2005

Parts Catalog

90, 115 HP (1950cc)

4 Stroke Models
J90PL4SOR J115PL4SOR
BJ90PL4SOR BJ115L4SOR
J90PX4SOR J115PX4SOR
BJ90PX4SOR BJ115X4SOR

90, 115 4 STROKE

© 2004 BRP US Inc. All rights reserved.

TM, ® Trademarks of Bombardier Recreational Products Inc. or its affiliates.
 ABOUT THIS CATALOG

Bombardier Recreational Products Inc. 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.

For the latest service part number information visit

EPC (Electronic Parts Catalogs) on the DealerPort™ website.

www.dealerport.com
Illustrations used in this catalog may not depict actual models or equipment, but are intended as repre-
sentative views for reference only. Certain features, equipment or accessories shown in this catalog
might not be found on or included with all models in all marketing areas.

IMPORTANT: This catalog is a part reference. Refer to the appropriate Evinrude/Johnson Service Man-
ual for exact service and maintenance information. Use exact engine model number, including any suffix
letter, when indentifying parts in this catalog.

The continuing accuracy of this catalog cannot be guaranteed.

PARTS LIST REFERENCE

Following Example for Reference Only d
1 584348 BATTERY CABLE, 10ft. (3.M) (DR Models Only) 1
a 2 351839 SCREW, Starter to C/C New 2 e
3 586774 STARTER SOLENOID Assy 1
(Solenoid Assy. included on DR, DE & DP models) f
4 N/A *DRIVE KIT NS 1

b
5 586103 **GROMMET, Starter solenoid mount Opt. 2 g
6 341512 BOLT, Double ended-Harness ground A 1

c
A Only used on WR, WPR Models c

a "N/A" Indicates part is NOT AVAILABLE or NOT AVAILABLE individually.

"*" Indicates parts are included in the preceding assembly.
b EXAMPLE SHOWN: (Ref #3) - P/N 586774 includes (Ref #4) - P/N 586101 and (Ref # 5) - "GROMMET". Also (Ref #4) -
P/N 586101 includes (Ref # 5) - "GROMMET".

c "A " Upper case alpha characters used as callout indicate additional part information is shown at the bottom of the list.
d Additional part information.
e "New" Indicates part and/or part number has been added or changed from previous model year.
f "NS" Indicates part is Not Shown in illustration.
g "Opt." Indicates part is an OPTIONAL or ACCESSORY part.

WARNING
When replacement parts are required, use Evinrude/Johnson Genuine Parts or
parts with equivalent characteristics, including type, strength, and material.
Using substandard parts could result in injury or product malfunction.
 TABLE OF CONTENTS
LITERATURE .............................................................................................................................. 2
PAINT .......................................................................................................................................... 2
MODEL FEATURES .................................................................................................................... 3
PARTS SHIPPED WITH ENGINE “IN BOX” ............................................................................... 3
PROFILE DRAWING ................................................................................................................... 4
2005 LITERATURE - ALL MODELS ........................................................................................... 5
DECALS ...................................................................................................................................... 6
ENGINE COVER ......................................................................................................................... 6
LOWER ENGINE COVER ........................................................................................................... 7
CYLINDER HEAD ....................................................................................................................... 7
CYLINDER & CRANKCASE ........................................................................................................ 8
CRANKSHAFT & PISTONS ........................................................................................................ 9
TIMING CHAIN ............................................................................................................................ 9
CAMSHAFT ............................................................................................................................... 10
INTAKE MANIFOLD .................................................................................................................. 11
AIR SILENCER.......................................................................................................................... 11
FLYWHEEL COVER ................................................................................................................. 12
FLYWHEEL ............................................................................................................................... 12
RECTIFIER................................................................................................................................ 13
IGNITION COIL ......................................................................................................................... 13
ENGINE ELECTRICAL HARNESS ........................................................................................... 14
ENGINE CONTROL MODULE & POWER TRIM SWITCH ....................................................... 14
FUEL VAPOR SEPARATOR ..................................................................................................... 15
FUEL PUMP .............................................................................................................................. 15
FUEL INJECTOR ...................................................................................................................... 16
THROTTLE BODY .................................................................................................................... 16
SENSOR GROUP ..................................................................................................................... 17
OIL PUMP ................................................................................................................................. 17
EXHAUST ADAPTER ................................................................................................................ 18
EXHAUST HOUSING ................................................................................................................ 18
OIL PAN .................................................................................................................................... 19
STERN BRACKET .................................................................................................................... 19
SWIVEL BRACKET ................................................................................................................... 20
GEARCASE ............................................................................................................................... 21

90, 115 4 STROKE

GEARS ...................................................................................................................................... 22
WATER PUMP .......................................................................................................................... 23
THERMOSTAT .......................................................................................................................... 24
SHIFT ROD ............................................................................................................................... 24
SHIFT LINKAGE ........................................................................................................................ 25
STARTER MOTOR ................................................................................................................... 25
TRIM CYLINDER....................................................................................................................... 26
TRIM MOTOR ........................................................................................................................... 27
STEERING & CONTROL COMPONENTS ............................................................................... 27
GASKET SET (ACCESSORY) .................................................................................................. 28
WATER PRESSURE HOSE KIT (ACCESSORY) ..................................................................... 28
DUAL ENGINE TIE BAR CONNECTOR (ACCESSORY) ......................................................... 29
DUAL ENGINE TIE BAR (ACCESSORY) ................................................................................. 29
DUAL CABLE STEERING KIT - PARALLEL ENTRY (ACCESSORY)..................................... 29
TILLER UPGRADE KIT (ACCESSORY) .............................................................................. 30-31
TILLER HANDLE ASSEMBLY (ACCESSORY) ................................................................... 32-33
PROPELLERS & HARDWARE ...................................................................................................34

1
 LITERATURE

5005998 SERVICE MANUAL – ENGLISH

5005999 SERVICE MANUAL – FRENCH
5035765 OPERATOR’S GUIDE – ENGLISH
5035766 OPERATOR’S GUIDE – FRENCH
5005924 SPECIAL TOOLS CATALOG

PAINT

COLOR
NAME
SPRAY CAN PPG # 1 PPG # 2
PRIMER 777172 DP40401 –
BLACK 3 777179 9696 –
WHITE 777171 90538 –
CLEARCOAT 772414 – –
1. ONE COAT FINISH FOR MIDSECTION & GEARCASE
2. BASE COAT PLUS CLEARCOAT FOR UPPER & LOWER
ENGINE COVERS
3. USED ON ENGINE CRANKCASE ASSEMBLY.

2
 MODEL FEATURES

All Models
Fuel
Cylinder Configuration Charging
Induction

4 Cylinder Injection 40 Amp

Model Specific
Model Number Shaft Length Color Steering Starting

J90PL4SOR 20 in. White Remote Electric

BJ90PL4SOR 20 in. White Remote Electric
J90PX4SOR 25 in. White Remote Electric
BJ90PX4SOR 25 in. White Remote Electric
J115PL4SOR 20 in. White Remote Electric
BJ115PL4SOR 20 in. White Remote Electric
J115PX4SOR 25 in. White Remote Electric
BJ115PX4SOR 25 in. White Remote Electric

PARTS SHIPPED WITH ENGINE “IN BOX”

P/N Name of Part Qty Application

90, 115 4 STROKE

5035765 Owners Manual 1 All Models
5033854 Propeller Hardware Kit 1 All Models
5033567 Thrust Washer, Propeller 1 All Models
5033856 Spacer, prop bushing stop 1 All Models
5033829 Battery cable 1 All Models
5032181 Clamp, battery cable 1 All Models
5030347 Clamp, harness connector 1 All Models
5033870 Steering link 1 All Models
5030840 Seal, steering cable 1 All Models
5030832 Tube 1 All Models
5030386 Bolts, transom 4 All Models
5030418 Nuts, transom bolt 4 All Models
5030839 Cap, transom bolt 4 All Models
5030436 Washer, transom bolt 4 All Models
5030438 Washer, transom bolt 4 All Models
5030462 Washer, transom lock 4 All Models
5035627 Tool kit 1 All Models
5035965 Cable grommet 1 All Models
5035626 Band, cable grommet 1 All Models
5033582 Cable stopper 1 All Models
5034131 Bolt, cable stopper 1 All Models
5034142 Washer, cable stopper 1 All Models
5030575 Clip 2 All Models
5031080 Washer 2 All Models

3
 PROFILE DRAWING

L: 998 (39 3/8 in.)

575mm (22 3/4 in.) UL:1116 (44 in.)

568 (22 3/8 in.)

132mm (5 1/4 in.)

757mm (29 7/8 in.)

811mm (32 in.)

629mm (24 7/8 in.)

.)

UL: 1683mm (66 3/8 in.)

5/8 in

L: 1556mm (61 3/8 in.)

m (14

UL: 666mm (26 1/4 in.)

L: 539mm (21 1/4 in.)
370m

FORWARD

75mm
(3 in.)
14° °
69

All Evinrude® / Johnson® outboards are designed

to function within the minimum clearances outlined
30° 30° in ABYC transom and motor well Standard S-12-83.

240mm 240mm
(9 1/2 in.) (9 1/2 in.)

346mm (13 5/8 in.)346mm (13 5/8 in.)

S = 15 in. (381mm) Model

L = 20 in. (508mm) Model
UL = 25 in. (635mm) Model

ALL MEASURMENTS BASED ON: GRAPHICAL REPRESENTATION ONLY: POWER TRIM & TILT:
TRANSOM ANGLE 14° ALL DIMENSIONS ± 1/4 in. (6.35mm) TOTAL RANGE 75°
TRANSOM THICKNESS 3 in. (76.2mm) MAXIMUM

4
 2005 LITERATURE - ALL MODELS

2 Stroke Models 4 Stroke Models

English French English French English French English French
Part
Description Operator's Operator's Part Catalog Service Service Description Operator's Operator's Service Service
Catalog
Guide Guide Manual Manual Guide Guide Manual Manual
3.5 HP 215587 215588 5006019 5005962 5005963 4/5/6 HP 5035751 5035752 5006036 5005988 5005989
6 & 8 HP 215589 215590 5006020 5005962 5005963 9.9/15 HP Rope 5035753 5035754 5006037 5005990 5005991
9.9/15 HP 215597 215598 5006021 5005964 5005965 9.9/15 HP Remote 5035755 5035756 5006037 5005990 5005991
15 HP Commercial 215597 215598 5006021 5005964 5005965 25 HP Rope & Tiller Electric 5035769 5035770 5006038 5005992 5005993
25/30 HP Rope 215593 215594 5006022 5005964 5005965 25 HP Remote 5035771 5035772 5006038 5005992 5005993
25/30 HP Tiller Electric 215593 215594 5006023 5005964 5005965 30 HP Rope & Tiller Electric 5035757 5035758 5006038 5005992 5005993
25/30 HP Remote 215595 215596 5006024 5005964 5005965 30 HP Remote 5035759 5035760 5006038 5005992 5005993
25 HP Commercial 215593 215594 5006022 5005964 5005965 40/50 HP 5035761 5035762 5006039 5005994 5005995
40 HP Rope 215599 215600 5006025 5005966 5005967 60/70 HP 5035763 5035764 5006040 5005996 5005997
50 HP Remote 215601 215602 5006025 5005966 5005967 90/115 HP 5035765 5035766 5006041 5005998 5005999
40 HP E-TEC Rope 215638 215640 5006027 5005968 5005969 140 HP 5035765 5035766 5006042 5005998 5005999
40-50 HP ETEC Remote 215639 215641 5006027 5005968 5005969 200/225 HP 5035767 5035768 5006043 5006000 5006001
60 HP E-TEC Commercial 215568 215659 5006027 5005968 5005969
75/90 HP E-TEC 215642 215643 5006028 5005970 5005971
55 HP Commercial 20 in. 215603 215604 5006029 5005972 5005973
55 HP Commercial 22.5 in. 215603 215604 5006029 5005972 5005973
115 HP Commercial 215605 215606 5006030 5005974 5005975
90 - 115 HP Carbureted 215605 215606 5006030 5005974 5005975
135 - 175 HP Carbureted 215605 215606 5006031 5005974 5005975
100 - 115 HP D.I. 215610 215611 5006032 5005976 5005977
135 - 175 HP D.I. 215610 215611 5006033 5005976 5005977
200 - 250 HP D.I. 215610 215611 5006035 5005978 5005979
200 - 250 HP E-TEC 215645 215647 5006061 5006059 5006060

Literature Sets

Description P/N

2005 Part Catalog Set - Paper 5006044

2005 Part Catalog Microfiche Set 5006045
Illustrated Parts & Accessory Catalog 5006046

90, 115 4 STROKE

2005 Genuine Parts Accessory Parts Dealer Catalog 778880
2004 Part Catalog CD (PDF Set) 5006072
2005 Part Catalog CD (PDF Set) 5006075
2005 English Service Manual Set - 2 Stroke 5005980
2005 French Service Manual Set - 2 Stroke 5005981
2005 English Service Manual Set - 2 Stroke D.I. & E-TEC 5005982
2005 French Service Manual Set - 2 Stroke D.I. & E-TEC 5005983
2005 English Service Manual Set - 4 Stroke 5005984
2005 French Service Manual Set - 4 Stroke 5005985

Shop Catalogs
Description P/N
2004 Special Tools Catalog 5005924
1913-2005 Model Number Reference Guide 5006145
2005 Warranty Procedures & Flat Rate Guide - English 5006217
2005 Warranty Procedures & Flat Rate Guide - French 5006218
Predelivery & Installation Guide - All Models - English 5006079
Predelivery & Installation Guide - All Models - French 5006121

5
DECALS
EPC3500

Ref P/N Name of Part Qty

1 5033237 DECAL, Stripe, Stbd A 1
2 5033236 DECAL, Stripe, Port A 1
3 5033242 DECAL, "BOMBARDIER" A 2
4 5032867 DECAL, "Johnson" - Port, Stbd A 2
1 5 5033239 DECAL, "90HP" 1
6 5033240 DECAL, "115HP" 1
7 5034204 DECAL, FUEL 1

A Included with "ENGINE COVER Assy".

3 4

7
5 6

ENGINE COVER
EPC3464
7
Ref P/N Name of Part Qty
6 1 5035966 ENGINE COVER Assy New A 1
2 5033862 *BRACKET 1
3 5033866 *BRACKET, FASTENER 2
4 5030519 *RIVET New 4
5 5033603 *RIVET 3
6 5033574 *HANDLE, TILT UP 1
8 7 5033859 *LOUVER 1
8 5033860 *SEAL 1
9 5033861 *FASTENER 1
10 5033867 *FASTENER, REAR STBD 1
11 5033868 *FASTENER, REAR PORT 1
12 5030560 *CUSHION 2
13 5033620 *CUSHION 2
1 14 5033606 *CAP 3
15 5030988 *BOLT 3
16 5030989 *BOLT 4
17 5030990 *BOLT 1
18 5031012 *SCREW 3
19 5034538 TOOL SET New 1

5 IMPORTANT: When ordering "ENGINE COVER Assy" also

14 A order appropriate "HP" Decal.
16
17 18
2 4 3
13
3
15 12
15 10 4
9 19
15
11

6
 LOWER ENGINE COVER
EPC3465
Ref P/N Name of Part Qty
1 5033857 SEAL, SIDE COVER - UPPER 1 1
2 5034642 SEAL, SIDE COVER - LOWER 1
3 5033578 COVER, SIDE STBD 1
4 5032128 PLUG, SIDE COVER 1
5 5033579 COVER, SIDE PORT 1 21
6 5033869 HOLDER, SIDE COVER 1
20 7 24
7 5036047 PANEL, FRONT New 1
8 5030402 BOLT (8X40mm) 2 25 22 26
5 23
9 5033589 SCREW (6X35mm) 7 17 23 8
10 5033590 SCREW (6X55mm) 2 24
11 5030473 WASHER 2 35
12 5030558 CUSHION 2 13 11
34
13 5033619 CUSHION 2 27 37
14 5031906 PIN 2 19 6 28 12 9
22 29
15 5031279 CLIP 1 18 33
4 32
16 5033575 LEVER, HOOK RR STBD 1 22
17 5033576 LEVER, HOOK RR PORT 1 3 31
18 5033863 HOOK, ENGINE COVER RR STBD 1 23 30
19 5033864 HOOK, ENGINE COVER RR PORT 1 24
20 5033865 HOOK, ENGINE COVER FRONT 1 25 16
21 5033577 LEVER, HOOK FRONT 1
22 5031821 BOLT (6X12mm) 3 10
23 5031833 WASHER (13.2X25X1.0mm) 3
24 5031858 WASHER, WAVE 3
25 5033518 BUSHING, REAR 2
26 5036048 BUSHING, FRONT New 1 15
27 5035965 GROMMET, CONTROL CABLE New 1
28 5033581 HOLDER, CONTROL CABLE 1 2
29 5033582 STOP, CONTROL CABLE 1
30 5030347 STRAP 1 14
31 5030989 BOLT 2
32 5034131 BOLT 1
33 5034142 WASHER (6.5X20X2.0mm) 1
34 5032150 FUEL CONNECTOR 1

90, 115 4 STROKE

35 5032817 BOLT (6X15) 1
37 5030430 WASHER 1

CYLINDER HEAD
EPC3467
Ref P/N Name of Part Qty 15 13
1 5035936 HEAD, CYLINDER New 1 6 17 14
2 5033636 *GUIDE, VALVE 16
3 5033638 *BOLT, CAM SHAFT HOUSING 21
4 5030515 *PIN 18
5 5033639 BOLT, CYLINDER HEAD New 10
6 5034645 GASKET, CYLINDER HEAD 1 8
7 5033638 BOLT New 8 21
8 5031014 PIN 2 20
9 5033640 COVER, CYLINDER HEAD 1
11 10 16
10 5033641 PLATE, BREATHER 1
11 5033642 GASKET, SPARK PLUG HOLE 4 17
12 5033643 GASKET, CYLINDER HEAD COVER 1 5
13 5030633 CAP, OIL FILLER 1
14 PROTECTOR, BREATHER HOSE 1
Cut to length from P/N 5032912 7
15 5030541 O RING 1
16 HOSE, BREATHER 1
Cut to length from P/N 5031064
17 5032822 CLIP 2
18 5030985 BOLT 11 22 24 18
19 5034124 BOLT 4 3 12
20 5034132 SCREW New 7
21 5033634 SPARK PLUG (BKR6E) 4
1
22 5034541 BOLT 8
9
19

7
CYLINDER & CRANKCASE
EPC3466
10 7
3 Ref P/N Name of Part Qty
8 1 5033646 HOOK, ENGINE 1
6 2 2 5034129 BOLT 2
3 5034542 BLOCK, CYLINDER 1
4 5033637 *BOLT, CRANKCASE 10
5 5 5033645 *GASKET, OIL GALLERY PLUG 3
6 5033604 *PLUG, OIL GALLERY 3
1 7 5034146 *COVER, C/C WTR JKT 1
8 5033648 *O RING, C/C WTR JKT COVER 1
9 5031066 *PIN 5
11 10 5030000 *BOLT 8
11 5034545 *BOLT 10
12 5034544 PLUG 1
4 13 5030521 PLUG 1

13
9

12
5
6

8
 CRANKSHAFT & PISTONS
EPC3468
Ref P/N Name of Part Qty
1 5035947 PISTON New 4 13
2 5033654 RING SET, PISTON 4
2 5033655 RING SET, PISTON (OS:0.050mm) Opt. 4
3 5033871 PIN, PISTON 4
4 5033623 CIRCLIP 8
5 5033522 CONNECTING ROD Assy 4
11
6 5033514 *NUT 8
7 5033521 BEARING SET, CONNECTING ROD 4
7 5033911 BEARING SET, CONNECTING ROD Opt. 4 4 12
(US:0.25mm)
8 5033523 CRANKSHAFT 1 3
9 5033529 BEARING SET, CRANKSHAFT - Green 5 1 2
9 5033530 BEARING SET, CRANKSHAFT - Black 5 5
9 5033531 BEARING SET, CRANKSHAFT - No color 5 6
9 5033532 BEARING SET, CRANKSHAFT - Yellow 5
9 5033533 BEARING SET, CRANKSHAFT - Blue 5
9 5033524 BEARING SET, CRANKSHAFT Opt. 5 8
(US:0.25mm) - Green
9 5033525 BEARING SET, CRANKSHAFT Opt. 5
(US:0.25mm) - Black
9 5033526 BEARING SET, CRANKSHAFT Opt. 5 7
(US:0.25mm) - No color
9 5033527 BEARING SET, CRANKSHAFT Opt. 5
(US:0.25mm) - Yellow 10
9 5033528 BEARING SET, CRANKSHAFT Opt. 5
(US:0.25mm) - Blue
10 5033872 BEARING SET, CRANK THRUST 1
10 5033873 BEARING SET, CRANK THRUST Opt. 1 9
(OS:0.12mm)
11 5030550 SEAL, OIL 1
12 5035946 PISTON SET (OS:0.50mm) New Opt. 4

90, 115 4 STROKE

13 5033656 *RING SET, PISTON (OS:0.50mm) Opt. 4

TIMING CHAIN
EPC3470
20 12
Ref P/N Name of Part Qty 15
1 5033662 GEAR, DRIVEN 1 16
2 5033663 PLUG, DRIVEN GEAR 1 8
3 5033664 SPROCKET, CAM SHAFT TIMING 2 13
4 5033585 BOLT (12X25mm) 2
5 5033608 BEARING 1 18 14
6 5033609 BEARING 1 10
7 5033516 O RING 1 19
8 5031015 PIN 2
3
9 5034140 CIRCLIP 1 5
10 5033665 CHAIN, TIMING 1 3
11 5033666 GUIDE, TIMING CHAIN 1 9 4
12 5033667 TENSIONER, TIMING CHAIN 1 7
13 5031337 *PAD, TIMING CHAIN TENSIONER 1 2
14 5033668 SPACER, TIMING CHAIN TENSIONER 1
15 5034356 ADJUSTER, TENSIONER 1
16 5034121 BOLT, STUD 1 1
17 5034125 BOLT 2
18 5031666 BOLT 1 17
19 5034126 BOLT 1 11
20 5034138 NUT 1
6

9
CAMSHAFT
EPC3469
5 10
11 7 8 Ref P/N Name of Part Qty
9 3 4 1 5033901 CAMSHAFT, INTAKE - 90HP 1
1 5033660 CAMSHAFT, INTAKE - 115HP 1
2 5033902 CAMSHAFT, EXHAUST - 90HP 1
6 9 2 5033661 CAMSHAFT, EXHAUST - 115HP 1
3 5033669 TAPPET 16
10 4 5033670 SHIM, TAPPET (T:2.18mm) AR
4 5033671 SHIM, TAPPET (T:2.20mm) AR
11 4 5033672 SHIM, TAPPET (T:2.23mm) AR
7 4 5033673 SHIM, TAPPET (T:2.25mm) AR
4 5033674 SHIM, TAPPET (T:2.28mm) AR
4 5033675 SHIM, TAPPET (T:2.30mm) AR
8 4 5033676 SHIM, TAPPET (T:2.33mm) AR
9 9 2 4 5033677 SHIM, TAPPET (T:2.35mm) AR
4 5033678 SHIM, TAPPET (T:2.38mm) AR
3 1 4 5033679 SHIM, TAPPET (T:2.40mm) AR
4 5033681 SHIM, TAPPET (T:2.43mm) AR
4 4 5033682 SHIM, TAPPET (T:2.45mm) AR
4 5033683 SHIM, TAPPET (T:2.48mm) AR
4 5033684 SHIM, TAPPET (T:2.50mm) AR
4 5033685 SHIM, TAPPET (T:2.53mm) AR
4 5033686 SHIM, TAPPET (T:2.55mm) AR
4 5033874 SHIM, TAPPET (T:2.58mm) AR
4 5033875 SHIM, TAPPET (T:2.60mm) AR
4 5033876 SHIM, TAPPET (T:2.63mm) AR
4 5033877 SHIM, TAPPET (T:2.65mm) AR
4 5033878 SHIM, TAPPET (T:2.68mm) AR
4 5033879 SHIM, TAPPET (T:2.70mm) AR
4 5033880 SHIM, TAPPET (T:2.73mm) AR
4 5033881 SHIM, TAPPET (T:2.75mm) AR
4 5033882 SHIM, TAPPET (T:2.78mm) AR
4 5033883 SHIM, TAPPET (T:2.80mm) AR
4 5033884 SHIM, TAPPET (T:2.83mm) AR
4 5033885 SHIM, TAPPET (T:2.85mm) AR
4 5033886 SHIM, TAPPET (T:2.88mm) AR
4 5033887 SHIM, TAPPET (T:2.90mm) AR
4 5033888 SHIM, TAPPET (T:2.93mm) AR
4 5033889 SHIM, TAPPET (T:2.95mm) AR
4 5033890 SHIM, TAPPET (T:2.98mm) AR
4 5033891 SHIM, TAPPET (T:3.00mm) AR
4 5033892 SHIM, TAPPET (T:3.03mm) Opt. AR
4 5033893 SHIM, TAPPET (T:3.05mm) Opt. AR
4 5033894 SHIM, TAPPET (T:3.08mm) Opt. AR
4 5033895 SHIM, TAPPET (T:3.10mm) Opt. AR
4 5033896 SHIM, TAPPET (T:3.13mm) Opt. AR
5 5033897 VALVE, INTAKE 8
6 5034594 VALVE, EXHAUST 8
7 5033899 SPRING, VALVE 16
8 5033900 RETAINER, VALVE SPRING 16
9 5033687 VALVE COTTER 32
10 5031959 SEAT, VALVE SPRING 16
11 5033614 SEAL, VALVE STEM 16

10
 INTAKE MANIFOLD

EPC3471
6 15
11 12
Ref P/N Name of Part Qty 9 1
1 5035951 MANIFOLD, INTAKE New 1 14
2 5033688 GASKET 1
3 5033689 COVER, WATER JACKET 1 2
4 5033690 RING 1
5 5033726 GASKET, IAC VALVE 1
10
5
6 5033727 VALVE, IAC 1
7 5033728 HOSE, IAC 1
8 5030121 INSULATOR 1
9 5030979 BOLT, STUD 1
10 5034122 BOLT, STUD 1
11 5030000 BOLT 10
12 5030998 BOLT 8
13 5031069 BOLT 1 7
14 5033288 PIN 2
15 5031021 NUT 2

13

4
3

90, 115 4 STROKE

11

AIR SILENCER
EPC3472
4
Ref P/N Name of Part Qty
1 5031070 ARRESTER, FLAME 1
2 5033694 SILENCER Assy 1
3 5033695 HOLDER 1
4 5033696 DUCT, SILENCER 1
5 5033697 GROMMET, SILENCER 1
6 5030056 WASHER, (6.5X18X1.6mm) 5 7 5 2
7 5033598 WASHER 5
8 5030556 CUSHION 5
9 5030001 BOLT 5

68
9

11
FLYWHEEL COVER
EPC3473
3
1 Ref P/N Name of Part Qty
1 5033650 COVER Assy 1
2 5030639 CUSHION 2
3 5030410 SCREW, (6X18mm) 1
4 5030336 DECAL, CAUTION 1

FLYWHEEL
EPC3474
7
Ref P/N Name of Part Qty
1 5033550 FLYWHEEL 1
8 2 5033819 COIL, BATTERY CHARGING 1
11 3 5034149 COIL, IGNITION TIMING 1
4 5031468 SENSOR, CAM POSITION 1
5 5 TUBE AR
Cut to length from P/N 5034182
6 5033584 BOLT (6X35mm) 4
7 5033512 BOLT (16X50mm) 1
1 8 5033515 WASHER (16.5X60.5X7.0mm) 1
9 5030989 BOLT 1
10 5034133 SCREW 2
11 5031024 KEY, WOODRUFF 1
12 5033818 DECAL, MAG BOLT 1

2
12 4

3
10

12
 RECTIFIER
EPC3475
5
Ref P/N Name of Part Qty
1 5034669 COVER, PROTECTION ANODE New 2 6
2 5030623 GASKET, COVER 2 16
3A 5034351 ANODE, PROTECTION Opt. 1
3 5031705 ANODE, PROTECTION 2
4 5030413 BOLT (6X14mm) 2
5 5033698 GASKET, RECTIFIER 1 2
6 5034603 RECTIFIER & REGULATOR 1 43
7 5034604 HOLDER, ELECTRIC PARTS 1 12 7 1
8 5033822 COVER, ELECTRIC PARTS HOLDER 1 10
9 5030428 WASHER (6.5X22X1.6mm) 1
10 5030557 CUSHION 2 11
11 5030559 CUSHION 1 17
12 5033022 CUSHION 1
13 5030135 CLAMP 1 13 15
14 5030989 BOLT 1
15 5030000 BOLT 4
16 5030001 BOLT 9
17 5034135 BOLT 1

9 14

IGNITION COIL

90, 115 4 STROKE

EPC3476
8
Ref P/N Name of Part Qty
1 5033823 COIL Assy, IGNITION 1
2 5033825 *LEAD, HIGH TENSION 1
3 5033828 *LEAD, HIGH TENSION 1
4 5033824 COIL Assy, IGNITION 1
5 5033826 *LEAD, HIGH TENSION 1
6 5033827 *LEAD, HIGH TENSION 1 1
7 5030590 CLAMP 2
8 5030000 BOLT 4 2
3

4
5
6
7

13
ENGINE ELECTRICAL HARNESS
EPC3477
Ref P/N Name of Part Qty
8 15 1 5033829 CABLE Assy, Battery 1
3 5031021 NUT 1
10 16,17,18,19 KEY SWITCH 5 5030800 CAP 1
20,21,22,23 SYSTEM CHECK 6 5035960 HARNESS Assy New 1
7 5032630 *FUSE (30A) 1
24,25,26 TRIM AND TILT 8 5033834 HOLDER 1
5 3 9 5034182 TUBE 1
9 10 5031690 SCREW 2
11 5033835 TERMINAL, MAIN FUSE 2
12 5033633 FUSE Assy 2
13 5034130 BOLT 2
12 11 14 5031020 NUT 2
27 15 5030347 STRAP 1
7
13 6 16 514687 CONNECTOR, 6-SKT 1
14 17 514790 *SEAL 1
31 18 514683 LOCKWEDGE 1
19 514680 TERMINAL, SOCKET 6
20 514688 CONNECTOR, 6-PIN 1
28 21 514679 TERMINAL, PIN 5
1 22 514684 LOCKWEDGE 1
23 514690 PLUG, SEAL - POS 4 1
24 514686 CONNECTOR, 3-PIN 1
25 514682 LOCKWEDGE 1
29 26 514679 TERMINAL, PIN 1
30
27 5030529 CAP 2
28 5034515 BRACKET 1
29 5035107 LEAD, BATTERY New 1
30 5035674 *FUSE Assy, 15A New 1
31 5035674 CAP New 1

ENGINE CONTROL MODULE & POWER TRIM SWITCH

EPC3478
6 7
15 16 Ref P/N Name of Part Qty
13 1 5033257 SWITCH, NEUTRAL 1
2 5030824 ACTUATOR, NEUTRAL SWITCH 1
3 5033837 BRACKET, NEUTRAL SWITCH 1
4 5030989 BOLT 2
12 14 10 5 5030827 SWITCH, TRIM/TILT 1
4 5 6 5034606 RELAY, TRIM/TILT 2
11 7 5030529 CAP 1
8 5036046 UNIT, ENGINE CONTROL - 90HP New 1
8 5036043 UNIT, ENGINE CONTROL - 90HP New 1
"B" Prefix Models only
8 5036044 UNIT, ENGINE CONTROL - 115HPNew 1
17 8 5036045 UNIT, ENGINE CONTROL - 115HPNew 1
"B" Prefix Models only
9 5032441 CUSHION, ENGINE CONTROL UNIT 1
10 5030135 CLAMP 2
9 11 5033264 RELAY, ENGINE CONTROL UNIT 1
12 5033258 HOLDER, RELAY 1
13 5034607 HOLDER, RELAY 1
14 5034516 SWITCH, Tilt limit 1
15 5034518 CLAMP, Tilt limit lead 1
16 5034517 BOLT New 1
8 17 5035347 TIE STRAP New 1
4

1 3
2

14
 FUEL VAPOR SEPARATOR
EPC3479
1
Ref P/N Name of Part Qty
1 5033705 SEPARATOR Assy, FUEL VAPOR 1 6
2 5031105 *VALVE, NEEDLE 1
3 5031107 *PLATE 1 5 23
4 5033702 *PUMP, FUEL 1
5 5033706 *SEAL 1 21
6 5031110 *SCREW (L:15mm) 5 3
7 5031111 *SCREW, DRAIN 1
8 5034147 *SPACER 1
8A 5034148 *FILTER 1 13 2
9 5032219 *FLOAT 1
10 5032220 *PIN 1 4 22
11 *HOSE, DRAIN 1 10
9
Cut to length from P/N 5031684 8A 14
12 5031650 *REGULATOR 1
13 5031106 *SCREW 1 8 12
14 5031652 *SCREW 1
15 5034595 PROTECTOR, EVAP HOSE 1 17
16 5030056 WASHER (6.5X18X1.6mm) 3
17 5033598 WASHER 3 20
18 5030556 CUSHION 3
19 HOSE (L:340mm) 1
Cut to length from P/N 5031274
20 5031278 CLIP 2 7 15
21 5031902 CLAMP 1
22 5033631 CLAMP 1 18 20
23 5030988 BOLT 1
24 5030990 BOLT 3 11 19
16
24

90, 115 4 STROKE

FUEL PUMP
EPC3481
TO CONNECTOR 14
Ref P/N Name of Part Qty 9
1 5033699 PUMP Assy, FUEL 1
2 5033700 HOSE, FUEL 1 13 8
3 5033701 HOSE, FUEL 1
4 5035974 FILTER, FUEL New 1 13
5035975 *CAP, FUEL FILTER (Not Shown) New 1
5030578 *CLIP (Not Shown) New 1 7 2
5 5036042 BRACKET New 1
6 PROTECTOR (L:610mm) A 1
7 PROTECTOR (L:450mm) A 1 13 6
8 PROTECTOR (L:160mm) A 1 3
9 PROTECTOR (L:230mm) A 1
10 5030540 O-RING 1 TO
11 5033618 CUSHION 1 SEPARATOR 12 4
12 HOSE, (L:530mm) B 1 13
13 5030578 CLIP 6 13
14 5033628 CLAMP 1 15
15 5030989 BOLT 2 10 13
16 5030990 BOLT 2

A Cut to length from P/N 5030753 1

B Cut to length from P/N 5030126
16
11 5

15
FUEL INJECTOR
EPC3480
13
24 Ref P/N Name of Part Qty
14 11 1 5033704 FILTER, FUEL 1
19 2 5033536 HOSE Assy, FUEL 1
3 5033708 INJECTOR Assy, FUEL 4
22 22 4 5032694 *GROMMET KIT 4
1 10 5 5030709 PIPE, SLEEVE 2
22 22 6 5036041 PIPE, DELIVERY New 1
22 17
18 7 5033709 COOLER, FUEL 1
16 20 22 8 5033538 UNION, FUEL HOSE 1
22 12 9 5033710 BRACKET 2
22 10 5031754 UNION, 3 way 1
21 20
12 11 5030056 WASHER, (6.5X18X1.6mm) 2
25 12 5030466 GASKET 6
12 13 5030471 WASHER, THROTTLE 2
9 14 5030555 CUSHION 2
21 15 5031139 CUSHION 4
5 12 16 HOSE (L:50mm) A 1
7 17 HOSE (L:110mm) A 1
18 HOSE (L:130mm) A 1
15 4 27 19 HOSE (L:50mm) A 1
20 5030567 BOLT 2
23 21 5030569 UNION 2
22 5030579 CLIP 10
3 23 5030979 BOLT, STUD 2
12
8 24 5030982 BOLT 2
6 25 5030989 BOLT 6
22 26 5031003 BOLT 1
27 5031021 NUT 2
2
22 Cut to length from P/N 5030566
12 A
26

THROTTLE BODY
EPC3482
1
2 Ref P/N Name of Part Qty
1 5033691 BODY Assy, THROTTLE 1
2 5033692 GASKET 1
19
3 5031642 BOLT 4
3 18 4 5033693 ROD, THROTTLE 1
6 5 5030088 *PIN, SPRING 1
16 6 5033781 HOLDER 1
7 5033782 LEVER, THROTTLE #1 1
8 5033783 ROD 1
9 5030760 CONNECTOR 1
5 10 5033784 LEVER, THROTTLE 1
8 11 5032289 PIN, CONNECTOR 1
12 11 12 5030403 BOLT 3
12 13 5030416 NUT 1
13 14 5031222 WASHER 2
10 12 15 5031236 SPACER 1
16 5030989 BOLT 3
15 4 17 5030002 BOLT 1
14 9 18 5030575 CLIP 2
19 5031080 WASHER (7X12X1.0mm) 2
7
14
17
16

16
 SENSOR GROUP
EPC3483
4
Ref P/N Name of Part Qty
1 5031392 SENSOR-IAT 1
2 5031393 GROMMET 1 7
3 5033780 SENSOR, PRESSURE 1
4 5034087 SENSOR Assy, TEMP 1
6 5030826 SWITCH, OIL PRESS. 1
7 5031173 O-RING 2
8 5034134 SCREW 2
9 5031118 TIE STRAP, Trim sender 1
9 5030589 TIE STRAP, Temp sender 1 1
10 5031474 SENDER Assy, TRIM 1
11 5031117 BOLT 2 3
12 5030409 SCREW, (6X10mm) 1 6
13 5030135 CLAMP, (L:80mm) 1

2
8

13
10
11
9

12

90, 115 4 STROKE

OIL PUMP
EPC3485
10
Ref P/N Name of Part Qty
1 5033534 GEAR, OIL PUMP 1
2 5033711 GEAR 1
15
3 5033712 PUMP Assy, OIL 1
4 5030712 VALVE Assy, OIL RELIEF 1 13
5 5033713 O-RING 1
6 5033714 STRAINER, OIL PUMP 1
7 5030469 GASKET, (16X22X2mm) 1
8 5033600 SHIM, (12X20.0.5mm) 1
9 5033607 PIN (5x8mm) 1
10 5033610 O-RING 1
11 5030985 BOLT 1 7 5
12 5034123 BOLT 2 6
13 5034125 BOLT 3 4
14 5034139 CIRCLIP 1 3
15 5033539 FILTER, OIL 1

11
12 8
9 1

2 14

17
EXHAUST ADAPTER
EPC3488
5 Ref P/N Name of Part Qty
1 5034629 HOLDER, ENGINE 1
2 5030442 *WASHER (18.5X28X2.6mm) A 1
10 3 5030522 *PLUG A 1
4 5033841 UNION, WATER RETURN 1
11 5 5034757 GASKET, ENGINE HOLDER New 1
6 5033587 BOLT (8X70mm) 4
4 7 5035665 BOLT (8X40mm) New 4
13 8 5030515 PIN 2
31 15 9 5030541 O RING 1
9 10 5033611 SEAL, OIL A 2
1 14
11 5033613 SEAL, OIL A 1
16 12 5030990 BOLT 1
12 13 5034127 BOLT 1
14 5033591 WASHER (8.5X19X2.3mm) 1
15 5033596 WASHER 1
7 6 16 5033288 PIN 3
17 5033560 BOLT, UPPER MOUNT 2
18 28 18 5033561 MOUNT, UPPER 2
8 19 5030419 NUT 2
22 2 3
19 30 20 5033594 WASHER (12.5X24X2.5mm) 2
21 29 21 5033904 WASHER (12X22X3.0mm) 2
22 5033842 MOUNT, UPPER THRUST REVERSE 2
23 5033562 COVER, UPPER MOUNT 2
24 5031609 BOLT (10X45mm) 4
20 25 5031221 NUT 2
27 17 26 5030057 WASHER (10.5X19X2.0mm) 4
27 5033597 WASHER (12.5X22X2.5mm) 2
28 5034630 BEARING, Clutch shaft A 1
23 26 29 5034631 SEAL, Clutch shaft A 1
25 30 5033609 BEARING A 1
24 31 5034601 PLUG, Clutch shaft 1
A Included in P/N 5034629

EXHAUST HOUSING
EPC3491
1 Ref P/N Name of Part Qty
1 5034635 HOUSING - 20 in. 1
1 5035962 HOUSING - 25 in. New 1
2 2 5035792 BOLT, (10X45mm) New 8
3 3 5030511 PIN 2
12 4 5033625 CIRCLIP - 25 in. Models 1
5 5033850 BUSHING, DRIVESHAFT - 25 in. Models 1
11
9 8 6 5030409
7 5033157
SCREW, (6X10mm)
LEAD (L:210mm)
2
1
15 14 8 5030885 STOP 2
9 5033844 MOUNT, LOWER 2
10 5033583 BOLT, (12X231mm) 2
11 5031221 NUT 2
18 12 5030437 WASHER, (12.2X40X3mm) 2
16 17 13 5030438 WASHER, (12.5X22X2.5mm) 2
4 14 5033843 MOUNT, LOWER THRUST 1
13 15 5033563 BRACKET 1
7
16 5033564 COVER, LOWER MOUNT 2
5 17 5030399 BOLT, (10X45mm) 6
6 18 5033593 WASHER, (12.5X30X2.5mm) 2

10

18
 OIL PAN
EPC3486
1
Ref P/N Name of Part Qty
1 5033649 GASKET, OIL PAN 1
2 5035944 PAN, OIL New 1
3 5032682 PLUG, WATER 1 13
4 5030850 PIPE, EXHAUST 1
5 5030930 COVER 1
6 5031173 *O-RING 1
7 5030929 TUBE, WTR INDICATOR 1
8 5035665 BOLT, (8X40mm) New 3 2
9 5033588 BOLT 8 11 10
10 5030465 GASKET 1 5
11 5034465 PLUG New 1
12 5030536 O-RING 1
13 5033715 GAUGE, OIL LEVEL 1 76
14 5033540 GUIDE 1
15 5032782 O-RING 1
16 5030988 BOLT 1
8 4
14
12
16
3
15

90, 115 4 STROKE

STERN BRACKET
EPC3489
16 21
Ref P/N Name of Part Qty
1 5034519 BRACKET, CLAMP STBD New 1 1 19
2 5035803 BRACKET, CLAMP PORT New 1 9 12 20
3 5034521 SHAFT, CLAMP BRACKET New 1 15 14
4 5030839 CAP, TRANSOM BOLT 4
5 5030907 ZINC, PROTECTION 1 15 2
6 5030391 *BOLT (6X25mm) 2
7A 5033511 BOLT Opt. 4
7 5030386 BOLT (12X115mm) 4 7
8 5030418 NUT 4
9 5032820 NUT 1
10 5030436 WASHER (12.5X35X3.2mm) 4
11 5030438 WASHER (12.5X22X2.5mm) 4
12 5031846 WASHER (22.5X38X1.0mm) 1
13 5030462 WASHER, LOCK 4
14 5030388 BOLT (10X20mm) 2
15 5030057 WASHER (10.5X19X2.0mm) 2
10
16 5030409 SCREW (6X10mm) 1 11 3
17 5033839 PIN, TILT LOCK Opt. 1
18 5030426 NUT Opt. 2 4
19 5034523 CAM, Tilt limit New 1
13 17
20 5034524 HOLDER, Tilt limit New 1 8
21 5033965 BOLT 2
18
22 5034522 ANODE Opt. New 1
22 5
6

19
SWIVEL BRACKET
EPC3490
Ref P/N Name of Part Qty
1 5030207 FITTING, GREASE 5
2 5030821 LEAD (CLAMP TO SWIVEL) 1
12 3 5033836 LEAD (SWIVEL TO MOUNT BRKT) 1
6 4 5034527 BRACKET, SWIVEL 20 in. New 1
13 4 5034625 BRACKET, SWIVEL 25 in. New 1
5 5032634 BUSHING, CLAMP SHAFT SWIVEL 2
7 6 5030852 BUSHING, STEERING 2
17 7 5033554 BRACKET, STEERING 20 in. 1
7 5034153 BRACKET, STEERING 25 in. 1
19 4 8 5030407 SCREW (5X8mm) 3
19 9 5030409 SCREW (6X10mm) 2
10 5030456 WASHER (39.5X64X1.0mm) 2
28 22 26 27 11 5032635 WASHER 2
11 5 12 5030477 SHIM (39.5X64X0.3mm) 4
18
13 5033605 PLUG 2
1 21 25 14 5030548 SEAL, OIL 1
9 15 5030572 CIRCLIP 1
24 20 16 5030135 CLAMP 2
17 5032917 LEVER, TILT LOCK 1
16 23 8 18 5030842 LEVER, TILT LOCK PORT 1
8 19 5030843 BUSHING, TILT STOP ROD 2
20 5030844 RUBBER, TILT LOCK LEVER 1
3 21 5032918 SPRING, TILT LOCK LEVER 1
6 2 22 5030846 LINK, TILT LOCK LEVER 1
23 5030847 BRACKET, TILT LOCK SPRING 1
14 24 5030409 SCREW (6X10mm) 1
10 25 5030417 NUT 1
5 26 5030429 WASHER (6.5X13X1.0mm) 1
12 27 5030512 PIN, COTTER 1
11
15 28 5030597 SPRING 1

20
 GEARCASE
EPC3492
14 6
Ref P/N Name of Part Qty 10
5034495 GEARCASE Assy, Complete (White) 20 in. 1
Not Shown 18 21 16
5034743 GEARCASE Assy, Complete (White) 25 in. 1
Not Shown
1
5 15
1 5034536 CASE SET, GEAR (WHITE) 1 8
2 5032541 *BEARING, PINION 1 19 2 7
3 5032882 *BEARING 1
4 5032929 TAB, TRIM 1 20 24
5 5030906 UNION, SPEEDOMETER HOSE 1
6 5032930 ANODE, GEAR CASE 1 Seal Kit
7 5032544 RUBBER, EXHAUST SEAL 1
8 5032545 PLATE, EXHAUST SEAL 1 13
9 5033847 HOUSING, SHIFT CAM 1 12 4
10 5030338 BOLT (6X12mm) 1
11 5034400 BOLT, TRIM TAB (8X22mm) 1 11
12 5030400 BOLT (10X55mm) 6
13 5030401 BOLT (10X80mm) 1
14 5030430 WASHER (6.5X15X1.0mm) 1 15 3
15 5030071 GASKET, DRAIN PLUG 2
16 5030511 PIN 2
17 5032549 PIN 2
18 5030094 PLUG, DRAIN 2
18
19 HOSE (L:940 mm) 20 in. models AR
Cut to length from P/N 5033622
19 HOSE (L:1100 mm) 25 in. models AR
Cut to length from P/N 5033622
23
20 5030568 FITTING 1
21 5031118 CLAMP 3 9
22 5030990 BOLT 3
23 5032685 PLUG 1

90, 115 4 STROKE

24 5033798 SEALING KIT, GEAR CASE 1
17 22

21
GEARS
EPC3494
Ref P/N Name of Part Qty
1 5034639 DRIVE SHAFT, 20 in.Models 1
1 5034640 DRIVE SHAFT, 25 in.Models 1
2 5032553 COLLAR, DRIVE SHAFT 1
6 5030532 BEARING 1
32 7 5034641 PINION/GEAR SET 1
8 5032877 NUT 1
31 9 5035810 SHIM SET, DRIVE SHAFT New 1
1 29 10 5035979 *SHIM (T:0.50mm) New AR
31
10 5035980 *SHIM (T:0.55mm) New AR
30
9-10 10 5030488 *SHIM (T:0.60mm) AR
6 10 5030489 *SHIM (T:0.65mm) AR
28 10 5030490 *SHIM (T:0.70mm) AR
10 5030491 *SHIM (T:0.75mm) AR
2 27
10 5030485 *SHIM (T:0.80mm) AR
25 10 5030492 *SHIM (T:0.85mm) AR
22 10 5030493 *SHIM (T:0.90mm) AR
13 25 10 5030494 *SHIM (T:0.95mm) AR
23 10 5030486 *SHIM (T:1.00mm) AR
10 5030495 *SHIM (T:1.05mm) AR
7 8 10 5030496 *SHIM (T:1.10mm) AR
26 10 5030497 *SHIM (T:1.15mm) AR
24 21 11 5032882 BEARING AR
14
12 5032559 SHIM (T:0.45mm) AR
19 12 5032560 SHIM (T:0.50mm) AR
12 5032561 SHIM (T:0.55mm) AR
15 12 5032562 SHIM (T:0.60mm) AR
18 12 5032563 SHIM (T:0.65mm) AR
11 12 5032564 SHIM (T:0.70mm) AR
12 12 5032565 SHIM (T:0.75mm) AR
16 17 12 5032566 SHIM (T:0.80mm) AR
20 12 5032567 SHIM (T:0.85mm) AR
12 5032568 SHIM (T:0.90mm) AR
13 5032569 SHIM (T:1.0mm) AR
13 5032570 SHIM (T:1.1mm) AR
13 5032571 SHIM (T:1.2mm) AR
13 5032572 SHIM (T:1.3mm) AR
13 5032573 SHIM (T:1.4mm) AR
13 5032574 SHIM (T:1.5mm) AR
13 5032575 SHIM (T:1.6mm) AR
14 5032576 SHIM (T:1.5mm) AR
14 5032577 SHIM (T:1.0mm) AR
14 5032578 SHIM (T:1.2mm) AR
14 5032579 SHIM (T:1.3mm) AR
14 5032580 SHIM (T:1.4mm) AR
14 5032581 SHIM (T:1.6mm) AR
15 5034158 SHAFT Assy, PROPELLER 1
16 5033953 SHIFTER, CLUTCH DOG 1
17 5032584 PIN 1
18 5033855 PIN, CONNECTOR 1
19 5034145 SPRING 1
20 5033952 SPACER 1
21 5033565 HOUSING, PROP SHAFT BEARING 1
22 5033845 *WASHER 1
23 5034143 *BEARING 1
24 5032589 *O RING 1
25 5032590 *OIL SEAL 2
26 5034137 *BEARING 1
27 5032592 *RING 1
28 5031216 BOLT (8X30) 2
29 5033846 HOUSING 1
30 5030542 *O RING 1
31 5033612 *OIL SEAL 2
32 5030398 BOLT (8X25mm) 4

22
 WATER PUMP
EPC3493
Ref P/N Name of Part Qty 6
1 5033716 WATER PUMP HOUSING 1
2 5033542 IMPELLER A 1
3 5030724 PANEL A 1
4 5030725 GASKET A 1
5 5033543 TUBE, WATER - 20 in. Models 1 14
5 5033544 TUBE, WATER - 25 in. Models 1 5
6 5033717 BUSHING, WATER TUBE 1 8
7 5030728 BUSHING 1
8 5030729 BUSHING 1
9 5032594 FILTER, WATER-Port 1
10 5032595 FILTER, WATER-Stbd 1 12
11 5030739 FILTER, WATER SUB 1 11A
12 5030398 BOLT, (8X25mm) 4 1
13 5030406 SCREW, (5X12mm) 2
7
14 5030461 WASHER 1 15
15 5030508 PIN 2 16 18 11
16 5034842 KEY New 1
17 5034510 SCREW 2
18 5033719 SPACER, Water tube - 25in. Models 1
2
19 5033541 WATER PUMP REPAIR KIT 1 13
20 5034509 PLUG, Water (Not Shown) 1
A Included in "WATER PUMP REPAIR KIT" 19
3

17
4 10 17
9

90, 115 4 STROKE

23
THERMOSTAT
EPC3484
21 Ref P/N Name of Part Qty
19 1 5033644 HOSE, WATER RETURN 1
24 2 5035956 COVER, WATER PRESSURE VALVE New 1
5 3 5033720 VALVE, WATER PRESSURE 1
TO
4 5033721 THERMOSTAT (60.C) 1
HOLDER
4 5033722 THERMOSTAT (71.C) Opt. 1
5 5033723 COVER, THERMOSTAT 1
4 6 5033724 3 way, WATER HOSE 1
19 1 16 7 5030391 BOLT (6X25mm) 2
8 5030541 O RING 1
9 HOSE (HOLDER TO 3 way) 1
17 Cut to length from P/N 5033621
22 19 10 HOSE (INMF CVR TO 3 way - L:50mm) A 1
18 11 HOSE (3 way TO 3 way - L:50mm) A 1
23 12 HOSE (3 way TO Fuel CLR - L:160mm) A 1
19 19 13 HOSE (3 way TO INMF - L:200mm) A 1
14 HOSE (3 way TO C/C LOWER - L:370mm) A 1
TO 10 15 HOSE (3 way TO INDICATOR - L:370mm) A 1
INMF 16 HOSE (C/C UPPER TO 3 way - L:450mm) A 1
13 19 15 17 HOSE (3-way TO HOLDER - L:690mm) 1
21 Cut to length from P/N 5033024
TO 18 5030127 3 way, WATER HOSE 2
COOLER TO INDICATOR
19 19 5030577 CLIP 16
19 20 5033626 CLIP 2
18 TO CRKC 21 5033627 CLIP New 2
19 22 5033629 CLIP 1
11 14 23 5033630 CLIP 1
12 9 19 24 5031046 BOLT New 3

19 20 A Cut to length from P/N 5030122

7
6 20 8 2
3

SHIFT ROD
EPC3495

Ref P/N Name of Part Qty

3 1 5033548 YOKE, SHIFTER 1
2 5034602 HOUSING, SHIFT ROD GUIDE 1
7 12 3 5033793 COVER, SHIFT GUIDE HSG OIL SEAL 1
4 5033794 MAGNET, GEAR CASE 1
5 5033795 SLIDER, SHIFT HORIZONTAL 1
6 5033796 ROD, SHIFT ASSIST- 20 in. MODELS 1
6 5033797 ROD, SHIFT ASSIST- 25 in. MODELS 1
2 7 5030396 BOLT (6X20mm) 3
6 8 5033595 WASHER (30X38X1.9mm) 1
10 9 5033601 PIN 1
13
4 10 5030096 BALL 1
11 5030544 O RING 1
12 5033517 SEAL, DUST 1
11 9 13 5030596 SPRING 1
1 14 5034141 CIRCLIP 1
8

14
5

24
 SHIFT LINKAGE
EPC3496
19
Ref P/N Name of Part Qty
1 5033546 LEVER, CLUTCH 1 10
2 5033547 HOLDER, CLUTCH LEVER 1
3 5034599 SHAFT, CLUTCH 1 3
5 5033787 ARM, CLUTCH SHAFT 1 12
7 5030207 FITTING, GREASE 1
8 5033789 ROD, CLUTCH - 20 in. 1
17 13
9
8 5033790 ROD, CLUTCH - 25 in. 1 1
9 5034600 LINK, CLUTCH LEVER 1 14
10 5033792 RING, CLUTCH ROD 1 15 12
12 5031147 WASHER (6.5X15X1.5mm) 2
13 5030512 PIN, CLUTCH LEVER LINK 2 7 13
14 5033615 BUSHING, CLUTCH LEVER LINK 2
15 5030553 BUSHING, CLUTCH LEVER 2
16 5033616 BUSHING, CLUTCH SHAFT 1
17 5033624 E RING 1 2
18 5030001 BOLT 2 18
19 5034601 PLUG 1

5 8

STARTER MOTOR

90, 115 4 STROKE

EPC3487

Ref P/N Name of Part Qty 23

1 5033799 STARTER, MOTOR 1 22
4
2 5033800 *BRUSH SET 1
3 5033801 *SPRING 4
4 5033803 *CASE, GEAR 1 5
5 5033804 *PLATE, CENTER 1 12
6 5033805 *BRACKET, GEAR 1 9 11
16
7 5033806 *COVER KIT, DUST 1
8 5033807 *HOLDER, BRUSH 1
9 5033808 *LEVER, SHIFT 1 6
10 5033809 *SWITCH, MAGNET 1 7
11 5033810 *ARMATURE 1
12 5033811 *PINION 1
13 5033812 *SHAFT, PINION 1
13 2
14 5033813 *INTERNAL GEAR 1 8
15 5033814 *GEAR, PLANETARY 3 10
16 5033815 *WASHER SET 1
3
17 5033816 BAND, STARTER MOTOR 1 15 16
18 5033817 DAMPER, LOWER 1
19 5033264 RELAY, STARTER MOTOR 1 14
20 5033258 HOLDER, RELAY 1
21 5030994 BOLT 2
20
22 5034128 BOLT 2
23 5034136 PIN 2 19 1
17
18
21

25
TRIM CYLINDER
EPC3497
9
2 Ref P/N Name of Part Qty
1 5032646 MANIFOLD Assy 1
2 5032647 JOINT, METAL 1
8 3 5034626 RESERVOIR TANK 1
4 5032660 PLUG, RESERVOIR 1
9 5 5032641 O-RING 1
11 6 5032663 BOLT, TANK 4
3
7 5032650 SHAFT 1
6 8 5032651 SHAFT 1
9 5030859 BUSHING 4
4 10 5033503 BOLT, (10X35mm) 2
11 5030571 CIRCLIP 2
12 5031279 CLIP 1
5 13 5031705 ANODE 1
16 14 5030413 BOLT, (6X14mm) 1
15 5034351 ANODE (Optional) 1
16 5030135 CLAMP 1
1
14 15
13

12

10
7

26
 TRIM MOTOR
EPC3498
Ref P/N Name of Part Qty
1 5034627 MOTOR Assy, TRIM/TILT 1 2
2 5031091 *SCREW 3
3 5032915 *O RING 1
4 5032638 *BRUSH Assy 1
4A 5031093 **BRUSH 1
5 5031094 *SPRING 2 9
6 5033802 *BREAKER 1
7 5032227 *HOLDER, BRUSH 1
8 5031092 *ARMATURE 1 1 3
8A 5030805 *SEAL, Oil 1
9 5032640 BOLT 4 8
10 5030866 JOINT, DRIVE 1 10
11 5032920 PUMP Assy 1
12 6
12 5030865 FILTER 1
13 5031096 O RING 1 5 4
4A
14 5034154 O RING 1 13
15 5032644 BOLT 1
5
16 5032645 BOLT 1 11
17 5032922 BOLT 1 14
18 5032643 VALVE, MANUAL 1
7
2
8A
16 15

17 18

STEERING & CONTROL COMPONENTS

90, 115 4 STROKE

EPC3499

Ref P/N Name of Part Qty

1 5030840 SEAL, STEERING CABLE 1
2 5033870 DRAG LINK Assy 1
3 5030958 *SPACER 1 1
4 5032247 *BOLT, DRAG LINK 1 2
5 5032175 *NUT 2
6 5032176 *WASHER 4

5
6
3
6

6 5

27
GASKET SET (ACCESSORY)

1
EPC3543
2
Ref P/N Name of Part Qty
3 1 5033519 GASKET SET 1
2 5033639 *GASKET, CYL HEAD 1
3 5033643 *GASKET, CYL HEAD CVR 1
4 5030623 *GASKET, COVER 2
5 5033649 *GASKET, OIL PAN 1
6 5033688 *GASKET, INTAKE 1
7 5033692 *GASKET, THROTTLE BODY 1
8 5033698 *GASKET, RECTIFIER 1
9 5030725 *GASKET, WATER PUMP 1
8 10 5033557 *GASKET, ADAPTER 1

9
7 6
4

5 10

WATER PRESSURE HOSE KIT (ACCESSORY)

EPC3855
1 Ref P/N Name of Part Qty
1 5033833 WATER PRESSURE HOSE KIT 1
2
2 5030577 *CLAMP 4
5 3 5032158 *TEE FITTING 1
4 *HOSE (L:110mm) 1
2 Cut to length from P/N 5030122
2 5 *HOSE (L:30mm) 1
4
Cut to length from P/N 5030122
3
2

28
 DUAL ENGINE TIE BAR CONNECTOR (ACCESSORY)

EPC3878
1
Ref P/N Name of Part Qty
1 351068 DUAL ENGINE, Tie bar connector kit 1
2 327254 *SCREW, Bar to adapter 2
3 351069 *ADAPTER, Steering Arm 2
3
4 351070 *SCREW, Adapter to arm 4

4
2

DUAL ENGINE TIE BAR (ACCESSORY)

EPC3445
Ref P/N Name of Part Qty
1 175171 ADJUSTABLE TIE BAR KIT, 18 1/4 in. to 1
24 in. (464-610mm)
1 175172 *ADJUSTABLE TIE BAR KIT, 23 1/2 in. to 1
30 1/2 in. (596-774mm)
1 175173 ADJUSTABLE TIE BAR KIT, 29 1/2 in. to 1
36 1/2 in. (749-927mm)
2 315077 *LOCKNUT, Rod end 2

90, 115 4 STROKE

DUAL CABLE STEERING KIT - PARALLEL ENTRY (ACCESSORY)
EPC3880
1
Ref P/N Name of Part Qty
1 5005819 CABLE MOUNTING BRACKET KIT 1
2 N/A *CABLE MOUNTING BRACKET 1
3 N/A *CABLE SUPPORT TUBE 1
4 N/A *CABLE CONNECTOR 1
5 N/A *WASHER, Flat 2
6 N/A *LOCKNUT 2
7 N/A *SCREW, Mounting bracket 4
8 N/A *WASHER, Support tube 2
9 N/A *NUT, Support tube 2
10 N/A *SEAL, Steering cable 1
11 N/A *BUSHING, Support tube 1

29
TILLER UPGRADE KIT (ACCESSORY)

1A

20 12 13

11
17
14

15 6 19
18
7
10

2
4 9
3
10
1 7

8
8

5
21 40
7

33
34
33 39
29
37 35
38
32

29 36 29 28
22
28 31
30 30
23

28 29 24 29 28

26 25 25 26
27

30
 TILLER UPGRADE KIT (ACCESSORY)

EPC3881
Ref P/N Name of Part Qty Ref P/N Name of Part Qty
5034246 TILLER UPGRADE KIT - WHITE 1 21 586841 ADAPTER, MWS wiring 1
1 5034281 *BRACKET, Tiller handle 1 Used only if installing System Check® gauge.
2 5034282 *SCREW, Tiller bracket 2 22 5034280 *STEERING DAMPER Assy 1
3 5030438 *WASHER, Flat 2 23 N/A **ROD, Link 1
4 5030462 *WASHER, Lock 2 24 5034295 **WASHER & SPACER SET 1
5 5031609 *BOLT, Tiller arm pivot 1 25 N/A ***WASHER, Flat 2
6 5030054 *LOCKNUT, Tiller arm pivot bolt 1 26 N/A ***WASHER, Rubber 2
7 5034283 *WASHER, Flat 4 27 N/A ***SPACER 1
8 5034284 *WASHER, Spring 2 28 5034292 **LOCKNUT 4
9 5034285 *SPACER 1 29 5034293 **WASHER, Flat 5
10 5034286 *BUSHING, Tiller arm pivot bolt 2 30 N/A **ARM, link 2
11 5030589 *TIE STRAP 1 31 N/A **CYLINDER Assy 1
12 5034387 *LEVER, Clutch 1 32 5034298 **BOLT, Drag link to steering arm 1
13 5034287 *GROMMET, Control cable 1 33 5034299 **LOCKNUT 2
14 5034288 *BRACKET, Trunnion 1 34 5034297 **BOLT, Drag link to bracket 1
15 5034289 *PLATE, Trunnion retaining 1 35 5034296 **BUSHING, Drag link bolt 1
16 5034290 *CUSHION, Control cable 1 36 5034294 **BOLT, Drag link bracket to cyl assy 2
17 5032155 *CONNECTOR, Control cable 2 37 5034296 **BUSHING, Drag link bolt to cyl assy 2
18 5034291 *SCREW, Trunnion plate 1 38 514688 CONNECTOR , 6 Pin 1
19 N/A TILLER ARM Assy 1 39 514690 PLUG, Seal 6
See TILLER HANDLE ASSEMBLY 40 586841 ADAPTOR CABLE Assy. 1
20 5034737 LEVER, Throttle 1

90, 115 4 STROKE

31
TILLER HANDLE ASSEMBLY (ACCESSORY)

16 31
6 60
14 87
8 62 65
11 65
62
14 66
13

11 9
2
11
10
12

63 62
20 63 61
10 21A 62
21 48
78 54
3
18

15 41 19
28
50
64
67
39
17

43
51
38
30 53
27
40
44
32 42
35 59
53
34 45
58 46
33
47
55 37 50
57 36
54 73 26
25 29
49 24 22
71 68
70 52 23
72
56
69

32
 TILLER HANDLE ASSEMBLY (ACCESSORY)
EPC3881A
Ref P/N Name of Part Qty Ref P/N Name of Part Qty
1 N/A TILLER HANDLE ASSEMBLY 1 30 5030315 *GRIP, HANDLE 1
Included with P/N 5034246 31 5030316 *MARK, HANDLE GRIP 1
TILLER HANDLE CONVERSION KIT 32 5031780 *SHAFT, THROTTLE 1
2 5034281 *BRACKET, TILLER HANDLE (WHITE) 1 33 5031576 *STOPPER, HANDLE ROD 1
3 5034282 *BOLT, TILLER HANDLE 2 34 5031577 *BUSH, HANDLE ROD 1
4 5030438 *WASHER 2 35 5031578 *PIN, HANDLE ROD 1
5 5030462 *WASHER, LOCK 2 36 5031781 *PLATE, THROTTLE SHAFT 1
6 5034280 *DAMPER ASSY, STEERING 1 37 5031782 *ADJUSTER, THROTTLE 1
7 5034292 **NUT, ROD 4 38 5032466 *ARM ASSY, THROTTLE 1
8 5034293 **WASHER, ROD 5 39 5032842 *GEAR ASSY, SHIFT 1
9 5034294 **BOLT, DRAG LINK PLATE 2 40 5031785 *BUSH, SHIFT GEAR 1
10 5034295 **SPACER/WASHER SET 1 41 5031786 *BUSH, SHIFT LEVER 1
11 5034296 **BUSH, DRAG LINK 3 42 5032871 *PLATE, LOCK 1
12 5034297 **BOLT, DRAG LINK 1 43 5032462 *PLATE, BALL GUIDE 1
13 5034298 **BOLT, DRAG LINK 1 44 5032463 *BALL 1
14 5034299 **NUT, DRAG LINK 2 45 5032464 *E RING 1
15 5032853 *LEVER, SHIFT (WHITE) 1 46 5034303 *CABLE, THROTTLE 1
16 5033995 *MARK, SHIFT 1 47 5031606 *GROMMET, THROTTLE CABLE 1
17 5034300 *CABLE, SHIFT 1 48 5032936 *GROMMET, WIRE HARNESS 1
18 5034301 *WIRE ASSY, HANDLE 1 49 5031787 *COVER, TRIM SWITCH 1
19 5032042 **TERMINAL 3 50 5031791 *E RING 2
20 5034302 *SWITCH ASSY, IGNITION 1 51 5031796 *BOLT (8X50) 1
21 5034304 **KEY (931) 1 52 5031797 *SCREW (5X14) 6
21 5034305 **KEY (932) 1 53 5031798 *SCREW (6X12) 4
21 5034306 **KEY (933) 1 54 5030049 *SCREW (6X23) 1
21 5034307 **KEY (934) 1 55 5031799 *SCREW (5X12) 2
21 5034308 **KEY (935) 1 56 5031801 *SCREW (2X6) 2
21 5034309 **KEY (936) 1 57 5031794 *WASHER, LOCK (6.4X12X0.5) 1
21 5034310 **KEY (937) 1 58 5031795 *SPRING 1
21 5034311 **KEY (938) 1 59 5031800 *SCREW 1
21 5034312 **KEY (939) 1 60 5031609 *BOLT (10X80) 1

90, 115 4 STROKE

21 5034313 **KEY (940) 1 61 5030054 *NUT 1
21 5034314 **KEY (941) 1 62 5034283 *WASHER (10.5X22X1.5) 4
21 5034315 **KEY (942) 1 63 5034286 *BUSH 2
21A 5034453 **CAP, KEY 1 64 5030589 *CLAMP 1
22 5034540 *SWITCH ASSY, EMERGENCY 1 65 5034284 *WASHER, WAVE 2
23 5030223 **PLATE 1 66 5034285 *SPACER 1
24 5030224 **NUT 1 67 5034387 *LEVER, CLUTCH 1
25 5031777 *SWITCH ASSY, TRIM 1 68 5034287 *GROMMET, REMOCON CABLE 1
26 5031778 *CAP 1 69 5035969 *HOLDER, REMOCON CABLE 1
27 5031484 *BUZZER 1 70 5034289 *STOPPER, REMOCON CABLE 1
28 5032814 *HOUSING, TILLER HANDLE 1 71 5034290 *CUSHION, REMOCON CABLE 1
29 5031779 *COVER, UNDER 1 72 5034291 *BOLT, STOPPER 1
73 5032155 *CONNECTOR, REMOCON CABLE 2

33
PROPELLERS & HARDWARE

EPC4000
Right Hand Left Hand
Blades Material Prop Size Propeller Hub
Propeller Propeller

13 3/4 x 13 776891 N/A

13 1/2 x 15 5033322
14 x 17 5033323
3 Aluminum N/A
14 x 19 5033324 5033992
14 x 21 5033325
14 x 23 5033326

13 7/8 x 17 777024 777029

13 7/8 x 19 777025 777030
Stainless
3 13 7/8 x 21 777026 777031 N/A
Steel
13 7/8 x 23 777027 777032
13 7/8 x 25 777028

Prop Hardware
Thrust washer spacer 5033856
90-115HP
Thrust washer 5033567
140HP Thrust washer 5033954
Propeller Hardware Kit 5033854
*Nut 5030422
90, 115, 140HP *Cotter Pin 5030087
*Spacer washer 5030441
*Spacer 5034638

Propeller Nut Cotter

Hub Pin
Spacer
Washer

Spacer
Thrust
Washer

Thrust
Washer Spacer
(90-115HP ONLY)

34
35
90, 115 4 STROKE
36
37
90, 115 4 STROKE
 2005
Parts Catalog

*5006041*