TIE STRAP AR SOLENOID Assy, Primer 1 *TERMINAL, Bullet 1 *SLEEVE 1 *PLUNGER 1 4 *SCREW, Cover to housing 1 *FILTER, Valve housing *GASKET, Housing 1 1 *VALVE, Plunger *COVER, Solenoid 1 1 *VALVE Assy, Maintenance **CAP VALVE 1

Cut to length from P/N 772571 Cut to length from P/N 772569 Cut to length from P/N 772568

Ref 49 50 51 52 53 54

P/N 331365 511986 511987 512876 513186

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 88 89 90 91 92 93

D E

13

513816 333407 436695 335240 124369 396521 336842 333639 327270 331365 326164 328649 332437 335112 336650 335234 335385 335236 335685 433190 326467 305739 343576 433410

339276 339278 335231 339279 315656 349010 336131 329518 336132 326164 339277 347108 348948

Name of Part **O-RING, Valve *SPRING, Valve *SPRING, Plunger *TERMINAL, Socket *SLEEVE, Terminal HOSE, Primer solenoid to primer C Stbd - 14 in. (356mm) HOSE, Primer solenoid to primer C Port - 10½ in. (267mm) SLEEVE, Pulse hose HOSE, Pulse VAPOR SEPARATOR Assy E *BRACKET, Fuel components *O-RING, Filter to vapor separator *FLOAT VALVE Assy, Vapor separator **SPRING CLIP *O-RING, Vapor sep nipple to brkt *GASKET, Fuel filter *O-RING, Vapor separator *SCREW, Hinge pin to separator *SCREW, Cover *O-RING, Vapor sep vacuum nipple *NUT, Fuel filter *PIN, Vapor float assy *NIPPLE, Vapor separator outlet *COVER, Vapor separator *SEAL, Vapor sep to bracket *RETAINER, Outlet nipple to bracket *FUEL FILTER Assy *NIPPLE, Vapor sep, vacuum pick-up *O-RING, Nipple, cover to manifold *NIPPLE, Fuel outlet *FLOAT & ARM Assy, Vapor sep HOSE, Vapor pump to tee, D 7 in. (178mm) CLAMP, Wire CLAMP, Wire, pulse hose O-RING, Primer solenoid to bracket CLAMP, Wire, fuel line SCREW, Primer solenoid to bracket HOSE, Fuel connector to filter HOSE, Bracket to manifold - Stbd GROMMET, Bracket to c/c HOSE, Bracket to port manifold SCREW, Nipple retainer to bracket CLAMP, Oil supply CLAMP, 13.8mm SPACER, Bracket to c/c

Cut to length from P/N 335738 Not Shown

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

150, 175 60° V6

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

CARBURETOR & INTAKE MANIFOLD

46

69

36

27 29

22

40

48

3

53

55

38

10 34

31 33

56

4

30

32

17 14

52

25

15

18 21

60

12

35

19 11 9

26

24

49

16 28 20

2 6

71

8

5 50

7

57

51 41 37

23 63

42

66 46

67 45

54

58 47 38

70 68

44 43

40 39 65

13

64

1

61 62

72 CARBURETOR REPAIR KIT

14

59

CARBURETOR & INTAKE MANIFOLD

Ref 1 1 1 1 1 1 2 2 2 2 2 2 3 4 5 6 7 8 9 10 10 10 11 12 13 14 15 16 16 16 17 18 19 20 21 22 23 24 25 26 27 28 29 29 29 A B C

P/N 5005559 5005558 5005554 5005555 5005556 5005557 437291 436848 436846 437290 436847 436845 328714 328765 340656 340657 340654 328649 433000 334568 323149 317473 396522 336842 343512 328714 336366 327487 327558 319831 335070 335077 433167 327116 326164 343613 335363 433364 335362 324643 351153 305739 439785 439785 438995

Name of Part Qty CARBURETOR Assy, 175 - Stbd 1 N CARBURETOR Assy, 175 - Port 1 N CARBURETOR Assy, 150 - Port A,N 1 CARBURETOR Assy, 150 - Stbd A,N 1 CARBURETOR Assy, 150 - Port B,N 1 CARBURETOR Assy, 150 - Stbd B,N 1 1 *THROTTLE BODY Assy, 175 - Port 1 *THROTTLE BODY Assy, 150 - Port A 1 *THROTTLE BODY Assy, 150 - Port B *THROTTLE BODY Assy, 175 - Stbd 1 1 *THROTTLE BODY Assy, 150 - Stbd A 1 *THROTTLE BODY Assy, 150 - Stbd B 1 **SCREW, Clip **CLIP 1 3 **COVER, Calibration pocket 3 **GASKET, Cover C **SCREW, Cover 6 12 *SCREW, Bowl to body *FLOAT CHAMBER Assy 3 *ORIFICE, #39 - 175 3 3 *ORIFICE, #38 - 150 A 3 *ORIFICE, #30 - 150 B *FLOAT VALVE Assy 3 C **SPRING CLIP 1 3 *GASKET, Nozzle well C 3 *SCREW, Clip, manifold 3 *CLIP, Manifold to throttle body *ORIFICE, High speed, #73D - 175 3 3 *ORIFICE, High speed, #69D - 150 A 3 *ORIFICE, High speed, #59D - 150 B 3 *GASKET, Float bowl C *PIN, Float 3 C 3 *FLOAT Assy C 3 *SCREW, Plug 3 *SCREW, Hinge pin 3 *SEAL, Carburetor body C *SCREEN, Throttle body 3 *FUEL MANIFOLD, Port & Stbd 1 6 *O-RING, Fuel manifold D 6 *SCREW, Carburetor body *SCREW, Carburetor body 3 N 3 *O-RING, Screw plug C CARBURETOR BODY Assy, 175 3 3 CARBURETOR BODY Assy, 150 A CARBURETOR BODY Assy, 150 3 B

Ref 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 58 59 60 61 62 63 64 65

P/N 335244 341084 341085 315656 332576 351137 336226 336227 318165 320107 433521 433241 433249 437773 336639 335121 335362 348947 389823 323412 323601 327074 317739 351138 432639 328735 335257 328744 437372 335242 333677 323626 335729 335403 335404

66 67 68 69

324678 303630 336821

70 71 72

324643 344038 438996

20 in. Models 25 in. Models Included in CARBURETOR REPAIR KIT

D E N

15

Name of Part Qty **SEAL, Air silencer 1 **COVER PLATE 1 **GASKET, Cover plate 1 C **SCREW, Cover plate 5 *SPRING, Needle valve 3 *NEEDLE VALVE 3 N GASKET, Manifold to block, Port 1 D GASKET, Manifold to block, Stbd 1 D RETAINER, Carburetor link 2 TIE STRAP, Hose to balance tube, Stbd 1 MANIFOLD Assy, Balance tube 2 INTAKE MANIFOLD Assy, Port 1 INTAKE MANIFOLD Assy, Stbd 1 *CHECK VALVE 6 *SCREEN 6 FITTING, Primer 2 O-RING, Balance tube 12 LINK, Port to carburetor, Stbd 1 LEAF PLATE Assy 6 *SHIM 1 *LEAF STOP 2 *SCREW 8 *LEAF VALVE 2 1 SCREW, Lever N ROLLER, Cam follower 1 WASHER, Lever 1 LEVER, Linkage adjustment 1 SCREW, Manifold to crankcase 16 AIR SILENCER Assy 1 *STRAP, Air silencer cover 4 SCREW, Reed block to manifold 12 SCREW, Throttle body to block 4 RETAINER, Balance tube 4 SEAL, Manifold to carburetor, Port D 1 SEAL, Manifold to carburetor, Stbd D 1 HOSE, Balance tube to lower main, E 1 Stbd, 15 in. (381mm) O-RING, Roller & sleeve 1 WASHER, Primer nipple 2 SEAL, Air silencer 6 D HOSE, Balance tube to air silencer E 1 drain, Port, 19 in. (483mm) SCREW, Carburetor to block 1 SCREW, Manifold, inner 6 CARBURETOR REPAIR KIT 1

Included in POWERHEAD GASKET KIT Cut to length from P/N 335733 New P/N for 2004

150, 175 60° V6

EPC3094

THROTTLE LINKAGE

13

23 3 20 16

18

7

11 5

13

6 10

18 17

12 4 24

19

9 14

8

21

2 21 1 15 26 25

22

EPC3095 Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 N

P/N 438957 335547 335544 351139 335545 351146 343978 335593 328702 342394 335592 335595 323326 315656

Name of Part THROTTLE CAM & ARM Assy *CAM, Throttle *SHAFT, Roller arm *SCREW, Roller arm *ARM, Roller *WASHER, Screw *HUB, Roller arm ARM, Idle roller WASHER, Clip SPRING, Sensor CAM, Spark LINK, Throttle ROLLER, Cam SCREW, Clamp linkage

N N

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 4

Ref 14 15 16 17 18 19 20 21 22 23 24 25 26

New P/N for 2004

16

P/N 5004426 335303 335543 335548 335717 333774 351146 315656 335591 351139 586343 328649 335300

Name of Part THROTTLE ARM & PIN RETAINER, Support, sensor, Stbd THROTTLE LEVER SHAFT, Throttle arm RETAINER, Linkage to cover CLIP, Link WASHER, Roller SCREW, Sensor retainers SUPPORT, Sensor SCREW, Roller assy SENSOR Assy SCREW, Sensor to support RETAINER, Support, sensor, Port

N

N

Qty 1 1 1 1 2 1 1 5 1 1 1 2 1

150, 175 60° V6

CRANKSHAFT & PISTONS

EPC3096 Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 A

P/N 340559 336232 327861 438930 326047 433503 306972 337087 337030 392591 308186 387787 335825 436243 436242

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 RETAINER SET SPLIT LINER, Bearing PISTON, Std -Stbd PISTON, Std - Port

A

A

Qty 1 1 6 1 1 1 1 1 1 6 2 6 3 3 3

Ref 14 14 14 14 15 15 15 16 17 18 19 20 21 22

Included in POWERHEAD GASKET KIT

17

P/N 439520 439027 439521 439519 436353 439029 436354 317831 387041 338518 337085 395627 307480 319244

Name of Part Qty PISTON/RING Assy, 0.020 in. O.S. (Stbd) 3 PISTON/RING Assy, 0.020 in. O.S. (Port) 3 PISTON/RING Assy, 0.030 in. O.S. (Stbd) 3 PISTON/RING Assy, 0.030 in. O.S. (Port) 3 RING SET, Std 6 *RING SET, 0.020 in. O.S. 6 *RING SET, 0.030 in. O.S. 6 *RETAINING RING 12 RETAINER & NEEDLE SET 3 O-RING, Housing 1 A SEAL, Lower housing 1 A BEARING & RETAINER 6 KEY, Timing wheel 1 SEAL RING 9

CYLINDER & CRANKCASE 23

64 22

21 84

34

33 29

41 1

85

20

86

32 65 7 71 24 51 50

7

64 25

30 69

87

15 16

46

18

84

26

3

17 68

5

2

14

28

57 63

31 4

54

27

67

9 7 8

79 39 58

66

84

55 37

52 35

78 77

38 47 42

45 70 44

40

56 12

11 10

36

74 80 76 82 81

44 70

48 19

13

73 83

72

62 6

43

75

61 60

59

49

88

44 53

18

CYLINDER & CRANKCASE

Ref 1 1 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

P/N 5004179 5004178 5004180 304178 305070 336630 336166 335611 335369 437784 437773 330263 340418 5004323 348449 437929 585184 511469 513357 329562 340734 585023 511469 512746 329562 331188 335981 350458 330935 328725 344044

A B C N

20 in. Models 25 in. Models Included in POWERHEAD GASKET SET New P/N for 2004

433817 332135 328724 335523 330933 343118 328725 306012 336136 311015 316195 202026 439333 328702 349060 303492

Name of Part Qty CYLINDER & C'CASE Assy, 150 1 A 1 CYLINDER & C'CASE Assy, 150 B 1 CYLINDER & C'CASE Assy, 175 *PIN, Dowel bearing 3 1 *PIN, Taper *PIN, Roll 4 6 *SCREW, Cylinder to crankcase *SCREW, Cylinder to crankcase 2 *FITTING, Drain 1 6 *FITTING & CHECK VALVE Assy *CHECK VALVE Assy, #1, 2 & 3 main brg 3 SCREW, Upper mount retention 1 1 RETAINER, Upper mount 1 MOUNT, Kit - Upper 2 *SCREW, Upper mount SPARK PLUG, Champion, QL78YC 6 TEMPERATURE SWITCH, Stbd 1 *TERMINAL, Pin 1 1 *CONNECTOR, 1-pin *COVER, Temperature switch 1 BUSHING, Shift arm 1 TEMPERATURE SWITCH, Port 1 *TERMINAL, Pin 2 *CONNECTOR, 2-pin 1 2 *COVER, Temperature switch 2 O-RING, Thermostat cover C SEAL, Thermostat 2 C SCREW, Cylinder to crankcase 18 BUSHING, Shift lever 1 SCREW, Shift rod lever 1 CLAMP, Cable to c/c 1 HOSE, Drain system E AR 1 LEVER Assy, Shift rod 2 PLUG, Cylinder head pressure tap 1 SCREW, Clamp, Cables to c/c O-RING, Cylinder head 6 C 1 SCREW, Shift arm to block LINK, Shift lever to shift arm 1 SCREW, Cover, trunnion 1 SPRING WASHER, Shift shaft 1 2 CLAMP, Grommet, exhaust BUSHING, Shift lever 1 SCREW, Guide to block 1 WASHER, Shift arm 1 SHIFT LEVER 1 WASHER, Link to shift arm 3 COVER, Trunnion 1 FITTING, Pulse, vapor pump 1

Ref 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 64 64 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86

P/N 330941 5005702 349061 435491 338174 328733 333774 439953 328744 335316 436857 349729 335521 340767 324677 329513 301967 337548 338311 338311 338082 337478 349557 349556 339066 333774 338632 585013 510818 513356 581656 317893 336430 512931 343398 513811 513134 333749 338990 512741 313537

87 88 D E F

19

437155

Name of Part PIN, Shift arm SHIFT SHAFT & ARM Assy N TRUNNION BLOCK THERMOSTAT Assy SPRING, Thermostat SPRING WASHER, Shift lever CLIP, Shift lever, shift arm GROMMET & INSERT, Exhaust relief SCREW, Trunnion to block SEAL, Shift rod PLUG & NOZZLE, Overboard indicator CLAMP, Grommet (14mm) BUSHING, Shift lever to block FITTING, Lower drain O-RING, Nipple, lower drain C SCREW, Lower drain nipple O-RING, Overboard indicator CYLINDER HEAD, 150 CX, PX B CYLINDER HEAD, 150 PL, GL CYLINDER HEAD, 175 (All models) CYLINDER HEAD, 150 ML, MX GUIDE, Stator wires MOUNT WASHER, Mount SCREW, Cylinder head HOSE, Cylinder vent, 18 in. (457mm) F CLIP, Shift link COVER, Thermostat SWITCH & CABLE *TERMINAL, Ring *CONNECTOR, 1-socket *TERMINAL, Socket *TIE STRAP *SLEEVE, Braided *TUBING, Heat shrink HOSE, Grommet BRACKET, Slider BRACKET, Snap SPRING, Shift assist PIN, Shift assist RETAINER, Connector TEE, Hoses, vent HOSE, Tee to air silencer, 2 1/4 in. D (57mm) HOSE, Tee to upper bearing vent, D 5½ in. (140mm) POWERHEAD GASKET SET

Cut to length from P/N 772570 Cut to length from P/N 772569 Cut to length from P/N 772571

Qty 1 1 1 2 2 1 1 1 2 1 1 2 1 1 1 1 1 2 2 2 2 1 4 4 40 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 3 1 1 1 1

150, 175 60° V6

EPC3097

ELECTRIC STARTER 2 19

1

18 16 BATTERY CABLE 6 3

6

6 17

27 13

11 4

26 25

23

7 18 22 5

9

8

6

21 14

23 15

24 12 20

10

EPC3098 Ref 1 2 3 4 5 6 7 8 9 10 11 12 13

P/N 586287 5001579 335856 433849 433852 335857 433850 586180 583995 328724 330112 335309 306556 335308

Name of Part STARTER MOTOR Assy *CAP Assy, Drive end *SEAL, Shaft *ARMATURE Assy *CAP Assy, Commutator *SCREW, Cap *BRUSH & SPRING SET SOLENOID Assy BAR & TUBING, Solenoid to starter SCREW, Battery cable ground CLAMP, Solenoid to starter GEAR, Drive, starter NUT, Terminal GEAR, Pinion & shaft

Qty 1 1 1 1 1 2 1 1 1 1 1 1 2 1

Ref 14 15 16 17 18 19 20 21 22 23 24 25 26 27

20

P/N 311349 335778 434517 513398 322000 435294 328724 331259 328701 331259 327283 311217 341613 586770

Name of Part NUT, Terminal NUT, Bus bar, starter motor PINION & SHAFT Assy RETAINING RING, Drive gear SCREW, Starter to crankcase PINION HARDWARE KIT Assy SCREW, Clamp, solenoid LOCK WASHER, Terminal LOCK WASHER LOCK WASHER LOCK WASHER, Terminal SLEEVE, Solenoid BUSHING, Pinion & shaft BATTERY CABLE, 12ft.(3.15m)

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

EXHAUST HOUSING

150, 175 60° V6

16

EPC3099 Ref 1 2 3 3 4 5 6 6 7 7 8 9 10 11 11

P/N 341910 317624 350964 350965 911042 301161 434629 434632 335520 335519 314008 328725 346354 341197 338664

Name of Part COVER, Mount bracket lower SCREW, Cover EXHAUST HOUSING, Outer EXHAUST HOUSING, Outer SCREW, Exhaust housing WASHER, Exhaust housing RUBBER MOUNT, Lower RUBBER MOUNT, Lower WATER TUBE WATER TUBE GROMMET, Water tube SCREW, Inner to outer hsg/block GASKET, Hsg to powerhead EXHAUST HOUSING, Inner, lower EXHAUST HOUSING, Inner, lower

A Included in POWERHEAD GASKET SET B 20 in. Models

B C

B C B C

A B C

Qty 2 8 1 1 6 6 2 2 1 1 1 5 1 1 1

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

P/N 334955 320936 320961 320936 319126 301250 336301 342979 341191 345776 910736 910741 301250 911201

Name of Part Qty EXHAUST HOUSING, Inner, upper 1 SEAL, Exhaust housing, lower 1 SEAL, Gearcase to inner housing 1 SEAL, Exhaust housing 1 SCREW, Housing to block, outer 4 WASHER, Screw, mount 8 ROLL PIN, Housing to block 1 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

C 25 in. Models

21

MIDSECTION 78

73 46 71 66

39

60 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

22

MIDSECTION EPC3100

A B C N

P/N 434691 434724 313607 908768 320962 335686 337579 336819 910992 327696 336210 328724 328724 328724 340006 338744 320746 335814 342191 319886 336230 334936 5001766 5001825 5001908 514686 335474 335475 320866 336172 335481 337586 335486 513817 335701 336529 433580 335554 337592 336853 335470 334241 335485 348449 336467 328724 584136 337580

Name of Part SWIVEL BRACKET A SWIVEL BRACKET B *FITTING, Lubrication *FITTING, Lubrication D *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 A MOUNT BRACKET B NUT, Mount bracket RETAINER, Trail lock spring SCREW, Retainer to bracket SCREW SPRING, Detent, tilt lock SCREW, Mount STEERING ARM Assy E STEERING ARM Assy B STEERING ARM Assy F,N CONNECTOR, Sending unit, 3-pin COVER, Stern bracket, Stbd C COVER, Stern bracket, Port C 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

20 in. Models 25 in. Models Accessory Item New P/N for 2004

Qty 1 1 2 2 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

Ref 44 45 46 47 48 49 50 51 52 53 54 55 56 57

P/N 336506 336209 435007 336171 324816 337593 337591 336525 313623 307238 320248 335487 328744 327053

Name of Part Qty STERN BRACKET, Starboard 1 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 SCREW, Sending unit 2 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 65 586160 SENDING UNIT Assy 1 66 513871 *TERMINAL, Ring 1 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 D ML, MX Models E 150PL, 150ML, 175PL Models F 150GL, 175GL Models

23

150, 175 60° V6

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

POWER TRIM/TILT HYDRAULIC ASSEMBLY

31 33

34

10 11

35 37

32

36 38 39

24

POWER TRIM/TILT HYDRAULIC ASSEMBLY EPC3101

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

P/N Name of Part 5005113 HYDRAULIC Assy 435340 *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

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

Ref 20 21 22 23 24 25 26

Name of Part Qty *RETAINING RING 1 1 *CAP Assy *TRIM ROD 2 *ROD AND EYE 1 *PISTON Assy 1 *NUT 1 SLEEVE, Trim motor & sending unit leads 1 27 335479 BUSHING, Upper & lower mount 4 28 336534 RETAINING RING 4 29 512258 SLEEVE, Motor leads 1 30 3010049 CONNECTOR, Motor 1 31 335480 PIN, Tilt cylinder 1 32 335463 ROD, Lower mount 1 33 585229 BRUSH & SEAL KIT, Trim motor 1 34 434519 O-RING & SEAL KIT 1 35 586074 SWITCH Assy, Trim & tilt lower cover 1 36 514686 *CONNECTOR, 3-pin 1 37 514679 *TERMINAL, Pin 3 38 514682 *LOCK WEDGE 1 39 334656 NUT, Switch 1

25

P/N 914069 390006 436389 436390 435263 324390 513816

150, 175 60° V6

Ref

POWER TRIM AND TILT ELECTRICAL

27 28 29 30 31

4

5

4

21 21 11,12,14,15 21

6,17

10,13,16 21

8

1,2,3,11

22

18,19,20 26 7,9

21 11,12,14,15

24 23

25

26

POWER TRIM AND TILT ELECTRICAL

Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

P/N 586636 176295 514788 127287 204053 317893 334191 512947 513167 513185 514679 514680 514681 514682 514685 514789

Name of Part RELAY & CABLE Assy *CONNECTOR, 2 Socket **SEAL, 2 Socket *LOCKWEDGE, 2 Socket *TERMINAL, Ring *TIE STRAP *BRACKET *TERMINAL, Bullet *TERMINAL, Socket *SLEEVE, Bullet *TERMINAL, Pin *TERMINAL, Socket *LOCKWEDGE, 3 Socket *LOCKWEDGE, 3 Pin *CONNECTOR, 3 Socket **SEAL, 3 Socket

Qty 1 1 1 1 2 11 1 1 8 1 3 7 2 1 2 2

Ref 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

A Cut to length from P/N 3010862 B Cut to length from P/N 3010933

27

P/N 514686 586224 3010023 3010484 3010485

315656 335572 907833 315656 586074 511469 514686 514682 334656

Name of Part Qty *CONNECTOR, 3 Pin 1 *RELAY 2 *SEAL, Terminal 2 *CONNECTOR, 2 Pin 1 *TERMINAL 2 *SLEEVE, Braided A AR *SLEEVE, Braided B AR 2 SCREW, Relay to bracket BRACKET, Trim & tilt relays 1 TIE STRAP, Bracket to carburetor 1 2 SCREW, Bracket to carburetor body TRIM SWITCH 1 *TERMINAL, Pin 3 *CONNECTOR, 3-pin 1 *LOCK WEDGE 1 NUT, Trim switch 1

150, 175 60° V6

EPC3102

GEARCASE - PL, GL MODELS

96

52

28

GEARCASE - PL, GL MODELS

Ref

P/N 5005401 5005551 1 439972 2 387817 3 324852 3A 332584 4 337061 5 337778 6 439476 7A 329922 7B 329923 8 389042 9 317624 10 389455 10B 331880 11 915954 12 911962 13 334163 14 322938 15 322941 16 328825 17 314728 18 5004765 19 314731 20 382408 21 333957 22 345905 23 324670 24 5004257 25 382407 26 436752 27 334950 28 305123 29 431708 30 908158 31 349001 32 916070 32A 345998 33 5004218 34 336561 34A 327656 36 328743 37 387656 38 337774 39 313448 40 324369 41 318544 42 311598 43 323362 43 323361 43 314745 44 327669 45 5004598 A B D E

Name of Part GEARCASE Assy (Primed) GEARCASE Assy, Graphite GL Models N *GEARCASE & BEARING ASSY. **BEARING, Pinion **RETAINING SCREW ***SEAL **SCREW, Screens **SCREEN *BEARING HOUSING & SEAL **SEAL, Upper D **SEAL, Lower D *THRUST BRG. ASSY., Fwd. gear *SCREW, Housing to gearcase *HOUSING & BEARING ASSY. **PIN, Housing *DETENT, Shifter *SPRING, Detent *CRADLE, Shifter *LEVER, Shift *SHAFT *PIN, Shift lever *O-RING, Driveshaft bearing D *PROPELLER SHAFT ASSY. *THRUST WASHER, Reverse gear *THRUST BEARING, Reverse gear *TAB, Retainer *DRIVESHAFT, Lower *GASKET, Shift rod cover D *BEARING HOUSING & SEAL ASSY. **NEEDLE BEARING ASSY. **NEEDLE BEARING ASSY. **SEAL D **O-RING, Bearing housing D **ANODE, Bearing housing **SCREW, Anode *WEDGE *SCREW, Wedge (OMC Ultra Lock) *SPRING WASHER *GEAR & PINION ASSY. **GEAR, Reverse *THRUST WASHER, Pinion *WASHER, Screw *THRUST BEARING, Pinion *SHIFTER, Clutch dog *PIN, Clutch dog *SPRING, Clutch dog pin *PLUG, Fill & drain **WASHER D *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.

Not Shown Refer to Genuine Part s Propeller Chart Contents of Gearcase Seal Kit Contents of Water Pump Repair Kit

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

Ref 46 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 63 64 65 66 66 67 68 69 70 71 72 73 74 75 76 78 78 79 80 83 83A 86 87 88 89 90 91 92 92 92 93 94 95 96 F G N

29

P/N 318372 302325 160084 341219 436745 350271 328702 311538 338504 321008 338484 314730 314008 338742 320943 320570 338486 338551 306643 313715 338485 338552 398042 306394 330265 331998 342994 331999 331353 5001593 331107 302035 126870 126869 5000615 330263 435959 338893 331188 302325 330266

Name of Part Qty **O-RING, Shift rod D 1 *SCREW, Cover 6 *BALL, Detent 1 *SCREW, Anode 1 *ANODE 1 *SCREW, Retainer tab 2 *WASHER 6 *ROLL PIN, Driveshaft 1 *RETAINER, Driveshaft 1 *GROMMET, Exh hsg to shift rod E 1 *GASKET, Impeller hsg. Plate D,E 1 *NUT, Pinion to driveshaft 1 GROMMET, Water tube E 1 TRIM TAB, Gearcase 1 GROMMET, Impeller housing E 1 SPACER, Propeller nut 1 CUP, Impeller housing E,F 1 CUP, Impeller housing G 1 SCREW, Cover to impeller E 2 SCREW, Trim tab 1 PLATE, Impeller housing E,F 1 PLATE, Impeller housing G 1 1 NUT & KEEPER, Propeller COTTER PIN, Propeller nut 1 WASHER, Screw, long 1 SCREW, Gearcase to housing 1 SHIFT ROD 1 SCREW, Gearcase to housing 4 SEAL, Impeller housing plate E 1 IMPELLER ASSY. E 1 *KEY, Impeller E 1 *O-RING, Impeller E 1 THRUST BUSHING, 3-blade 1 THRUST BUSHING, 4-blade 1 DRIVESHAFT Assy, Upper (Incl.#54-55) 1 SCREW, Gearcase, rear 1 IMPELLER HOUSING, Gearcase E 1 COVER, Impeller housing E 1 O-RING, Cup to housing E 1 SCREW, Impeller housing, 1 in.

E 4 WASHER 5 PROPELLER B AR 332394 *CONVERGING RING, 3-blade 1 313926 *SLEEVE, Bushing 1 387157 *BUSHING Assy, Alum Prop., 3-blade, 1 175401 *BUSHING Assy, SST Prop., 3-blade, 1 431730 *BUSHING Assy, Prop., 4-blade 1 5000411 GEARCASE SEAL KIT 1 5001595 WATER PUMP REPAIR KIT, Includes 1 impeller housing 435526 CHROME CUP & PLATE KIT 1 349354 SEAL, Impeller hsg to exhaust hsg C 1 Stainless Steel Chrome Plated New P/N for 2004

150, 175 60° V6

EPC3674

GEARCASE - ML, MX, PX 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

86 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

106

109 30

43

100 CHROME CUP & PLATE KIT

102 105 103

101

30

GEARCASE SEAL KIT

82 WATER PUMP REPAIR KIT

GEARCASE - ML, MX, PX MODELS Ref

P/N 5004633 5005549 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 5001582 387656 327656 321008 350038 337774 313448 324369 318544 311598 323362 323361 314745 327669 5004598 318372 439476

Name of Part Qty GEARCASE Assy, Complete - Primed 1 GEARCASE Assy, White PX Models N 1 1 *GEARCASE & BEARING Assy **BEARING, Pinion 1 1 **SCREW, Pinion bearing ***SEAL, Pinion brg screw 1 1 **CAP, Pitot tube fitting **NIPPLE, Pitot tube 1 **SCREW, Pitot seal 1 **WASHER & SEAL Assy, Pitot A 1 **SCREW, Anode 1 **ANODE, Gearcase 1 **LOCK WASHER, Anode 1 1 *RING, Propeller seal 1 *WASHER, Wedge screw 1 *WEDGE, Propshaft hsg to GC 1 *SCREW, Wedge *BALL, Detent 1 *WASHER, Shift rod cover screw 1 *O-RING, Driveshaft bearing hsg A 6 1 *SCREW, Housing to gearcase 4 *BEARING HSG Assy, Fwd Gear ** BEARING, Fwd Gear 1 1 **PIN, Housing *SPRING, Detent 1 *CRADLE, Shifter 1 *LEVER, Shift 1 *SHAFT, Shift 1 *PIN, Shift lever 1 *SCREW, Retainer tab 1 *PROPELLER SHAFT 2 1 *THRUST BEARING, Reverse gear 1 *THRUST BEARING, Fwd gear *TAB, Retainer 1 *THRUST WASHER, Reverse gear 2 *GASKET, Shift rod cover A 1 1 *BEARING HSG Assy, Propshaft 1 **NEEDLE BEARING Assy, Front 1 **NEEDLE BEARING Assy, Rear **SEAL, Propshaft A 1 ** O-RING, Propshaft housing A 2 1 **ANODE, Bearing housing **SCREW, Anode 1 *NUT, Pinion to driveshaft 2 *GEAR SET, Fwd, Rev, Pinion 1 *THRUST BEARING, Driveshaft 1 *THRUST WASHER, Driveshaft 1 1 *GROMMET, Exh hsg to shift rod *WASHER, Pinion nut 1 1 *SHIFTER, Clutch dog *PIN, Clutch dog 1 1 *SPRING, Clutch dog pin *SCREW, Fill & drain A 1 **SEAL, Fill & drain screw 2 2 *SHIM, 0.003 in. (0.07mm) *SHIM, 0.004 in. (0.10mm) AR AR *SHIM, 0.005 in. (0.12mm) *THRUST WASHER, Forward gear AR 1 *COVER & SEAL Assy, Shift rod **O-RING, Shift rod A 1 1 *BEARING HSG Assy, Driveshaft

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 57 A Contents of GEARCASE SEAL KIT

Ref P/N Name of Part Qty 58 329922 **SEAL, Upper A 1 59 329923 **SEAL, Lower A 1 60 347371 *DRIVESHAFT, Lower 1 61 302325 *SCREW, Shift rod cover 6 62 338504 *RETAINER, Driveshaft 1 63 311538 *ROLL PIN, Driveshaft 1 64 328743 *WASHER, Tab screw 2 65 347377 *DETENT, Shifter 1 1 66 5005063 *WATER SCREEN KIT, High flow 67 337061 **SCREW, Water intake screens 2 1 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 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 D 1 71 5000615 DRIVESHAFT Assy, Upper E 1 72 349591 SHIFT ROD D 1 72 349590 SHIFT ROD E 1 73 321122 SPACER, Shift rod cover D 1 74 331409 SEAL, Trim tab 1 75 338742 TRIM TAB 1 76 313715 SCREW, Trim tab 1 1 77 330263 SCREW, Mounting, 3/8 in. X 3.50 in.

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

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

5 81 330266 WASHER, Mounting screw, 3/8 in.

82 5001595 WATER PUMP REPAIR KIT, 1 1 83 320943 *GROMMET, Pump to exh housing 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 1 95 338893 *COVER, Impeller housing 96 338484 *GASKET, Impeller plate A 1 97 338601 *GROMMET, Sleeve to exh hsg D 1 99 338636 *SLEEVE, Pump cover extension D 1 100 435526 CHROME CUP & PLATE KIT F 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 E

B Not shown

F

C Refer to EVINRUDE / JOHNSON Genuine Part s Propeller D 25 in. Models

N

31

20 in. Models Included on J175MXSRC model, also available as accessory for standard models.

New P/N for 2004

150, 175 60° V6

EPC3054

GEARCASE - CX MODELS 17

14 15

105 101

73

13

77

27

102

57 59 69

107 48

96

66

33 67

87

104

106

34

10 11

79 80

93

6

98 81

100

85 5

86

4 3

61

99

92

89

58 9 8

82 7 83

86

97

WATER SCREEN KIT HIGH PERFORMANCE

78

103 95

94

WATER SCREEN KIT HIGH FLOW

74

76

75

65 64

84

53 55 50

91

51

56 52 51

49 12

47 46

88 87

65 64

62 63 68

38

54

31

24 56

37 72 71

45

70

116

21

30 23

32

35

42

114

117

26 36

60 39

16

44 43

19

22 18 20

108 109 111 113

115

25 28

40 41

112

29

110

32

90

GEARCASE - CX MODELS Ref

Name of Part GEARCASE Assy, White *GEARCASE & BEARING Assy **BEARING, Pinion **SCREW, Pinion bearing ***SEAL, Pinion brg screw **SCREW, Anode **ANODE **LOCKWASHER, Anode *NIPPLE, Pitot tube *CAP, Pitot tube fitting *SCREW, Pitot seal *WASHER & SEAL Assy, Pitot tube *RING, Propeller seal *BEARING HSG Assy, Driveshaft **SEAL, Upper **SEAL, Lower *THRUST WASHER, Propshaft *SCREW, Housing to gearcase *BEARING HSG Assy, Rev Gear **BEARING, Rev gear **PIN, Housing *DETENT, Shift *SPRING, Detent *CRADLE, Shift *LEVER, Shift *SHAFT, Shift *PIN, Shift lever *O-RING, Driveshaft bearing hsg *PROPELLER SHAFT *THRUST BEARING, Propshaft *THRUST BEARING, Reverse gear *CLUTCH SHAFT Assy **KIT, Clutch Shaft Retainer *THRUST WASHER, Driveshaft *GASKET, Shift rod cover *BEARING HSG Assy, Propshaft **NEEDLE BEARING Assy, Front **NEEDLE BEARING Assy, Rear **SEAL, Propshaft **O-RING, Propshaft shaft hsg **ANODE, Bearing housing **SCREW, Anode *SCREW, Wedge *WEDGE, Propshaft hsg to GC *WASHER, Wedge screw *THRUST WASHER, Reverse gear *NUT, Pinion to driveshaft *WASHER, Pinion nut *SHIM, 0.003 in. (0,07mm) *SHIM, 0.004 in. (0,10mm) *SHIM, 0.005 in. (0,12mm) *GEAR SET Assy **SHIM, 0.003 in. (0,07mm) **SHIM, 0.004 in. (0,10mm) **SHIM, 0.005 in. (0,12mm) **THRUST BEARING, Fwd gear **BEARING, Fwd gear **SET SCREW, Thrust flange **HOUSING, Fwd gear **THRUST FLANGE, Fwd gear **GEAR SET, Fwd, Rev, Pinion *COVER & SEAL ASSY, Shift rod **O-RING, Shift rod *SCREW, Shift rod cover

Ref 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77

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 48 48 49 50 50 50 51 52 53 54 55 56 57 58 59

P/N 5005550 5001589 387817 324852 332584 341219 436745 307161 336535 305749 341220 437330 346462 439476 329922 329923 313447 317624 5001602 389039 331880 347378 911962 334163 322938 348484 328825 314728 5001578 382408 389042 5000249 5005096 327656 324670 5001588 431926 436752 334950 326849 431708 908158 916070 349001 345998 327669 314730 350038 323362 323361 314745 5004995 338717 338718 338719 385043 389039 338716 333885 337796 5001585 5004598 318372 302325

A B C

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

N

A

A A

A

A

A A

A

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

78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108

109 110 111 111 112 113 114 115 116 117 N

33

P/N 160084 347371 313448 324369 318544 311598 321122 387656 337774 328702 333957 328743 350271 5005063 337061 349162 349163 5005124 337061 348479 348480 349591 5000624 311538 338504 330265 331998 331999 330263 330266 313715 338743 331409 5001595 338484 338485 338486 306643 320943 314008 331353 5001593 331107 302035 338893 302325 338601 435959 338636 331188 321008 435526 338551 338552 313926 175401 387157 320570 126870 398042 306394 5000411 350228

Name of Part *BALL, Detent *DRIVESHAFT, Lower *PIN, Clutch dog *SPRING, Clutch dog pin *SCREW, Fill & drain A **SEAL, Fill & drain screw *SPACER, Shift rod cover *THRUST BEARING, Driveshaft *SHIFTER, Clutch dog *WASHER, Shift rod cover screw *TAB, Retainer *WASHER, Tab screw *SCREW, Retainer tab *WATER SCREEN KIT, High flow **SCREW, Water intake screens **SCREEN, Wtr intake-high flow, Port **SCREEN, Wtr intake-high flow, Stbd WATER SCREEN KIT, High Perf *SCREW, Water intake screens B *SCREEN, Wtr intake-high perf, Port B *SCREEN, Wtr intake-high perf, Stbd B SHIFT ROD DRIVESHAFT Assy, Upper *ROLL PIN, Driveshaft *RETAINER, Driveshaft WASHER, Mounting screw, 7/16 in.

SCREW, Mounting, 7/16 in. X 3.50 in.

SCREW, Mounting, 3/8 in. X 1.75 in.

SCREW, Mounting, 3/8 in. X 3.50 in.

WASHER, Mounting screw, 3/8 in.

SCREW, Trim tab TRIM TAB SEAL, Trim tab WATER PUMP REPAIR KIT *GASKET, Impeller plate A *PLATE, Impeller hsg-(Stainless) *CUP, Impeller-(Stainless) *SCREW, Cover to impeller hsg *GROMMET, Pump to exh hsg *GROMMET, Water tube to cover *SEAL, Impeller housing plate *IMPELLER Assy *KEY, Impeller *O-RING, Impeller to plate *COVER, Impeller housing *SCREW, Impeller housing *GROMMET, Sleeve to exh hsg *IMPELLER HOUSING *SLEEVE, Pump cover extension *O-RING, Cup to housing GROMMET, Exh hsg to shift rod CHROME, CUP & PLATE KIT *CUP, Impeller-(Chrome) B *PLATE, Impeller hsg-(Chrome) B PROPELLER C *SLEEVE, Propeller bushing *BUSHING, S.S. propeller *BUSHING, Alum. propeller SPACER, Propeller nut THRUST BUSHING, Propeller NUT & KEEPER, Propeller COTTER PIN, Propeller nut GEARCASE SEAL KIT RETAINER, Ring

New P/N for 2004

Qty 1 1 1 1 2 1 1 1 1 6 2 2 2 1 2 1 1 1 2 1 1 1 1 1 1 1 4 1 5 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 AR 1 1 1 1 1 1 1 1 1

150, 175 60° V6

EPC3055

STEERING LINK KIT 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

A Accessory

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

34

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

35

150, 175 60° V6

36

37

150, 175 60° V6