2007 Evinrude E-TEC 115-200 HP 60° V4/V6 Outboard Service & Repair Manual (P/N 5007213)

BRP US Inc.'s 2007 Evinrude E-TEC service manual covers the 115, 150, 175, and 200 HP 60° V4/V6 outboards. Publication P/N 5007213 (copyright 2006) contains 13 technical sections covering installation, maintenance, diagnosis, and repair.

• EMM diagnosis: LED indicators, stored and persistent faults, static and dynamic tests, timing verification, and TPS calibration.

• Electrical and ignition: Crankshaft position sensor, ignition coil, stator, charging-system, and starter solenoid tests, plus flywheel and starter servicing.

• Fuel and intake: Fuel-pressure testing, vapor separator replacement, injector servicing, and throttle body and reed plate inspection.

• Oiling and cooling: Oil-pump circuit tests, manifold priming, temperature checks, thermostat and pressure relief valve service, and water-pump rebuilding.

• Powerhead repair: Removal, crankcase disassembly, piston and crankshaft inspection, bearing and seal installation, and reassembly with factory clearances and torque sequences.

• Midsection and gearcase: Exhaust housing and stern bracket service, pressure/vacuum leak testing, driveshaft shimming, and separate counter-rotation procedures.

• Trim and tilt: Single-piston and FasTrak troubleshooting, relay and motor checks, hydraulic leakdown tests, and three-piston cylinder seal service.

This manual was written for qualified, factory-trained technicians already familiar with Evinrude/Johnson special tools; it assumes workshop experience.

EMM Diagnosis and Electrical Fault Tracing

Live engine data and cylinder-drop tests help isolate a rough-running cylinder and compare ignition and fuel delivery before components are replaced. The Trouble Check Chart and EMM Service Code Chart connect symptoms and faults to further checks, SystemCheck warnings, S.A.F.E. operation, and shutdown conditions.

Software-based procedures use Evinrude Diagnostics P/N 763724 and interface cable P/N 437955. EMM replacement and software transfer coverage includes the timing verification required after EMM, CPS, flywheel, or crankshaft work.

The EMM Inputs and Outputs Diagram supports circuit identification. Color wiring diagrams include the MWS Instrument Wiring Harness and separate V4/V6 engine layouts.

Rigging coverage addresses I-Command/CANbus instrumentation, propeller selection, predelivery checks, and EPA-related service requirements.

Fuel Injection and Oil Delivery

Pressure, leakdown, vacuum, and resistance tests distinguish supply restrictions from pump, regulator, or injector problems. The Injector / Circulation Pump Circuits Diagram links fuel components to their electrical connections. The vapor separator and circulation pump are serviced as an assembly.

Injector coefficients are assigned by serial number and cylinder location; incorrect positioning or compensation programming can lead to powerhead failure. Oiling coverage includes TC-W3 and XD100 settings, break-in oiling, and separate V4/V6 Oil Supply and Distribution Diagrams with recirculation hose routing.

Pressurized fuel and stored electrical energy require the manual's pressure-relief and electrical-isolation precautions.

Powerhead Inspection, Cooling, and Maintenance

Internal repair coverage includes compression testing, cylinder-bore and ring inspection, and piston/connecting-rod assembly. The manual warns that incorrect rod-cap alignment or tightening without Alignment Fixture P/N 396749 can permanently damage the connecting rod and crankshaft.

Hose Routing and Water Flow Diagrams support cooling-system checks. Temperature diagnosis compares both cylinder banks and distinguishes low-speed thermostat faults from high-speed pressure relief problems.

Maintenance covers steering, swivel bracket, and propeller shaft lubrication, sacrificial anode checks, automatic self-winterizing, and procedures for submerged engines.

Gearcase, Midsection, and Trim/Tilt Service

Gearcase procedures distinguish S/S2, O, L, and M designs, with separate counter-rotation assembly instructions. Driveshaft shimming uses Tool P/N 5005925; exploded service charts identify component positions, torque specifications, and assembly materials.

Midsection instructions cover tilt tube, exhaust housing, and stern bracket disassembly, including the V4 exhaust valve actuator. The shift-interrupt switch section identifies the V4 tiller-kit application; its signal is unused on the covered remote-control models.

Trim/tilt chapters include hydraulic fault charts and three-piston cylinder work. The FasTrak pump manifold is replaced as an assembly rather than internally rebuilt.

A Sample of Ring-Clearance and Fuel-Pressure Data

These are a few of the service values included in the manual. Piston-ring inspection specifies an end gap of 0.011–0.023 in. (0.28–0.58 mm) for standard or oversize rings, measured in their respective bores.

The fuel specifications list 22–28 psi on the high-pressure side and 3–4 psi from the lift pump at 500 ± 50 RPM idle. Separate test sections cover pressure loss, regulator operation, and fuel-supply restrictions.

Searchable Service Text and Printable Diagrams

Search, bookmarks, and diagram detail: Service chapters have searchable text and chapter/subsection bookmarks. The MWS key-switch diagram on PDF p. 435 has no searchable labels. Small wiring pin numbers require zooming. The “Return to Menu” entry references a separate menu file.

The download is one printable English PDF with 443 pages. That total includes two covers, five front-matter pages, and one blank separator, along with the service chapters, safety section, index, Trouble Check Chart, wiring diagrams, and EMM Service Code Chart.