2008 Evinrude E-TEC 200, 225, 250 HP 3.3 L Service Manual P/N 5007531
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- 2008 Evinrude E Tec 200 250 HP Service Manual
Original Certified Evinrude Service and Repair Manual for 2008 Evinrude E-TEC 200HP, 225HP, 250HP 3.3 L Outboard Motors.
P/N: 5007531
This manual covers the following model(s):
Evinrude E-TEC 200, 225, 250 HP 90° V6 (3.3L) 2008 (2 stroke)
| Model Number | Shaft | Color | Gearcase |
|---|---|---|---|
| E200DHLSCM | 20" | BL | "L" |
| E200DHLSCF | 20" | BL | "L" |
| E200DHLSCG | 20" | BL | "L2" |
| E200HSLSCR | 20" | WH | "L" |
| E200HSLSCF | 20" | WH | "L" |
| E200HSLSCG | 20" | WH | "L2" |
| E200HVLSCS | 20" | WH | "M" |
| E200HVLSCF | 20" | WH | "M" |
| E200HVLSCG | 20" | WH | "M2" |
| E200DHXSCR | 25" | WH | "M" |
| E200DHXSCF | 25" | WH | "M" |
| E200DHXSCG | 25" | WH | "M2" |
| E200HCXSCR | 25" | WH | "M" CR |
| E200HCXSCF | 25" | WH | "M" CR |
| E200HCXSCG | 25" | WH | "M2" CR |
| E225DPLSCM | 20" | BL | "M" |
| E225DPLSCF | 20" | BL | "M" |
| E225DPLSCG | 20" | BL | "M2" |
| E225DHLSCM | 20" | BL | "L" |
| E225DHLSCF | 20" | BL | "L" |
| E225DHLSCG | 20" | BL | "L2" |
| E225HSLSCS | 20" | WH | "L" |
| E225HSLSCF | 20" | WH | "L" |
| E225HSLSCG | 20" | WH | "L2" |
| E225DHXSCA | 25" | BL | "L" |
| E225DHXSCF | 25" | BL | "L" |
| E225DHXSCG | 25" | BL | "L2" |
| E225DPXSCM | 25" | WH | "M" |
| E225DPXSCF | 25" | WH | "M" |
| E225DPXSCG | 25" | WH | "M2" |
| E225DCXSCM | 25" | WH | "M" CR |
| E225DCXSCF | 25" | WH | "M" CR |
| E225DCXSCG | 25" | WH | "M2" CR |
| E225DPZSCM | 30" | WH | "M" |
| E225DPZSCF | 30" | WH | "M" |
| E225DPZSCG | 30" | WH | "M2" |
| E225DCZSCM | 30" | WH | "M" CR |
| E225DCZSCF | 30" | WH | "M" CR |
| E225DCZSCG | 30" | WH | "M2" CR |
| E250DPLSCM | 20" | BL | "M" |
| E250DPLSCF | 20" | BL | "M" |
| E250DPLSCG | 20" | BL | "M2" |
| E250DPXSCM | 25" | WH | "M" |
| E250DPXSCF | 25" | WH | "M" |
| E250DPXSCG | 25" | WH | "M2" |
| E250DCXSCM | 25" | WH | "M" CR |
| E250DCXSCF | 25" | WH | "M" CR |
| E250DCXSCG | 25" | WH | "M2" CR |
| E250DPZSCM | 30" | WH | "M" |
| E250DPZSCF | 30" | WH | "M" |
| E250DPZSCG | 30" | WH | "M2" |
| E250DCZSCM | 30" | WH | "M" CR |
| E250DCZSCF | 30" | WH | "M" CR |
| E250DCZSCG | 30" | WH | "M2" CR |
This manual has exceptional quality with hundreds of high quality images and diagrams.
Manual Chapters:
- INTRODUCTION
- SPECIAL TOOLS
- INSTALLATION AND PREDELIVERY
- MAINTENANCE
- ENGINE COVER SERVICE
- ENGINE MANAGEMENT MODULE (EMM)
- SYSTEM ANALYSIS
- ELECTRICAL AND IGNITION
- FUEL SYSTEM
- OILING SYSTEM
- COOLING SYSTEM
- POWERHEAD
- MIDSECTION
- GEARCASE
- GEARCASE STANDARD ROTATION
- GEARCASE COUNTER ROTATION
- TRIM AND TILT
- SAFETY
- INDEX
- TROUBLE CHECK CHART
- DIAGRAMS
- EMM SERVICE CODE CHART
Manual has high quality images and color diagrams. It is searchable and deeply indexed.
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"2008 Evinrude E-TEC 200, 225, 250 HP 3.3 L Service Manual P/N 5007531" manual can be saved to any computer hard drive, flash storage, burned to a CD or DVD ROM or any other digital media.This Manual PDF file is:
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Reference and Info files
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Full list of manual chapters:
INTRODUCTION
ABBREVIATIONS USED IN THIS MANUAL
Units of Measurement
List of Abbreviations
ENGINE EMISSIONS INFORMATION
Manufacturer's Responsibility
Dealer's Responsibility
Owner's Responsibility
EPA Emission Regulations
MODEL DESIGNATION
MODELS COVERED IN THIS MANUAL
Identifying Model and Serial Numbers
SERVICE SPECIFICATIONS
STANDARD TORQUE SPECIFICATIONS
PRODUCT REFERENCE AND ILLUSTRATIONS
SPECIAL TOOLS
DIAGNOSTIC TOOLS
UNIVERSAL TOOLS
ELECTRICAL / IGNITION TOOLS
FUEL /OIL SYSTEM TOOLS
POWERHEAD TOOLS
GEARCASE TOOLS
TRIM AND TILT TOOLS
SHOP AIDS
INSTALLATION AND PREDELIVERY
BOAT RIGGING
Remote Controls
Battery Installation
Battery Switches and Multiple Batteries
Auxiliary Battery Charging
Battery and Switch Wiring Diagrams
Fuel System Requirements
Oiling System Set-Up
Cable and Hose Installation
OUTBOARD INSTALLATION
Hull Preparation
Transom Measuring and Drilling
Drilling and Hardware Diagrams
Lifting the Outboard
Steering Systems
Outboard Mounting
OUTBOARD RIGGING
Cable, Hose, and Wire Routing
Control Cable Installation
Electrical Harness Connections
Water Pressure Gauge
CANbus Connections
FUEL AND OIL PRIMING
Fuel Requirements
Fuel System Priming
Oil Requirements
Oil Injection Rate
Break-In Oiling
Oil Supply Priming
BEFORE START-UP
Gearcase Lubricant
Oil Level
Trim and Tilt Fluid
RUNNING CHECKS
Engine Monitoring System
Fuel System
Emergency Stop / Key Switch
Remote Control Operation
Start-In-Gear Prevention
Tachometer Pulse Setting
Water Pump Overboard Indicator
Operating Temperature
Idle Speed
Break-In
PROPELLERS
Propeller Selection
Propeller Hardware Installation
FINAL ADJUSTMENTS
Tilt Limit Switch Adjustment
Trim Sending Unit Adjustment
Trim Tab Adjustment
Dual-Outboard Alignment
NOTES
Technician's Notes
Related Documents
MAINTENANCE
INSPECTION AND MAINTENANCE SCHEDULE
ANTI-CORROSION PROTECTION
Sacrificial Anodes
Testing Procedure - Continuity
Metallic Component Protection
Exterior Finishes
COOLING SYSTEM
Flushing
Water Intake Screens
Additional Maintenance
LUBRICATION
Steering System
Swivel Bracket and Trailering Bracket
Tilt Tube
Throttle and Shift Linkage
Propeller Shaft
Gearcase Lubricant
Trim and Tilt
BATTERY AND BATTERY CONNECTIONS
FUEL AND OIL SYSTEMS
Fuel Filter
Oil Filters and Oil Reservoir
Air Silencer
Hoses and Connections
SPARK PLUGS
Indexing
EXHAUST PRESSURE FITTING
Operation Test
Cleaning
STORAGE
Fuel System Treatment
Internal Engine Treatment
Additional Recommendations
PRE-SEASON SERVICE
Outboard Mounting Bolts
Gearcase Lubricant
Battery(s)
Power Trim and Tilt
Operational Checks
SUBMERGED ENGINES
Engine Dropped Overboard (Not Running)
Engine Dropped Overboard (Running)
Engine Dropped Overboard (In Salt Water)
Prolonged Submersion (Fresh or Salt Water)
ENGINE COVER SERVICE
UPPER COVER SERVICE
Latch Hook Installation
Upper Cover Cap Replacement
LOWER COVER SERVICE
Lower Cover Removal
Lower Cover Installation
Latch Handle Installation
Trim Switch Installation
ENGINE MANAGEMENT MODULE (EMM)
DESCRIPTION
EMM Functions
EMM Connections
LED Indicators
EMM INPUTS AND OUTPUTS DIAGRAM
INTERNAL SENSORS
EMM Temperature Sensor
55 V Circuit Sensor
12 V Circuit Sensor
Barometric Pressure Sensor
Exhaust Pressure Sensor
EXTERNAL SENSORS
Air Temperature Sensor
Engine Temperature Sensor
Oil Pressure Sensor
Throttle Position Sensor
Crankshaft Position Sensor
INTERNAL EMM FUNCTIONS
Start Assist Circuit (SAC)
ROM Verification
Idle Controller
RPM Limiter
Shift Interrupt
Engine Monitor and Warning Systems
Fault Code Creation and Storage
ENGINE MONITORING SYSTEM
System Self-Test
Service Mode
Engine Running
S.A.F.E. WARNING SYSTEM
Activation
Recovery
SHUTDOWN MODE
Recovery
DIAGNOSTIC SOFTWARE FUNCTIONS
Communication
Static Information
Dynamic Information
Stored Service Codes (Faults)
Hard Faults
Persistent Faults
Static Tests
Dynamic Tests
Oil Control Settings
Ignition Timing
TPS Calibration
Fuel Injector Servicing
Reports
Software Replacement
EMM Transfer
EMM SERVICING
Removal
Installation
SYSTEM ANALYSIS
DIAGNOSTIC PROCEDURES
Visual Inspections
Operational Inspections
Troubleshooting
DYNAMIC TESTS
Cylinder Drop Tests
Fuel Control Adjustment
Inductive Amp Meter Test
EMM LED INDICATORS
Key ON
Starting
Running
IGNITION OUTPUT TESTS
Required Ignition Systems
Wiring Inspection
Crankshaft Position Sensor (CPS) Test
System Voltage Test
Ignition Voltage Test
Static Ignition Test
Running Ignition Tests
Ignition Primary Circuit Resistance Test
Ignition Coil Tests
Capacitor Test
FUEL DELIVERY TESTS
Fuel Pump Static Test
Fuel Injector Static Test
Running Fuel System Tests
ELECTRICAL AND IGNITION
SERVICE CHART
DASH CONNECTIONS, INSTRUMENT HARNESS
ELECTRICAL HARNESS CONNECTIONS
Engine Harness to Stator Connector
EMM J1-A Connector
EMM J1-B Connector
EMM J2 Connector
GROUND CIRCUITS
EMM Ground Tests
Additional Ground Tests
FUSE
SENSOR TESTS
Crankshaft Position Sensor (CPS) Test
Throttle Position Sensor (TPS) Test
Engine Temperature Sensor Test
Air Temperature Sensor (AT) Test
STATOR TESTS
Stator Resistance Tests
Stator Voltage Output Test
CHARGING SYSTEM TESTS
12 V Charging Circuit
Auxiliary Battery - Charge Wire
55 V Alternator Circuit
ELECTRIC START CIRCUIT
Start Circuit Diagram
Start Circuit Operation
ELECTRIC START TESTS
Starter Solenoid Test
No Load Current Draw Test
REMOTE CONTROL SWITCH TESTS
Key Switch Test
Neutral Start Circuit Test
Neutral Start Switch Test
Emergency Stop Switch Test
TILT/TRIM RELAY TEST
Operation
Test Procedure
SystemCheck CIRCUIT TESTS
Gauge Self-Test Check
CHECK ENGINE Circuit Test
WATER TEMP/ HOT Circuit Test
LOW OIL Circuit Test
NO OIL Circuit
TACHOMETER CIRCUIT TESTS
FLYWHEEL AND STATOR SERVICING
Flywheel Removal
Stator Service
Flywheel Installation
TIMING ADJUSTMENTS
Timing Pointer
Timing Verification
TPS CALIBRATION
ELECTRIC STARTER SERVICING
Starter Removal
Starter Disassembly
Starter Cleaning and Inspection
Starter Assembly
Starter Installation
CONNECTOR SERVICING
DEUTSCH Connectors
AMP Connectors
Packard † Connectors
FUEL SYSTEM
SERVICE CHART
FUEL SYSTEM HOSE ROUTING
FUEL SYSTEM CIRCUIT DIAGRAM
COMPONENTS
Fuel Lift Pump
Fuel Filter
Vapor Separator
Fuel Circulation Pump
Fuel Manifolds
Fuel Injectors
FUEL SYSTEM TESTS
Fuel System Pressure Test
Pressure Regulator Test
Vapor Separator Vent Check
Fuel Injector Pressure Test
Fuel Injector Resistance Test
Circulation Pump Resistance Test
Lift Pump Pressure Test
Lift Pump Vacuum Test
Lift Pump Diaphragm Test
Anti-Siphon Valve Test
FUEL COMPONENT SERVICING
Relieving Fuel System Pressure
Fuel Filter Service
Fuel Lift Pump Service
Vapor Separator Service
Fuel Manifold Service
Fuel Injector Service
Intake Manifold Service
Installation
NOTES
Technician's Notes
Related Documents
OILING SYSTEM
SERVICE CHART
OILING SYSTEM CIRCUIT DIAGRAM
OIL SUPPLY DIAGRAMS - V6
OIL RECIRCULATION DIAGRAMS - V6
COMPONENTS
Oil Tank Assembly
Oil Injection Pump
Oil Pressure Sensor
Electrical Circuit (55 V)
LOW OIL Warning
NO OIL Warning
Cylinder and Crankcase
Oil Recirculation System
OIL CONTROL SETTINGS
Oil Priming
Oiling Rates
Break-in Oiling
OILING SYSTEM TESTS
Oil Injection Pump Static Test
Oil Injection Pump Voltage Test
Oil Injection Pump Circuit Resistance Test
Oil Supply Vacuum Test
Oil Injection Pump Function Test
Oil Injection Fittings Flow Test
LOW OIL Sending Unit Test
OIL COMPONENT SERVICING
Oil Distribution Hoses
Oil Injection Pump
COOLING SYSTEM
HOSE ROUTING AND WATER FLOW DIAGRAM
COMPONENTS
Water Pump and Intakes
Water Supply Tube
Adapter Housing
Pressure Relief Valve
Thermostats
Block Venting
OPERATION
Cylinder Block / Cylinder Head Cooling
EMM and Vapor Separator Cooling
ENGINE TEMPERATURE CHECK
Software Method
Pyrometer Method
Idle Operating Temperature Troubleshooting (Below Range)
THERMOSTAT SERVICING
Disassembly
Inspection
Assembly
PRESSURE RELIEF VALVE SERVICING
Disassembly
Inspection
Assembly
NOTES
Technician's Notes
Related Documents
POWERHEAD
SERVICE CHART
Taper Pin Tool
POWERHEAD REMOVAL
POWERHEAD DISASSEMBLY
General
Throttle Linkage Removal
Shift Linkage Removal
Crankcase Disassembly
Cylinder Head Removal
Connecting Rods and Pistons
Crankshaft Removal
CYLINDER BLOCK CLEANING
POWERHEAD INSPECTION
Cylinder Head
Crankshaft
Cylinder Bore
Pistons
Piston Rings
Bearings
POWERHEAD ASSEMBLY
Crankshaft
Pistons and Connecting Rods
Cylinder Head Installation
Crankshaft and Connecting Rods
Crankcase Assembly
Shift Linkage Installation
Throttle Linkage Installation
Final Powerhead Assembly
POWERHEAD INSTALLATION
POWERHEAD VIEWS
Port Hose Routings
Starboard Hose Routings
Port
Starboard
Front
Rear
Top
MIDSECTION
SERVICE CHART
TILT TUBE
Removal
Installation
EXHAUST HOUSING
Exhaust Housing Removal
Exhaust Housing Disassembly
Cleaning and Inspection
Exhaust Housing Assembly
Exhaust Housing Installation
STERN BRACKET
Removal
Stern Bracket Disassembly
Stern Bracket Assembly
EXHAUST RELIEF MUFFLER ASSEMBLY
GEARCASE
SERVICE CHARTS
GEARCASE TYPES
Housing Identification
Housing Profiles
PROPELLER SERVICE
Inspection
GEARCASE LEAK TEST
SHIFT INTERRUPT SWITCH
GEARCASE REMOVAL AND INSTALLATION
Gearcase Removal
Gearcase Installation
WATER PUMP SERVICE
Disassembly
Inspection
Assembly
SHIFT ROD ADJUSTMENT
GEARCASE - STANDARD ROTATION
GEARCASE DISASSEMBLY
Pre-Disassembly Inspection
Propeller Shaft Bearing Housing Removal - "L" and "M" Type
Propeller Shaft Bearing Housing Removal - "L2" and "M2" Type
Pinion Gear and Driveshaft Removal
Driveshaft Service
Shift Housing, Gear and Propeller Shaft Removal
Water Intake Screens
GEARCASE HOUSING INSPECTION
SHIFTER, BEARING AND SEAL SERVICING
Shift Housing Disassembly
Shift Housing Assembly
Pinion Bearing Removal
Pinion Bearing Installation
Driveshaft Bearing Housing Service
Propeller Shaft Bearing Housing Service
DRIVESHAFT SHIMMING
GEARCASE ASSEMBLY
Water Intake Screens
Shift Housing, Gear, and Propeller Shaft Installation
Shift Rod Cover
Pinion Gear and Driveshaft Installation
Propeller Shaft Bearing Housing and Gear Installation - "L" and "M" Type
Propeller Shaft Bearing Housing and Gear Installation - "L2" Type
Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
Final Assembly and Adjustment
GEARCASE - COUNTER ROTATION
GEARCASE DISASSEMBLY
Pre-Disassembly Inspection
Propeller Shaft Bearing Housing Removal - "M" Type
Propeller Shaft Bearing Housing Removal - "M2" Type
Pinion Gear Removal and Driveshaft Servicing
Shift Housing, Gear and Propeller Shaft Removal
Water Intake Screens
GEARCASE HOUSING INSPECTION
SHIFTER, BEARING AND SEAL SERVICING
Shift Housing Disassembly
Shift Housing Assembly
Pinion Bearing
Propeller Shaft Bearing Housing and Forward Gear
DRIVESHAFT SHIMMING
GEARCASE ASSEMBLY
Water Intake Screens
Shift Housing, Gear, and Propeller Shaft Installation
Shift Rod Cover
Pinion Gear and Driveshaft Installation
Propeller Shaft Bearing Housing and Gear Installation - "M" Type
Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
Final Assembly and Adjustment
NOTES
Technician's Notes
Related Documents
TRIM AND TILT
SERVICE CHART
SYSTEM DESCRIPTION
Manual Adjustment
Trailering Bracket and Tilt Support
MODES OF OPERATION
Trim-OUT / Tilt-UP Mode
2
Tilt-DOWN / Trim-IN Mode
Impact Relief
1
Shallow Water Drive Tilt Relief
Thermal Expansion Relief
Manual Release - UP
Manual Release - DOWN
ROUTINE INSPECTIONS
General
Reservoir Fluid
Manual Release Valve
Stern Brackets
TROUBLESHOOTING
Symptoms Chart
Service Procedures
Pressure Leakdown Test
ELECTRICAL CIRCUIT TESTS
Relay Testing
Trim and Tilt Motor Current Draw Tests
Trim and Tilt Motor No Load Test
Trim Gauge Test
Trim Sender Test
TRIM AND TILT SERVICE
Removal
Installation
Disassembly
Tilt Piston Removal
Tilt Piston Identification
Tilt Piston Assembly
Tilt Rod Assembly
Trim Rod Removal
Trim Rod Assembly
Manifold and Reservoir Installation
Trim Rod Installation
Tilt Rod Installation
Motor Installation
ADJUSTMENTS
NOTES
Technician's Notes
Related Documents
SAFETY
TABLE OF CONTENTS
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM
Outboard Shift Systems and Safety
Outboard Speed Control System and Safety
Outboard Steering Control System and Safety
Outboard Fuel, Electrical System, and Safety
Outboard Mounting System and Safety
If weakened, parts could fail later on the water, when not expected
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
Outboard Emergency Stop System and Safety
Summing up
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM
Handling Outboards
Handling Lead/Acid Batteries
Gasoline - Handle With Care!
Hazardous Products
Safety Awareness Test
INDEX
TROUBLE CHECK CHART
OUTBOARD WILL NOT START
OUTBOARD WILL NOT START
OUTBOARD HARD TO START
OUTBOARD WILL NOT SHUT OFF
OUTBOARD STARTS AND STALLS
OUTBOARD STARTS, LOW MAXIMUM RPM
EXCESSIVE SMOKING
OUTBOARD SURGES, RUNS ROUGH
DIAGRAMS
