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Special Tools

*5007858* Printed in the United States. © 2010 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
ABOUT THIS CATALOG
Bombardier Recreational Products (BRP) develops service tools to support technicians who are performing
specific Evinrude ®/Johnson ® service procedures. These tools allow procedures to be performed efficiently
and accurately. Evinrude/Johnson service tools should be used whenever specific procedures in the service
manuals call for their use.

WARNING
If you use procedures or service tools that are not recommended by Bombardier Recreational
Products, you alone must decide if your actions can injure people or damage the equipment
being serviced.
Always follow common shop safety practices. If you have not had training related to common
shop safety practices, you should do so not only to protect yourself, but also to protect the
people around you.
Your understanding and adherence to the safety recommendations contained in the service
manuals and use of good judgment when servicing outboards will help promote safety.
Always be alert and careful: a good foundation for safety.

IMPORTANT: This catalog is a tool reference. Refer to the appropriate Evinrude or Johnson service man-
ual for exact application and usage information.
The tools listed in this catalog are intended for use on current and late model Evinrude and Johnson out-
boards. For tool pricing, availability, and ordering information, contact Evinrude/Johnson Genuine Parts.

FEATURES
This catalog has many features that make it easy to use. They include:
• A complete table of contents listing 2-stroke and 4-stroke outboard tools by category or outboard system.
• Descriptive headers at the top of each page that indicate outboard type and tool category.
• Text description for each tool indicates specific use or model information.
• Two complete indexes are provided – one index lists tool names and descriptive names and the second
index lists tools by part number.

WARRANTY
Evinrude/Johnson tools are warranted against defects in materials and workmanship for a period of one
year after the date of sale. Any tool returned to BRP and found by BRP to be defective will be repaired or
replaced at the option of BRP. BRP expressly disclaims any other warranty, whether expressed or implied, at
the end of the one-year period. You may have other rights that vary from jurisdiction to jurisdiction.

† AMP is a registered trademark of Tyco International, Ltd.


† Amphenol is a registered trademark of The Amphenol Corporation.
† Deutsch is a registered trademark of The Deutsch Company.
† Oetiker is a registered trademark of Hans Oetiker AG Maschinen.
† Palm is a registered trademark of Palm, Inc. or its subsidiaries.
† Packard is a registered trademark of Delphi Automotive Systems.
† Sony is a registered trademark of Sony Corporation of America.
† Torx is a registered trademark of Textron Fastening Systems.
† Windows is a registered trademark of Microsoft Corporation.
‡ “Bombardier” and the Sprocket symbol are trademarks of Bombardier Inc. used under license.
The following trademarks are the property of Bombardier Recreational Products Inc. or its affiliates:
Evinrude ® Ficht ®
Evinrude ® E-TEC ® Johnson ®
Evinrude ® / Johnson ® Genuine Parts Twist-Grip ™

Printed in the United States.


© 2010 BRP US Inc. All rights reserved.
TM, ® and the BRP logo are registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
2
TABLE OF CONTENTS

TABLE OF CONTENTS
2-STROKE ............................................................................................................4
DIAGNOSTICS ..................................................................................................................................... 4
Computer Requirements for Diagnostic Software: .................................................................... 4
UNIVERSAL ......................................................................................................................................... 5
ELECTRICAL / IGNITION .................................................................................................................... 8
FUEL / OIL .......................................................................................................................................... 11
POWERHEAD .................................................................................................................................... 13
GEARCASE ........................................................................................................................................ 16
General ......................................................................................................................................... 16
Driveshaft and Pinion ................................................................................................................. 17
Propeller Shaft ............................................................................................................................. 21
Counter Rotating (C/R) ............................................................................................................... 24
Forward Bearing .......................................................................................................................... 24
Shift Rod and Shifter .................................................................................................................. 24
TRIM / TILT ......................................................................................................................................... 25
MANUAL STARTER ........................................................................................................................... 26
TEST PROPELLERS .......................................................................................................................... 26
4-STROKE ..........................................................................................................28
DIAGNOSTICS ................................................................................................................................... 28
Computer Requirements for 4 Stroke Diagnostic Software: .................................................. 28
UNIVERSAL ....................................................................................................................................... 29
ELECTRICAL / IGNITION .................................................................................................................. 30
FUEL / OIL .......................................................................................................................................... 31
POWERHEAD .................................................................................................................................... 32
GEARCASE ........................................................................................................................................ 34
General ......................................................................................................................................... 34
Driveshaft and Pinion ................................................................................................................. 34
Propeller Shaft ............................................................................................................................. 37
Forward Gear ............................................................................................................................... 38
TEST PROPELLERS .......................................................................................................................... 39
TRIM / TILT ......................................................................................................................................... 39
INDEX — TOOL DESCRIPTIONS .....................................................................40
INDEX — BY PART NUMBERS ........................................................................44

3
2-STROKE
DIAGNOSTICS

DIAGNOSTICS
2-STROKE

Version 1.42b

Floppy Disk
version 3030336

Diagnostic Software (Windows † based)


005444 Diagnostic Software (DOS) Bootstrap tool 002276

P/N 765338 P/N 5005388 P/N 5000901 (old P/N 586551)


(2000 and newer Evinrude DI and (DI and Ficht) Use during program upgrades
Evinrude E-TEC outboards)

Engine Diagnostic Software for PDA 002516 Interface cable (2-stroke) 45583 Modem cable 002566

with Palm † OS P/N 437955 P/N 776463 (Sony † brand S360 PDA)
P/N 777230 (2000 and newer Evinrude Computer serial port to O/B communication P/N 775387 (Palm brand M500 PDA)
DI and Evinrude E-TEC outboards) connector Use with PDA to connect interface cable.

+ +
L
-

S
-
N2K Bus

-
Tester
H

H
L

+ +

DEVICE

BUSS

Diagnostic Power Supply 587005 Accessory Power Cable Kit 5008092 I-Command Network Tester Kit 765023

P/N 587005 (2004 and newer Evinrude P/N 5008092 P/N 765023
E-TEC rope-start outboards) Use with Diagnostic Power Supply, Use to troubleshoot open, shorted and
P/N 587005, to change engine management grounded circuits on I-Command network
software and perform static tests.

Computer Requirements for Diagnostic Software:


• IBM-compatible type – Battery • RAM memory – 64 MB or higher • 3½ inch floppy drive (add-on
powered laptop/portable com- (128 MB preferred) external floppy drives available)
puter • Harddrive capacity – 20 MG • RS-232 / 9 pin serial port con-
• Windows operating system – “free space” for installation nector (add-on USB to serial
2000, XP, Vista or 7 • Display resolution – 800 x 600 adapters available)
• Processor – Pentium 133 Mhz or minimum
higher • CD-ROM drive

4
2-STROKE
UNIVERSAL

UNIVERSAL

Lifting ring assembly, P/N 396748 354717 Filter wrench 002622

Includes one set 1 1/8 in. screws, P/N 502227


P/N 398067 and one set 1 3/4 in. screws, Universal Puller Set 32885
Fits filters up to 4 in. (100 mm)
P/N 434292 P/N 378103
Contents of kit:
P/N 307636, puller body
P/N 307637, pressing screw
P/N 307638, handle
P/N 307639, washer (3), 11/32 in I.D.
P/N 307640, washer (3), 13/32 in. I.D.
P/N 307641, screw (3), 1/4-20 x 2 1/8 in.
P/N 307642, screw (3), 5/16-18 x 2 3/4 in.
P/N 307645, center guide
P/N 309492, screw (3), 5/16-24 x 2 7/16 in.
P/N 316982, screw (2), 5/16-18 x 8 in.
Flywheel puller screws
P/N 115308, screw (3 required:2, 2.3, 3.3, 5)
P/N 5000007, screw and washer kit (40–70
Lifting tool 354717
4-stroke) Torque wrench extension 23656

P/N 342672 P/N 912031 (Steering drag link)


Use with 60° V4/V6 DI and Evinrude E-TEC

Engine Lifting Kit 354717 Transom drill fixture, heavy-duty 24496 Temperature gun 45240
P/N 354717 P/N 434367 P/N 772018
Use with 15 – 30 HP Evinrude E-TEC (40 thru V8 outboards)

Lifting eye 001024 Transom drill fixture 33199 Oetiker † pincers 001081

P/N 321537 P/N 385368 P/N 350860


Use with Universal Puller Set, P/N 378103 (40 thru V8 outboards)

5
2-STROKE
UNIVERSAL

Tie strap installation tool 18105 Drive handle, 5/8-11 thread 31932 Tilt tube nut wrench 46879

P/N 323716 P/N 311880 P/N 342680

Tie strap installation tool 32613 Drive handle, snap-on (no threads) 002585 Tilt tube service kit 33249

P/N 509785 P/N 378737 P/N 434523

Tie strap installation tool 32614 Remover, ball socket 002584 Twist-Grip™ remover COA6017

P/N 509786 P/N 342226 P/N 390767

Hose clamp wrench 23674 Installer, ball socket 002583 Spanner wrench (5/32, 3/16, 1/4 in. 32213

P/N 325043 P/N 342225 holes)


P/N 912084
Replacement tip kit, P/N 987742

6
2-STROKE
UNIVERSAL

Puller bridge 23146 Puller wrench 23147 Adapter, puller jaws 002597

P/N 432127 P/N 334359 (Use with puller jaws, P/N 334358
Use with 432129, 432130, 432131 P/Ns 432129, 432130, 432131) Adapts puller jaws, P/Ns 432129, 432130,
and 432131, to slide hammer, P/N 391008

Puller jaws, large 23148 Slide hammer 15345 Adapter, slide hammer 39345

P/N 432129 P/N 432128 P/N 340624


Replacement jaws, P/N 437954 Use with slide hammer, P/N 391008, to
remove tilt pin on 40/50

Puller jaws, bearing 23149 Slide hammer CO1577 Puller jaws COA6003

P/N 432130 P/N 391008 P/N 391011


Replacement jaws, P/N 437953 Includes: Slide, P/N 326002, Slide hammer Replacement for puller, P/N 391010
bolt, P/N 390897, Adapter set, P/N 390898

Puller jaws, small 23150 Puller jaws, wide (use with 391008) 001267 Guide pin set 2050

P/N 432131 P/N 391012 P/N 383175


Replacement jaws, P/N 437952 Replacement jaws, P/N 391009

7
2-STROKE
ELECTRICAL / IGNITION

ELECTRICAL / IGNITION

Timing light/tachometer 49789 Spark checker 49798 Flywheel service kit (60°V) 46215

P/N 775389 P/N 508118 (All models, V6/V8) P/N 434649


P/N 507975 (4-wire) 60° E-TEC requires P/N 5007181

Multimeter, analog 49793 Stator test adapter 354719 Flywheel puller adapter kit 005314

P/N 501873 P/N 3547199 P/N 5007181


(Evinrude E-TEC 15–30) Used with P/N 434649

Peak reading voltmeter 49799 Stator test adapter 002273 Flywheel holder 42938

P/N 507972 P/N 5005799 P/N 771311


(Evinrude E-TEC 40–90) Engages flywheel ring gear

Test probe kit 45241 Stator test adapter 004222 Flywheel holder 002586

P/N 342677 P/N 5006211 P/N 507976


(Evinrude E-TEC V4 & V6) Strap type for no ring gear flywheel

8
2-STROKE
ELECTRICAL / IGNITION

1 2 3 4
AMP † connector tools: 002277 Cable shears 002608 Removal tool, electrical pin DRC7183

1. Primary Lock, P/N 777077 P/N 502226 P/N 345117


2. Secondary Lock, P/N 777078 Removes TPS pins from connector on DI
3. Release, P/N 351413 outboards
4. Installer, P/N 777079

Amp Pro-Crimper III Hand Tool 005514


Battery terminal crimper 002604
Ignition coil terminal extender CO3010
P/N 777281 P/N 502224 P/N 502054
Use on Superseal 1.5 contacts
Replacement dies, P/N 777282

Amphenol crimping pliers 30387 Deutsch † connector tool 42004


Pack load adapter 49797
P/N 322696 P/N 342667 P/N 507983

1 2 3
Amphenol connector tools: 000798
Wire harness adapter leads 40269
1. Insert, P/N 322697 Coil locating ring 001274
P/N 342228 P/N 342674
2. Pin removal, P/N 322698 Use on Packard † connectors
3. Socket removal, P/N 322699 (3.5)

9
2-STROKE
ELECTRICAL / IGNITION

Coil locating ring 32211 Ignition analyzer, 60°V carb models 23471 Ignition analyzer 49791

P/N 334994 P/N 434017 – Includes 60° V6 harness kit, P/N 501890
(6/8) P/N 434127. Tests ignition sensor and
allows static adjustment of idle and full
advance ignition timing.

2 4 1 4 3

Flywheel holder 32611


Harness kit, 60° V4 carb models 39651 Amphenol † or Deutsch connector 73158

P/N 115315 P/N 437270 jumper wires – Make from:


(2.3-3.5) Use with Ignition analyzer, P/N 434017 1. No. 16 wire, 8 in. (200 mm)
2. Pin, P/N 511469 (Amphenol), or
Pin, P/N 514679 (Deutsch)
3. Socket, P/N 581656
4. Shrink tube, 510628

10
2-STROKE
FUEL / OIL

FUEL / OIL

Fuel pressure gauge (15 PSI) 004560 Fuel pressure test adapter (High) 000778 Oil pressure adapter 000179

P/N 5006397 P/N 350902 P/N 350618


Includes adapter valve P/N 353322 (DI and Evinrude E-TEC) (75–250 DI models)

Fuel pressure gauge (60 PSI) 005339 Fuel vacuum tester 23286 Oil pressure test fitting 002801

P/N 5007100 P/N 390954 P/N 773539


Includes adapter valve P/N 353322 (1997–2001 DI models)

Fuel pressure gauge (100 PSI) 002275 Injector test fitting kit 002465 Service fitting 5000911

P/N 5000902 P/N 5005844 P/N 5000911 (Inlet)


Includes adapter valve P/N 346189 (Evinrude E-TEC fuel injector test) (75–250 DI models)

Fuel pressure test adapter (Low) 000777 Plug 007736 Service Fitting 5000912

P/N 350929 P/N 315391 P/N 5000912 (Outlet)


(DI and Evinrude E-TEC) (15–30 E-TEC models) (75–250 DI models)

11
2-STROKE
FUEL / OIL

Plug/Holder 000241A Torx driver, 6 point tamper resistant 000113 Orifice plug driver 23608

P/N 329661 P/N 787134 P/N 328026


(75–250 DI models) (Various linkages, 2001 & newer)

Cap 000241A Screwdriver, 7/64 in. ballhex 23664 Orifice plug screwdriver 23611

P/N 328074 P/N 327622 P/N 317002


(75–250 DI models)

Syringe 50243 Nipple cleaning tool 23655 Orifice plug screwdriver 23103

P/N 346936 P/N 326623 P/N 390542


Replacement blade, P/N 328027

Torx driver, 5 point tamper resistant 002561 Float gauge 23678


P/N 351204 P/N 324891
(2004 & newer 9.9/15, 90–175 carb models)

12
2-STROKE
POWERHEAD

POWERHEAD

Cylinder bore gauge 45303 Wrist pin bearing installers: 41029 Wrist pin retainer installer 354720

P/N 775589 P/N 336660 (60°V, 25/30, 40/50, and P/N 354720
V4/V6 crossflow) (15–30 E-TEC models)
P/N 338646 (90°V)

Rod cap alignment fixture 21596 Wrist pin bearing remover/installer 23604 Powerhead Alignment Pin Kit 005279

P/N 396749 P/N 327645 (5-8) P/N 5007167


P/N 327637 (2, 4, 4.5)

1 2
Ring compressors: CO3768 1. Wrist pin retaining ring drivers: DR1641 Wrist pin pressing pins: 23668

–Standard size P/N 396747 (90°V) P/N 396747 (90°V)


P/N 336314 (60°V & 40–90 Evinrude E-TEC) P/N 318599 (60°V, 40/50, 25/30 P/N 326356 (25/30, 60°V, 40–90 Evinrude
P/N 326592 (40/50) and V4/V6 crossflow) E-TEC)
P/N 326591 (25/30) P/N 392511 (9.9/15, driver and
P/N 392511 (9.9/15)
cone)
P/N 339754 (9.9/15) P/N 333141 (6/8)
P/N 333141 (6/8)
P/N 326589 (6/8)
2. Wrist pin cones:
–Oversize P/N 331913 (90°V)
P/N 336313 (60°V & 40–90 Evinrude E-TEC) P/N 318600 (60°V, 40/50, 25/30
P/N 330222 (40/50) and V4/V6 crossflow)
P/N 330223 (25/30) P/N 333142 (6/8)
P/N 339755 (9.9/15)

13
2-STROKE
POWERHEAD

Torquing socket, rod screws 000797/50242 Remover, crankshaft bearing 001264 Wrench, offset 32961

P/N 331638 (5/16 in. 12 point hex) P/N 115316 P/N 322700
P/N 346187 (3/8 in. 12 point hex) (3.5) (25/30)

Piston stop tool 46543b Installer, lower crankcase seal 22431 Crankshaft upper seal remover 23624

P/N 342679 P/N 339752 P/N 387780


Replacement tip kit, P/N 5006098 (40/50 and 3 cyl. 1993 and newer, 55C 1989 (25/30)
DI models and newer)

Piston stop tool 46543a Installer, crankshaft lower seal 22428 Installer, upper crankcase seal 22534

P/N 384887 P/N 333520 P/N 334500


Carburetor models (25/30) (40/50, 55C)

1 2
Piston Cradles: 23106 Installer, crankshaft lower seal 23660 Installer, crankshaft upper seal 16718

1. P/N 326572 (Evinrude E-TEC, V4, V6, P/N 433391 P/N 321539
2 thru 4.5) (9.9/15) (25/30)
2. P/N 326573 (5 thru 70 3 cyl.)

14
2-STROKE
POWERHEAD

Crankshaft upper seal 23102 Crankshaft bearing/sleeve installers: 21953B

remover/installer kit P/N 338649 (90°V)


P/N 391060 P/N 338647 (60°V)
Contains: P/N 338648 (V4/V6 crossflow)
Remover, P/N 326270 (9.9/15) P/N 342686 (40/50, 55C, 50-70 3 cyl.)
Remover, P/N 326269 (5–8) P/N 339749 (25/30)
Remover, P/N 326268 (3–4.5)
Pressing screw, P/N 342227
Body, not available separately

15
2-STROKE
GEARCASE

GEARCASE
General

Gearcase filler 49790 Puller, heavy duty (2 required) 353803 Gearcase Alignment Gauge (L2) 5007750

P/N 501882 P/N 353803 (Use with body and screw from P/N 5007750
Universal Puller Kit, P/N 378103 to remove Use with Gearcase Alignment Gauge Kit,
bearing housing) P/N 5006349

Testers 49794 Shift rod height gauge (30 in. rod) 32872 Gearcase Alignment Gauge (M2) 5007749

P/N 507977, Pressure tester P/N 389997 (40 and above) P/N 5007749
P/N 507982, Vacuum tester P/N 339029 (30 in. rod only) Use with Gearcase Alignment Gauge Kit,
P/N 5006349

Gearcase Alignment Pin Kit 005401 Gearcase Alignment Gauge Kit 004315 Gauge Remover Shaft 354718

P/N 5007231 P/N 5006349 P/N 354718


Use on V4 and V6 gearcase housings Use with Gearcase Alignment Gauge Kit,
P/N 5006349 and Alignment Gauges,
P/N 5007749, and P/N 5007750
Note: Refer to Service Bulletin
2010-03(S) for Gearcase Alignment
Gauge instructions.

2 1
1. Retaining ring pliers 2036 Gearcase Alignment Gauge (“S”, “S2”) 352879
P/N 331045 P/N 352879
2. Replacement tip set Use with Gearcase Alignment Gauge Kit,
P/N 395967 P/N 5006349

16
2-STROKE
GEARCASE

Driveshaft and Pinion

1 2
1. Pinion nut wrench, P/N 334455 40371 Lower Driveshaft Spline Tool Kit 005074 Lower driveshaft puller 47257

2. Wrench retainer, P/N 341438 P/N 5007052 P/N 342681


(V4/V6) (V4,V6) Use with P/N 391008

Driveshaft pullers: 32884/47254 Backing plate 23621 Lower Driveshaft Wrench 005073

1. P/N 387206 (40-70) P/N 325867 P/N 352877


2. P/N 390706 (V4/V6) Use with 387206 and 390706 pullers

Driveshaft Seal Protectors: 23692 Pinion nut holder 40372 Lower Driveshaft Shimming Bolt 005445

1. P/N 312403 (40–60 D.I.; 40–60 2 cyl.; 1. P/N 342216, (V4/V6, 40/50) P/N 352878
55C 1993 thru; 50–70 3 cyl. 1989 thru) 2. P/N 320675, (40–60 Evinrude E-TEC, Use with Universal Driveshaft Shimming
2. P/N 318674 (75/90 D.I., V4/V6) 55C) Tool Kit to shim “S2” gearcase

1 2

Installer, driveshaft seal, single 38032 Installer, driveshaft seal, back to back 32924 Driveshaft Sockets 16302

P/N 341439 P/N 330268 (V4, V6, V8 1999 to 1. P/N 334995 (40–60 2 cyl. All; 55C 1993
(V4, V6, V8, 1995–1999) present and 1994 and older) thru; and 50/60/70 3 cyl. 1989 thru)
2. P/N 311875 (V4, V6 ALL, and 70
4-stroke)

17
2-STROKE
GEARCASE

Pinion Bearing Remove/Install Kit (2-Stroke), Includes:


P/N 5005927* (previously P/N 391257) 1. P/N 326574 Remover/installer
2. P/N 326575 Remover/installer
3. P/N 326577 Remover/installer
16 12 20 7 4. P/N 326578 Remover/installer
13 5. P/N 326579 Remover
14 5 6. P/N 326580 Remover
7. P/N 326582 Rod
8. P/N 326583 Pilot plate
19 9. P/N 326584 Spacer
10. P/N 326585 Spacer
11. P/N 326586 Nut
1 12. P/N 330067 Spacer
13. P/N 330068 Spacer
15 14. P/N 334986 Spacer
2 15. P/N 334987 Pilot plate
8 16. P/N 339753 Spacer
17. P/N 341437 Spacer
3 18. P/N 350932 Spacer
19. P/N 350958 Installer
20. P/N 391260 Pilot plate
11 21. 1/4 x 1/2 in. hex-head screw (1)
18 17 4 6 22. 1/4-20 x 1 1/4 in. hex-head screw (1)
23. 1/4-20 x 1 3/4 in. hex-head screw (1)
10 9 24. 1 in O.D. x 1/4 I.D. flat washer (1)
24 21 22 23 *Contains components required to service pinion bearing on
Evinrude/Johnson gearcases 9.9 –300/V6 (1989 and newer).
Note: Refer to 4-Stroke Pinion Bearing Remove/Install Kit, P/N
5005928, for additional components required to service 4-stroke
gearcases.

Pinion Bearing Remove/Install Tool Chart


2-Stroke Models
(Use Pinion Bearing Remove/Install Kit, P/N 5005927)
40-60 75-90 V4/V6
Evinrude Evinrude “O” type
E-TEC, E-TEC, V6 V6
55C 60° V4 90° V4 “L” type “M” type V6/V8
9.9/15 25/30 40/50 (50-70 3 cyl.) (“S” type) (NOT “S” type) “L2” type “M2” type (Non-current)

Rod 326582 326582 326582 326582 326582 326582 326582 326582 326582
334987
Pilot plate 326583 326583 391260 391260 391260 391260 391260 391260
(433033)
Nut 326586 326586 326586 326586
Remover 326580 326579 326579 326579
326578 326577 326757 326574 326574
Installer 326575 350958 350958 326574
Washer 326587
326585 330067 334986
Spacer(s) 326584 341437 326585 326584 350932 326584
339753 330068 (433033)

18
2-STROKE
GEARCASE

Universal Driveshaft Shimming Tool Kit (2-Stroke), Includes:


P/N 5005925* (previously P/N 393185) 1. P/N 328363 Collar
2. P/N 328366 Gauge bar
3. P/N 328367 Gauge bar
9 4. P/N 334984 Gauge bar
5. P/N 334985 Collar
6. P/N 341440 Collar (replaces P/N 328362)
7. P/N 349957 Gauge bar (V6 “M” style)
8. P/N 352878 Lower driveshaft shimming bolt (S2 gearcase)
7 9. P/N 393279 Pressure screw

*Contains components required to shim Evinrude/Johnson


6 3 gearcases 40–250/V6 (1989 and newer).
Note: Refer to 4-Stroke Shimming Kit, P/N 5005926, for additional
1 2 components required to shim 4-stroke gearcases.

5 4

8
002601

Driveshaft Shimming Tool Reference Chart (2-Stroke)


Outboard Model/Type Year Collar Gauge Bar
40, 48, 50 1989 and newer 334985 334984
40–60 Evinrude E-TEC; 55 C 1979 and newer 328363 328366
75/90 Evinrude E-TEC, 60° V4
1995 and newer 341440 328367
“S” & “S2” type gearcase
V6 – “O” “L” & “L2”
1976 and newer 341440 328367
type gearcase
V6 – “M” & “M2”
2002 and newer 341440 349957
type gearcase
50 1972–1974 328361 328366
2 cyl. recreational* 1988 and older 328361 328365/328364*
Non-current

3 cyl. (20 in. shaft) 1972 and newer 328363 328366


3 cyl. (15 in. shaft) 1975–1986 328363 328365
90° V4 1969 and newer 341440 328366
V8 1985 and newer 341440 330224
* Refer to applicable service manuals and bulletins.
Note: Collar, P/N 341440, supersedes from collar, P/N 328362.
Below: Gauge bars and collars not contained in the Universal Driveshaft Shimming Tool Kit, P/N 5005925.

Gauge bars (typical) 41553 Collars (typical) 49794


P/N 328364 (2 cyl.; see chart) P/N 328361 (50 1972-74)
P/N 328365 (2 cyl., 3 cyl.; see chart)
P/N 330224 (V8 gearcase only)

19
2-STROKE
GEARCASE

Installer, driveshaft seal 002610 Plate 21813 Installer, pinion bearing 001268

P/N 326554 P/N 318122 P/N 319878


(9.9/15) (25/30) (6/8)

Installer, driveshaft seal 002609 Driveshaft bearing installer/remover 001266 Remover, pinion bearing 001265

P/N 326552 P/N 392092 P/N 319880


(25/30) (3.5) (6/8)

Installer, driveshaft/prop seal 42232 Driveshaft bearing installer, upper 32639 Remover/installer, prop shaft bearing 001295

P/N 342666 P/N 319931 P/N 392091


(40/50, 1996 and newer) (9.9/15) (3.5)

Installer, driveshaft seal 32886 Installer, driveshaft bearing 21887A

P/N 335823 P/N 322923


(40,48,50, 1989 and newer) (25/30)

20
2-STROKE
GEARCASE

Propeller Shaft

Puller, prop shaft bearing housing 006784 Installers, prop shaft bearing housing 354058 Installer, prop shaft front/rear bearing 32880

P/N 354060 P/N 354058, “L2” Installer P/N 339750


Use to remove propeller shaft bearing hous- Use with P/N 354059, and P/N 345822 to (1993 and newer V6)
ing on “L2” and “M2” type gearcase install propeller shaft bearing housing

Pressing Fixture 006782 Handle, Installer 002575 Installer, prop shaft front bearing 32880

P/N 354059 P/N 345822 P/N 340820


Use with “L2”/”M2” gearcases (“O” type gearcase)

Alignment pins 006788 Installer, prop shaft seal (back to back) 32973 Installer, rear prop shaft bearing 006825
P/N 354140 P/N 336311 P/N 354139
Use with P/N 354057 to align propeller shaft (V6 1999 and newer, 1994 and older) Used to install rear propeller shaft bearing
bearing housing on “M2” gearcase on “M2” type gearcase and newer “O”, “L”,
“M” and “L2” bearing housings with
extended 0.065 in. for fish line trap feature.

Installers, prop shaft bearing housing 354057 Installer, prop shaft seal 006824

P/N 354057, “M2” Installer P/N 354056


Use with P/N 354140, P/N 354059, and Use to install inner and outer propeller shaft
P/N 345822 to install propeller shaft bearing seals on “M2” type gearcase
housing

21
2-STROKE
GEARCASE

Installer, prop shaft seal (small shaft) 32970


Installer, prop shaft/driveshaft seal 42233
Installer, prop shaft bearing 22420

P/N 326690 (single extended lip) P/N 335820


(V6/V8, 1991 and older) P/N 342665 (1996 & newer 3 cyl. /V4 thru 1998) (25/30)

Installer, front prop shaft bearing 15355 Installer, prop shaft/driveshaft seals 42232 Installer, front prop shaft bearing 32999

P/N 432401 P/N 342666 P/N 321428


(1992 and older V6) (1996 and newer 40/50) (25/30)

Installer, prop shaft seal 002603 Installer, prop shaft bearings 23547 Installer, prop shaft seal 40993

P/N 326551 P/N 334997 P/N 342663


(40–90 Evinrude E-TEC, 55C, V4, 3 cyl) (1989 and newer 40/50) (9.9/15)

Installer, front/rear prop shaft bearing 32962 Installer, prop shaft seal 22429 Puller kit, propeller shaft bearing 32627

P/N 326562 P/N 335821 housing


(40–90 Evinrude E-TEC, 55C, V4, 3 cyl) (25/30) P/N 386631 (9.9/15), Includes:
1. P/N 319873, Screw
2. P/N 319874, Tool Bridge

22
2-STROKE
GEARCASE

Installer, prop shaft bearing 32881 Remover, propeller shaft bearing 23699 Installer, prop shaft seal 002613

P/N 339751 P/N 319880 P/N 327572


(9.9/15) (9.9/15) (3.5)

Use Propeller Shaft Seal Tools to remove and install propeller shaft seals without removing the propeller shaft
bearing housing from the gearcase. Refer to Service Bulletin 2008-02(S) for Propeller Shaft Seal Tool instructions.

PROPELLER SHAFT SEAL TOOL REFERENCE CHART


Remover
Handle Remover Seal
Outboard Model / Gearcase Type (1)
Installer Spacer
Kit End Installer
Kit(2)
20-35 Thru-Hub, 25/30 E-TEC 436003 T19629 T19630 T19631
T19617
40/48/50, 75 (15 in.) 3 cyl. 435104 T19626 T19628
T19627
40/50/60/65C E-TEC
434822 T19613 T19616 T19619
55C, 50-70 3 cyl., V4 (20 in.)
434422
70 4 stroke 5000001(3) T19634 T19635 T19619
V6 and V8 (1991 and older) 434821 T19612 T19615 T19618
V6 and V8 (1992 and newer)
V6 “M2” 2008 and newer 434469 T19623 T19638 T19625
(“O”, “L”, “L2” with extended housing)
(1) Use with specific Remover/Installer Kit
(2) Includes remover end, seal installer, and spacer
(3) Includes T19636 installer nut

23
2-STROKE
GEARCASE

Counter Rotating (C/R)

Spanner wrench (C/R Models) 15358 Propeller shaft adapter 15356 Installer, forward gear bearing 32519

P/N 432400 (V6) (C/R Models) (C/R Models)


P/N 432399 (V8) P/N 432398 P/N 339778

Forward Bearing

Forward bearing service kit 16541 Installer, forward bearing race 23218 Installer, forward bearing race 001270

P/N 433034 P/N 319929 P/N 326025


(1989 and newer 40/50) (9.9/15) (6/8)

Shift Rod and Shifter

Shift detent sleeve 23544 Shift rod bushing remover 23542 Clutch dog spring depressor 001269

P/N 328081 P/N 327693 P/N 390766


(25/30) (9.9/15 and 25/30) (6/8)

Shift rod bushing installer 23563 Yoke locator DR4845

P/N 304515 P/N 319991


(25/30) (9.9/15)

24
2-STROKE
TRIM / TILT

TRIM / TILT

Gauge assembly, 2000 psi 33023 Tilt cylinder seal protector 23694 Tilt cylinder end cap wrench 005340

P/N 983975 P/N 326005 (Evinrude E-TEC)


P/N 352932

1 2
Trim and tilt service kit 33023 Hydraulic cylinder rod holder 23665 Trim cylinder end cap 33742

P/N 390010 P/N 983213 remover/installer,


1. P/N 436710
2. Replacement tip, P/N 437951

Trim sleeve remover 002607 Tilt cylinder end cap wrench 33741

P/N 325065 P/N 326485 2 1


Trim/tilt service kit, 27340
1. P/N 434524
2. O-ring kit for adapter tips,
P/N 434729

25
2-STROKE
MANUAL STARTER

MANUAL STARTER

Starter rope threading tool, 23682 Starter spring winder/installer, CO3583 Starter spring winder/installer 50068

P/N 378774 P/N 392093 P/N 342682


20–35, 40–70 4–8, 9.9/15, 25/35 3-cyl., 5–15 4-Stroke
OMC and 15–30 Evinrude E-TEC

TEST PROPELLERS

Test propellers (2-stroke): 002796

P/N 115306 (3.5)


P/N 390239 (6/8)
P/N 340177 (9.9/15)
P/N 434505 (25/30)
P/N 432968 (40/50 carb)
P/N 382861 (55C, 40/50 Evinrude E-TEC)
P/N 433068 (90–115 D.I./carb 20”, 105C)
P/N 386246 (75/90 Evinrude E-TEC 20”)
P/N 387388 (150/175 D.I./carb, 90 Evinrude
E-TEC 25” models)
P/N 398673 (150/175 CR or V4 CR models)
P/N 436080 (200–250)
P/N 436081 (200/250 CR)

26
27
4-STROKE
DIAGNOSTICS

DIAGNOSTICS
4-STROKE

Diagnostic Software (Windows † based) 002800 Injector test cord 002802 Test cords: 002550

P/N 5033251 P/N 5034229 2 pin, P/N 5034617


(4-Stroke outboards) (40–225, 2001 and newer) (25/30, 2000 and newer)
3 pin, P/N 5035744
(200/225 2004 and newer)
4 pin, P/N 5034228
(25/30 & 60/70)
4 pin, P/N 5034230
(40–70, 1998–2000)
6 pin, P/N 5034618
(25/30, 2000 and newer)
6 pin, P/N 5034231
(40–70, 1998–2000)
8 pin, P/N 5034232
(40–70, 1998–2000)
12 pin, P/N 5034233
(40–70, 1998–2000)
Interface cable (4-stroke) 002803 Test cord, 44 pin 002643

P/N 787053 P/N 5034223


(40–140, 2001 and newer)

O2 Sensor and Lead 48237 Test cord, 26 and 34 pin 00

P/N 5000002 P/N 5035745


(200/225, 2004 and newer)

Computer Requirements for 4 Stroke Diagnostic Software:


• IBM-compatible type – Battery powered laptop/portable computer
• Windows operating system – 95, 98, 2000, or XP
• Processor – Pentium 133 Mhz or higher
• RAM memory – 64 MB or higher (128 MB preferred)
• Harddrive capacity – 20 MG “free space” for installation
• Display resolution – 800 x 600 minimum
• CD-ROM drive
• RS-232 / 9 pin serial port connector (add-on USB to serial adapters available)

28
4-STROKE
UNIVERSAL

UNIVERSAL
IMPORTANT: Refer to UNIVERSAL tools in 2-STROKE section on page 4 for additional tool listings.

Lifting eye 001024 Cable shears 002608

P/N 321537 P/N 502226


Use with Universal Puller Set, P/N 378103 Universal Puller Set 32885

P/N 378103
Contents of kit:
P/N 307636, puller body
P/N 307637, pressing screw
P/N 307638, handle
P/N 307639 Washer (3), 11/32 in I.D.
P/N 307640 Washer (3), 13/32 in. I.D.
P/N 307641 Screw (3), 1/4-20 x 2 1/8 in.
P/N 307642 Screw (3), 5/16-18 x 2 3/4 in.
P/N 307645 Center guide
P/N 309492 screw (3), 5/16-24 x 2 7/16 in.
P/N 316982 Screw (2), 5/16-18 x 8 in.
Flywheel puller screws
Lift hook 002606 Battery terminal crimper 002604

P/N 5033048 (Use with P/N 5030994 bolt) P/N 502224 P/N 115308, screw (3 required)
(9.9/15) (2, 2.3, 3.3, 5)
P/N 5000007, screw and washer kit
(40/50 and 70 4-stroke)
P/N 5034235, screw and washer kit
(2002 and newer 9.9/15)

Temperature gun 45240 Filter wrench 002622

P/N 772018 P/N 502227


Fits filters up to 4 in. (100 mm)

29
4-STROKE
ELECTRICAL / IGNITION

ELECTRICAL / IGNITION

Timing light/tachometer 49789 Spark checkers 49798 Deutsch connector tool 42004

P/N 507980 P/N 508118 (All models, V6/V8) P/N 342667


P/N 507975 (4-wire)

Multimeter, analog 49793 Adapter, ignition coil high tension lead 002798 Flywheel removal, screw/washer kit 002581

P/N 501873 P/N 5034234 (40/50) P/N 5000007


P/N 5035748 (200/225) not shown (40/50, 60/70, 90–140)
Use with 378103, Universal puller

Peak reading voltmeter 49799 Flywheel holder 002605 Stator alignment guide 002598

P/N 507972 P/N 5034227 P/N 342670


(40–140) Use with 334994 locating ring to align
ignition/alternator coils
5/6 and 8/9.9 (211cc)

Wire harness adapter leads 40269 Flywheel removal, screw/washer kit 002570

P/N 342228 P/N 5034235


9.9/15 (305cc) and EFI models (2002 and newer 9.9/15)

30
4-STROKE
FUEL / OIL

FUEL / OIL

Carburetor flange nut wrench 40059 Fuel pressure adapter 002795 Fuel pressure gauge 002275

P/N 342211 P/N 5000900 P/N 5000902


(5–15) (40/50, 60/70, 90–140, 200/225)

Fuel mixture socket, idle DRC7785 Fuel pressure adapter 002624 Oil pressure adapter 002623

P/N 910245 P/N 350931 P/N 350930


9.9/15, (305cc) (40/50, 60/70, 90–140, 200/225)

Carburetor balancer set 002797

P/N 5034619
25/30, (597cc)

31
4-STROKE
POWERHEAD

POWERHEAD

Cylinder bore gauge, 45303 Valve lifter adapter kit 002625 Crankshaft holder 002588

P/N 775589 P/N 5000899 P/N 345827


(25/30, 40/50, 60/70, 90–140, 200/225) (60, 70)

Tappet holder 001206 Valve spring compressor 38351 Piston pin remover/installer 002626

P/N 5034226 (wedge only, P/N 351172) P/N 341446 P/N 345826
(40/50, 90–140, 200/225) 5/6, 8/9.9 (211cc) and 9.9/15 (305cc) (40/50, 60/70)

Tappet holder 002580 Valve spring compressor 50025 Crankshaft sleeve installers 38203

P/N 345832 P/N 346186 P/N 342675, 5/6


(25/30, 40/50) (25/30, 40/50, 60/70, 90–140, 200/225) P/N 342662, 8/9.9 (211cc)
P/N 342210, 9.9/15 (305cc)

Tappet adjusting tool 38202 Crankshaft holder, 002587 Compression gauge adapter 005515

P/N 341444 P/N 5034236 P/N 5037485


(5–15) (2002 and newer 9.9/15) (2.5)

32
4-STROKE
POWERHEAD

1 2

3 4 5
Gear alignment pin set 005516 Pressing screw 002617 Crankshaft, upper seal installer: 45943

P/N 5037488 P/N 342227 (5 thru 15) 1. P/N 342661, 8/9.9 (211cc)
25 (2 cyl.) Use with seal remover, P/N 391060, to 2. P/N 342213, 9.9/15 (305cc)
remove camshaft seal. Crankshaft, lower seal installer:
3. P/N 342215, 5/6, 8/9.9 (211cc) and
9.9/15 (305cc)
Camshaft seal installer:
4. P/N 342214, 5/6 and 9.9/15 (305cc)
5. P/N 342668, 8/9.9 (211cc)

Wrist pin remover 40253 Crankshaft remover / installer 005518

P/N 342657 P/N 5037487


(5–15) 25 (2 cyl.)

Wrist pin retaining ring installer 002616 Seal remover, camshaft 002794

P/N 341441 P/N 342229


9.9/15 (305cc) 8/9.9 (211cc) Use with 391060

33
4-STROKE
GEARCASE

GEARCASE
General

Gearcase filler 49790 Gearcase fill/drain adapter 48642 Testers 49794

P/N 501882 P/N 772269 P/N 507977, Pressure tester


P/N 507982, Vacuum tester

Gearcase fill/drain adapter – 2.5 005517

P/N 5037486

Driveshaft and Pinion

Driveshaft socket 002592 Driveshaft socket 002792 Installer, driveshaft seals 48356

P/N 345834 P/N 5034239 P/N 342685 (or P/N 914708)


(25/30, 40/50) (90–140, 200/225) (25/30, 60/70, 90–140)

Driveshaft socket 16302 Wrench, upper driveshaft housing 00 Installer, driveshaft bearings and seals 002589

P/N 311875 P/N 5035743 P/N 345829


(60/70) (200/225) (40/50)

34
4-STROKE
GEARCASE

Pinion Bearing Remove/Install Kit (2-Stroke), Includes:


P/N 5005927* (previously P/N 391257) 1. P/N 326574 Remover/installer
2. P/N 326575 Remover/installer
3. P/N 326577 Remover/installer
16 12 20 7 4. P/N 326578 Remover/installer
13 5. P/N 326579 Remover
14 5 6. P/N 326580 Remover
7. P/N 326582 Rod
8. P/N 326583 Pilot plate
19 9. P/N 326584 Spacer
10. P/N 326585 Spacer
11. P/N 326586 Nut
1 12. P/N 330067 Spacer
13. P/N 330068 Spacer
15 14. P/N 334986 Spacer
2 15. P/N 334987 Pilot plate
8 16. P/N 339753 Spacer
17. P/N 341437 Spacer
3 18. P/N 350932 Spacer
19. P/N 350958 Installer
20. P/N 391260 Pilot plate
11 21. 1/4 x 1/2 in. hex-head screw (1)
18 17 4 6 22. 1/4-20 x 1 1/4 in. hex-head screw (1)
23. 1/4-20 x 1 3/4 in. hex-head screw (1)
10 9 24. 1 in O.D. x 1/4 I.D. flat washer (1)
24 21 22 23 *Contains components required to service pinion bearing on
Evinrude/Johnson gearcases 9.9 –300/V6 (1989 and newer).
Note: Refer to 4-Stroke Pinion Bearing Remove/Install Kit,
P/N 5005928, for additional components required to service 4-stroke
gearcases.

Pinion Bearing Remove/Install Tool Chart


4-Stroke Models
(Use Pinion Bearing Remove/Install Kits: P/N 5005927 and P/N 5005928)
60/70 60/70
9.9/15 25/30 40/50 (‘99–’00) (‘01 thru) 90–140
Rod 326582 326582 326582 326582 326582 326582
Pilot plate 326583 5000009 5000009 5000003 391260 391260
Remover/Installer 351055 5034763 5000009 326574 341437 326574
Spacer 326585 350932 326584 326584 341437 341437

Pinion Bearing Remove/Install Kit 002791 Installer kit, pinion bearing 002647

P/N 5005928 P/N 5000009 Included in Driveshaft


Includes: Shimming Kit (4-Stroke) P/N 5005926
351055 remover/installer (60/70)
5000003 remover/installer
5000009 remover/installer, plate, screw
5034763 remover/installer
Use with Pinion Bearing Remove/Install Kit
(2-Stroke), P/N 5005927. Refer to Pinion
Bearing Remove/Install Tool Chart

35
4-STROKE
GEARCASE

Universal Driveshaft Shimming Tool Kit (2-Stroke), Driveshaft Shimming Kit (4-Stroke),
P/N 5005925* (previously P/N 393185) P/N 5005926

9
1
7
2
6 3
3
1 2
4
5 4
5
8
002601 002790

Includes: Includes:
1. P/N 328363 Collar 1. P/N 342687 gauge bar (70, 1999–2000)
2. P/N 328366 Gauge bar 2. P/N 351048 gauge bar (140)
3. P/N 328367 Gauge bar 3. P/N 351049 gauge bar (90/115)
4. P/N 334984 Gauge bar 4. P/N 351050 gauge bar (60/70, 2002 thru)
5. P/N 334985 Collar 5. P/N 351051 collar (90/115/140)
6. P/N 341440 Collar (replaces P/N 328362) Use with Universal Driveshaft Shimming Tool Kit, P/N 5005925.
7. P/N 349957 Gauge bar (V6 “M” style)
8. P/N 352878 Lower driveshaft shimming bolt (S2 gearcase)
9. P/N 393279 Pressure screw
*Contains components required to shim Evinrude/Johnson
gearcases 40–250/V6 (1989 and newer).

Driveshaft Shimming Tool Reference Chart (4-Stroke)


Outboard Model/Type Year Collar Gauge Bar
70 1999–2000 328362 or 341440 342687
60/70 2002 thru 328362 or 341440 351050
90/115 All 351051 351049
140 All 351051 351048

36
4-STROKE
GEARCASE

Propeller Shaft

Propeller shaft bearing housing puller 002573 Propeller shaft bearing housing 002571 Installer, prop shaft bearing 002576

studs retainer socket P/N 345823


P/N 5000004 (70, 1999–2000) P/N 342688 (60/70)
Use with Universal Puller Kit, P/N 378103 (70 thru 2001)

Remover, prop shaft bearing 002568 Installer, prop shaft bearing housing 002578 Installer, prop shaft bearings 002590

P/N 351126 P/N 342690 P/N 345835


(60/70, 90–140, 200/225) (40/50, 60/70, 90–140, 200/225) (40/50)

Installer, prop shaft bearing 002569 Handle and nut kit 002579 Installer, prop shaft seals 002615
P/N 351058 P/N 434422 P/N 345830
(60/70, 90–140) Use with seal remover installer, P/N 500001 (40/50)

Handle, housing installer 002575 Seal remover/installer kit 002579 Installer, prop shaft bearing, 002645

P/N 345822 P/N 5000001 (60/70) P/N 5034774


Use handle and nut kit, P/N 434422 (25/30)

37
4-STROKE
GEARCASE

Remover, prop shaft bearing 002646 Installer, prop shaft seal 002793 Remover, prop shaft 002644

P/N 5034764 P/N 326551 P/N 5034762


(25/30) (60/70, 90–140) (25/30)

Remover, prop shaft, 002630 Installer, prop shaft seal 23408 Remover, prop shaft / bearing housing 002628

P/N 5034237 P/N 326545 P/N 345831


(2002 and newer 9.9/15) (25/30) (40/50, 60/70, 90–140, 200/225)
Use with P/N 391008 slide hammer

Forward Gear

Installer kit, forward bearing race, 002594 Gear adjust spring set, 00 Installer, fwd/rev gear bearings 002574

P/N 5000008 P/N 5035749 P/N 345824


(40/50) (200/225 CR models) (40/50 and 60/70)

Backlash indicators 48966 Gear holder 001225

P/N 345836 (40/50) P/N 342689 (60 thru 140)


P/N 345825 (60/70) Lower plate only, P/N 351235
P/N 5035747 (200/225) not shown P/N 5035746 (200/225) not shown

38
4-STROKE
TEST PROPELLERS

TEST PROPELLERS

Test propellers (4-stroke): 002629

P/N 5032468 (25/30)(Use bushing, P/N


5034620 and stopper, P/N, 5034621)
P/N 5032458 (40/50)
P/N 5032478 (60/70)
P/N 5034161 (90–140)

TRIM / TILT

Spanner wrench (5/32,3/16,1/4 in. 32213 Tilt cylinder end cap wrench 33741

holes) P/N 326485


P/N 912084
Replacement tip kit, P/N 987742

39
INDEX — TOOL DESCRIPTIONS

INDEX — TOOL DESCRIPTIONS


A Diagnostic Software for PDA with Palm® OS, 2
Accessory Power Cable Kit 4 Stroke 4
Adapter, fuel pressture test (low) 11 Diagnostic Software for Windows based PC, 2
Adapter, fuel pressure test (high) 11 Stroke 4
Adaptor, ignition coil high tension lead 30 Diagnostic Software for Windows based PC,
Adaptor, oil pressure 11 4-Stroke 28
Adaptor, power pack testing 9 dies. Amp Pro-Crimper III 9
Adaptor, puller jaws 7 Drive handle, 5/8-11 threads 6
Adaptor, slide hammer 7 Drive handle, snap-on (no threads) 6
Alignment pins 21 Driveshaft bearing installer, upper 20
AMP connector tools 9 Driveshaft bearing installer/remover 20
Amp Pro-Crimper III Hand Tool 9 Driveshaft pullers 17
Amphenol connector jumper wires 10 Driveshaft Seal Protectors 17
Amphenol connector tools 9 Driveshaft Shim Tool Ref. Chart (2S) 19, 36
Amphenol crimping pliers 9 Driveshaft Shimming Kit (4S) 36
B Driveshaft Shimming Tool Kit (2S) 19, 36
Backing plate 17 Driveshaft socket 34
Backlash indicators 38 Driveshaft Sockets 17
Battery terminal crimper 9, 29 E
Bootstrap tool 4 Engine Lifting Kit 5
C Evinrude Diagnostics software 4
Cable shears 9, 29 Extender, ignition coil terminal 9
Camshaft seal installer 33 F
Cap 12 Filter wrench 5, 29
Carburetor balancer set 31 Float gauge 12
Carburetor flange nut wrench 31 Flywheel holder 30
checker 8 Flywheel holder (2.3-3.5) 10
Clutch dog spring depressor 24 Flywheel holder (engages ring gear) 8
Coil locating ring 10 Flywheel holder (strap type) 8
Coil locating ring (2.3-3.5) 9 Flywheel puller adapter kit 8
Collars 19 Flywheel removal, screw/washer kit 30
Compression gauge adaptor 32 Flywheel service kit (60°V) 8
Computer Requirements for Diagnostic Software 4 Forward bearing service kit 24
Crankshaft bearing/sleeve installers 15 Fuel mixture socket, idle 31
Crankshaft holder 32 Fuel pressure adaptor 31
Crankshaft remover / installer 33 Fuel pressure gauge 31
Crankshaft sleeve installer 32 Fuel pressure gauge (100 PSI) 11
Crankshaft upper seal remover 14 Fuel pressure gauge (15 PSI) 11
Crankshaft upper seal remover/installer kit 15 Fuel pressure gauge, 60 PSI 11
Crankshaft, lower seal installer 33 Fuel pressure test adapter (High) 11
Crankshaft, upper seal installer 33 Fuel pressure test adapter (Low) 11
Cylinder bore gauge 13, 32 Fuel vacuum tester 11
D G
Deutsch connector jumper wires 10 Gauge assembly (2000 PSI) 25
Deutsch connector tool 9, 30 Gauge bars 19
Diagnostic Power Supply 4 Gauge Remover Shaft 16
Diagnostic Software for PC (DOS), 1.42b 4 Gauge, fuel pressure 11

40
INDEX — TOOL DESCRIPTIONS

Gear adjust spring set 38 Installer, prop shaft bearings 22, 37


Gear alignment pin set 33 Installer, prop shaft front/rear bearing 21
Gear holder 38 Installer, prop shaft seal 21, 22, 23, 38
Gearcase Alignment Gauge 16 Installer, prop shaft seal (back to back) 21
Gearcase Alignment Gauge (S, S2) 16 Installer, prop shaft seal (small shaft) 22
Gearcase Alignment Gauge Kit 16 Installer, prop shaft seals 37
Gearcase Alignment Pin Kit 16 Installer, prop shaft/driveshaft seal 22
Gearcase alignment pin kit 16 Installer, prop shaft/driveshaft seals 22
Gearcase fill/drain adaptor 34 Installer, rear prop shaft bearing 21
Gearcase fill/drain adaptor - 2.5 34 Installer, upper crankcase seal 14
Gearcase filler 16, 34 Installers, prop shaft bearing housing 21
Gearcase testers 16, 34 Interface cable (2S) 4
Guide pin set 7 Interface cable (4S) 28
H L
Handle and nut kit 37 Lift hook 29
Handle Kit 23 Lifting eye 5, 29
Handle, housing installer 37 Lifting ring assembly 5
Handle, Installer 21 Lifting tool (60°V DI and Evinrude E-TEC) 5
Harness Kit, 60°V4 carb 10 Lower driveshaft puller 17
Hose clamp wrench 6 Lower Driveshaft Shimming Bolt 17
Hydraulic cylinder rod holder 25 Lower Driveshaft Spline Tool Kit 17
I Lower Driveshaft Wrench 17
I-Command Network Tester Kit 4 M
Ignition analyzer, 10 Modem cables 4
Ignition analyzer, 60°V carb 10 Multimeter, analog 8, 30
Ignition coil terminal extender 9 N
Injector test cord 28 Nipple cleaning tool 12
Injector test fitting kit (Evinrude E-TEC) 11
O
Insert tool 9
O2 Sensor and Lead 28
Installer kit, forward bearing race 38
Oetiker pincers 5
Installer kit, pinion bearing 35
Oil pressure adaptor 11, 31
Installer tool 9
Orifice plug driver 12
Installer, ball socket 6
Orifice plug screwdriver 12
Installer, crankshaft lower seal 14
O-ring kit for adapter tips 25
Installer, crankshaft upper seal 14
Installer, driveshaft bearing 20 P
Installer, driveshaft bearings and seals 34 Pack load adaptor 9
Installer, driveshaft seal 20, 34 Peak reading voltmeter 8, 30
Installer, driveshaft seal, back to back 17 Pin removal tool 9
Installer, driveshaft seal, single 17 Pinion Bearing Remove/Install Kit (2S) 18, 35
Installer, forward bearing race 24 Pinion Bearing Remove/Install Kit (4S) 35
Installer, forward gear bearing (C/R models) 24 Pinion Bearing Remove/Install Tool Chart 18, 35
Installer, front prop shaft bearing 22 Pinion nut holder 17
Installer, front propeller shaft bearing 22 Pinion nut wrench 17
Installer, front/rear prop shaft bearing 22 Piston Cradles 14
Installer, fwd/rev gear bearings 38 Piston pin remover/installer 32
Installer, lower crankcase seal 14 Piston stop tool (carb) 14
Installer, pinion bearing 20 Piston stop tool (DI & E-TEC) 14
Installer, prop shaft bearing 22, 23, 37 Plate 20
Installer, prop shaft bearing housing 37 Pliers, crimping 9

41
INDEX — TOOL DESCRIPTIONS

Plug 11 Secondary lock tool 9


Plug/Holder 12 Service fitting, fuel inlet (DI models) 11
Powerhead alignment pin kit 13 Service fitting, fuel outlet (DI models) 11
Pressing 21 Shift detent sleeve 24
Pressing screw 33 Shift rod bushing installer 24
Pressure tester 34 Shift rod bushing remover 24
Primary lock tool 9 Shift rod height gauge 16
Prop shaft bearing housing puller studs 37 Slide hammer 7
Propeller shaft adapter (C/R models) 24 Socket 37
Propeller shaft bearing housing retainer socket 37 Socket removal tool 9
Propeller Shaft Seal Tool Ref. Chart 23 Software 28
Puller bridge, 7 Spacer 23
Puller jaws 7 Spanner wrench (5/32,3/16,1/4 in. holes) 6, 39
Puller jaws, bearing 7 Spanner wrench (C/R models) 24
Puller jaws, large 7 Spark checkers 8, 30
Puller jaws, small 7 Starter rope threading tool 26
Puller jaws, wide 7 Starter spring winder/installer 26
Puller kit, propeller shaft bearing housing 22 Stator alignment guide 30
Puller screw (3 required) (2, 2.3, 3.3, 5HP) 5 Stator Test Adapter (15-30 E-TEC) 8
Puller screw and washer kit (40-70 4S) 5 Stator Test Adapter (40-90 E-TEC) 8
Puller Set 29 Stator Test Adapter (V4 & V6 E-TEC) 8
Puller wrench 7 Syringe 12
Puller, heavy duty 16 T
Puller, prop shaft bearing housing 21 Tachometer 8, 30
R Tappet adjusting tool 32
Release tool 9 Tappet holder 32
Removal tool, electrical pin 9 Temperature gun 5, 29
Remover End 23 Test cord, 26 and 34 pin 28
Remover Installer Kit 23 Test cord, 44 pin 28
Remover, ball socket 6 Test cords 28
Remover, crankshaft bearing 14 Test probe kit 8
Remover, pinion bearing 20 Test propellers (2S) 26
Remover, prop shaft 38 Test propellers (4S) 39
Remover, prop shaft / bearing housing 38 Tester, fuel vacuum 11
Remover, prop shaft bearing 37, 38 Testers 16, 34
Remover, propeller shaft bearing 23 Tie strap installation tool 6
Remover/installer, prop shaft bearing 20 Tilt cylinder end cap wrench 25, 39
Replacement jaws 7 Tilt cylinder seal protector 25
Replacement tip 25 Tilt tube nut wrench 6
Replacement tip kit 6, 39 Tilt tube service kit 6
Replacement tip set 16 Timing light/tachometer 8, 30
Retainer socket 37 Torque wrench extension (Steering drag link) 5
Retaining ring pliers 16 Torquing socket, rod screws 14
Ring compressors 13 Torx driver, 5 point tamper resistant 12
Rod cap alignment fixture 13 Torx driver, 6 point tamper resistant 12
S Transom drill fixture 5
Screwdriver, 7/64 in. ballhex 12 Transom drill fixture, heavy-duty 5
Seal Installer 23 Trim and tilt service kit 25
Seal remover, camshaft 33 Trim cylinder end cap remover/installer 25
Seal remover/installer kit (60/70) 37 Trim sleeve remover 25

42
INDEX — TOOL DESCRIPTIONS

Trim/tilt service kit 25


Twist-Grip remover 6
U
Universal Driveshaft Shimming Tool Kit (2S) 19, 36
Universal Puller Set 5, 29
V
Vacuum tester 34
valve 11
Valve lifter adaptor kit 32
Valve spring compressor 32
Volt/ohm meter, analog 8
W
Wire harness adaptor leads 9, 30
Wrench retainer 17
Wrench, offset 14
Wrench, upper driveshaft housing 34
Wrist pin bearing installers 13
Wrist pin bearing remover/installer 13
Wrist pin cones 13
Wrist pin pressing pins 13
Wrist pin remover 33
Wrist pin retainer installer 13
Wrist pin retaining ring drivers 13
Wrist pin retaining ring installer 33
Y
Yoke locator 24

43
INDEX — BY PART NUMBERS

INDEX — BY PART NUMBERS


Numerics 326005 25 330222 13
115306 26 326025 24 330223 13
115308 5, 29 326268 15 330224 19
115315 10 326269 15 330268 17
115316 14 326270 15 331045 16
304515 24 326356 13 331638 14
307636 5, 29 326485 25, 39 331913 13
307637 5, 29 326545 38 333141 13
307638 5, 29 326551 22, 38 333142 13
307639 5, 29 326552 20 333520 14
307640 5, 29 326554 20 334358 7
307641 5, 29 326562 22 334359 7
307642 5, 29 326572 14 334455 17
307645 5, 29 326573 14 334500 14
309492 5, 29 326574 18, 35 334984 19, 36
311875 17, 34 326575 18, 35 334985 19, 36
311880 6 326577 18, 35 334986 18, 35
312403 17 326578 18, 35 334987 18, 35
315391 11 326579 18, 35 334994 10, 30
316892 5 326580 18, 35 334995 17
316982 29 326582 18, 35 334997 22
317002 12 326583 18, 35 335820 22
318122 20 326584 18, 35 335821 22
318599 13 326585 18, 35 335823 20
318600 13 326586 18, 35 336311 21
318674 17 326589 13 336313 13
319873 22 326591 13 336314 13
319874 22 326592 13 336660 13
319878 20 326623 12 338646 13
319880 20, 23 326690 22 338647 15
319929 24 327572 23 338648 15
319931 20 327622 12 338649 15
319991 24 327637 13 339029 16
320675 17 327645 13 339749 15
321428 22 327693 24 339750 21
321537 5, 29 328026 12 339751 23
321539 14 328027 12 339752 14
322696 9 328074 12 339753 18, 35
322697 9 328081 24 339754 13
322698 9 328361 19 339755 13
322699 9 328362 19 339778 24
322700 14 328363 19, 36 340177 26
322923 20 328364 19 340624 7
323716 6 328365 19 340820 21
324891 12 328366 19, 36 341437 18, 35
325043 6 328367 19, 36 341438 17
325065 25 329661 12 341439 17
325867 17 330067 18, 35 341440 19, 36
326002 7 330068 18, 35 341441 33

44
INDEX — BY PART NUMBERS

341444 32 346187 14 389997 16


341446 32 346189 11 390010 25
342210 32 346936 12 390239 26
342211 31 349957 19, 36 390542 12
342213 33 350618 11 390706 17
342214 33 350860 5 390766 24
342215 33 350902 11 390767 6
342216 17 350929 11 390897 7
342225 6 350930 31 390898 7
342226 6 350931 31 390954 11
342227 15, 33 350932 18, 35 391008 7
342228 9, 30 350958 18, 35 391009 7
342229 33 351048 36 391011 7
342657 33 351049 36 391012 7
342661 33 351050 36 391060 15
342662 32 351051 36 391257 18, 35
342663 22 351055 35 391260 18, 35
342665 22 351058 37 392091 20
342666 20, 22 351126 37 392092 20
342667 9, 30 351172 32 392093 26
342668 33 351204 12 392511 13
342670 30 351235 38 393185 19, 36
342672 5 351413 9 393279 19, 36
342674 9 352877 17 395967 16
342675 32 352878 17, 19, 36 396747 13
342677 8 352879 16 396748 5
342679 14 352932 25 396749 13
342680 6 353322 11 398067 5
342681 17 353803 16 398673 26
342682 26 354056 21 432127 7
342685 34 354057 21 432128 7
342686 15 354058 21 432129 7
342687 36 354059 21 432130 7
342688 37 354060 21 432131 7
342689 38 354139 21 432398 24
342690 37 354140 21 432399 (V8) 24
345117 9 354718 16 432400 (V6) 24
345822 21, 37 354719 8 432401 22
345823 37 354720 13 432968 26
345824 38 378103 5, 16, 29 433033 18
345825 38 378737 6 433034 24
345826 32 378774 26 433068 26
345827 32 382861 26 433391 14
345829 34 383175 7 434017 10
345830 37 384887 14 434292 5
345831 38 385368 5 434367 5
345832 32 386246 26 434422 23, 37
345834 34 386631 22 434469 23
345835 37 387206 17 434505 26
345836 38 387388 26 434523 6
346186 32 387780 14 434524 25

45
INDEX — BY PART NUMBERS

434649 8 502224 9, 29 508118 8, 30


434729 25 502226 9, 29 509785 6
434821 23 502227 5, 29 509786 6
434822 23 5030994 29 586551 4
435104 23 5032458 39 587005 4
436003 23 5032468 39 765023 4
436080 26 5032478 39 765338 4
436081 26 5033048 29 771311 8
436710 25 5033251 28 772018 5, 29
437270 10 5034161 39 772269 34
437951 25 5034223 28 773539 11
437952 7 5034226 32 775387 4
437953 7 5034227 30 775389 8
437954 7 5034228 28 775589 13, 32
437955 4 5034229 28 776463 4
5000001 23, 37 5034230 28 777077 9
5000002 28 5034231 28 777078 9
5000003 35 5034232 28 777079 9
5000004 37 5034233 28 777230 4
5000007 5, 29, 30 5034234 30 777281 9
5000008 38 5034235 29, 30 777282 9
5000009 35 5034236 32 787053 28
5000899 32 5034237 38 787134 12
5000900 31 5034239 34 910245 31
5000901 4 5034617 28 912031 5
5000902 11, 31 5034618 28 912084 6, 39
5000911 11 5034619 31 914708 34
5000912 11 5034620 39 983213 25
5005388 4 5034621 39 983975 25
5005799 8 5034762 38 987742 6, 39
5005844 11 5034763 35
5005925 19, 36 5034764 38
5005926 35, 36 5034774 37
5005927 18, 35 5035743 34
5005928 35 5035744 28
5006098 14 5035745 28
5006211 8 5035746 38
5006349 16 5035747 38
5006397 11 5035748 30
5007052 17 5035749 38
5007100 11 5037485 32
5007167 13 5037486 34
5007181 8 5037487 33
5007231 16 5037488 33
5007749 16 507972 8, 30
5007750 16 507975 8, 30
5008092 4 507976 8
501873 8, 30 507977 16, 34
501882 16, 34 507980 30
501890 10 507982 16, 34
502054 9 507983 9

46
Special Tools

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