Warranty Flat Rate Manual

Evinrude E-TEC G2
200, 225, 250, 300 HP, 74°V6 (3.4 L)
12/07/2015

© 2014 Bombardier Recreational Products Inc. All rights reserved. ®, TM and the BRP logo are trademarks of Bombardier Recreational Products or its affiliates
 INTRODUCTION
This manual provides Warranty Flat Rate Allowances for Evinrude® E-TEC® G2™ outboards. This
manual can also be useful in determining shop hours required to perform non-warranty service work
or maintenance.

1. HOW DOES IT WORK

Follow the procedures detailed in the Evinrude E-TEC G2 Service Manual. The flat rate time is the
maximum time allowed for a repair involving any given part. FLAT RATE TIME IS NOT CUMULATIVE.
You must use the flat rate time given for the longest lasting operation. All flat rate times are based on
the actual time required for a factory trained technician to complete the various operations using the
appropriate tools and Evinrude E-TEC G2 special tools.

All fractions of hours are in tenths.

2. COMPILATION
Flat rate times include an allowance for diagnosis as well as time for the removal and
replacement of all components necessary to complete the repair. Where appropriate, the flat
rate times also include time for performance tests with recommended test equipment. Flat rate
times are not cumulative. Only use the flat rate time for the longest operation. Be aware of this when
comparing flat rate hours claimed and those actually paid. If Flat Rate times overlap, this extra time
will be cut from the claim without notification. Flat rate times do not include the additional work
required for removal of corroded screws. Dealers in salt water areas may add this time, when
appropriate. See flat rate codes “Y” for additional allowances. Only one salt water allowance may be
submitted for each major repair. Any additional time required due to corrosion will be the responsibility
of the customer. See applicable Evinrude E-TEC G2 Limited Warranty.

The Flat Rate Time Schedule is compiled as follows:

The actual time required to perform the repair plus (+) 30% correction factor up to 3.0 hours or (+) 15%
over 3.0 hours time to take into account, among others:

• Vehicle handling
• Obtaining the parts
• Diagnosis
• Cleaning
• Special compensation (rusted bolts)

1
NOTE CODES
Details for specific repair procedure:
1 Authorization required prior to repair/ordering parts for repair – contact After Sales Support.

2 Includes return packaging.

3 Contact dealer services for assistance.

4 When servicing or replacing two or more components, call for prior authorization.

Add 0.5 (H101) for lower engine cover removal when replacing injector/coil assembly on bottom cylinder(s) or
5
replacing lower tube assembly.

6 Includes timing verification.

7 Add 1.0 for counter rotation models.

8 Flat rate time includes removal of lower engine covers.

9 Flat rate time includes removal of oil reservoir. Add 0.5 for removing lower covers (H101) for bottom injector only.

Use failing part number 8888885 for software updates unless the EMM software update is being performed as a
10 result of a specific warranty bulletin. Refer to the applicable warranty bulletin for unique failing part numbers
related to specific warranty campaigns.

11 Replacement Item Only – Contact After Sales Support – Tech Service.

12 Includes R&R of engine covers and frames

13 Includes R&R of Gearcase assembly

14 Install new shift lever and cradle

15 Includes allowance time for assistance from second technician

16 Includes steering system bleed

3. JOB REQUIREMENTS
All the flat rate times mentioned in the following pages include the required operations such as: engine
timing, connecting rod(s) alignment, cylinder head(s) torque or use of parallel bar, use of ignition
tester, piston clearance/ring end gap measurement, crankshaft to crankcase measurement, cylinder
honing, and engine leak test.

4. REQUEST FOR REVIEW OF FLAT RATE TIME STANDARD

This form is for your convenience to request a review of an established Flat Rate Time Standard.
The information you provide will assist in our efforts to pay for warranty work fairly. Thank you for your
help.

2
 Engine Covers and Frames (SAP System Code 28)
DESCRIPTION NOTE CODE TIME

Top, Front, Rear, Port, or Starboard Engine Cover 1 C402 0.1

All Engine Covers 1 C403 0.3

Port or Starboard Side Frame (includes engine covers) – one 1 C404 0.5

Port and Starboard Side Frames (includes engine covers) – both 1 C405 0.7

Front (Motor) Frame (includes engine covers) 1 C406 1.0

Center Frame (includes engine covers) 1 C407 2.5

Decal application C408 0.2

Rigging Center 16 C409 1.0

3
Electrical / Ignition (SAP System Code 24)
DESCRIPTION NOTE CODE TIME

Flywheel 6 E401 2.8

Stator 6 E403 3.0

Ignition Coil Assembly (One) E411 0.5

Ignition Coil Assembly (Each Additional) E412 0.3

Engine Wiring Harness 1 E417 2.5

Electric Starter Motor - Replace E420 1.0

Engine Temperature Sensor E426 1.0

EMM Assembly 1,3,6 E427 3.0

EMM Reprogram 10 EP40 0.5

Crank Position Sensor (CPS) 6 E428 1.0

Air Temperature Sensor (AT) E437 1.3

Capacitor E438 0.8

Knock Sensor (One or Both) E442 1.0

Sensor Assembly Exhaust Temperature (EGT) E443 1.0

Fuse box E444 0.5

Fuse 5 amp E445 0.3

Dynamic Power Steering (DPS) Module Replace E446 1.5

DPS Module Reprogram E447 0.5

DPS Sensor Assembly E448 1.0

Trim and Tilt Relay Assembly E449 1.3

4
 Fuel System / Oil System (SAP System Code 25)
DESCRIPTION NOTE CODE TIME

Intake Manifold/Reed Plate - Repair/Replace 6 F407 2.0

Fuel Hoses or Connectors - Repair/Replace F416 0.5

Oil Pump or Pick Up Assembly - Oil Tank F419 1.6

Mechanical Fuel Lift Pump Assembly 12 F421 1.5

Fuel Filter Assembly F422 0.8

Water Sensor Assembly F423 1.0

Vapor Separator and Electric Fuel Pump Assembly F426 1.5

Oil Pump Assembly - Replace Manifold Assembly 8 F427 1.5

Rear oil distribution pump (One or Both) F428 1.5

Fuel Injector Assembly - Replace or Service 1 (Includes tubes & o-rings) 4,5 F434 1.5

One or Both Fuel Rails 5 F435 3.0

Throttle Body / Throttle Valve Assembly F437 1.3

Vapor Vent Solenoid F438 1.0

Fuel Injector Assembly - (Each Additional, Includes tubes & o-rings) 4,5 F439 0.5

Oil Tank Assembly Replace 12 F440 2.0

Oil filter, inline F442 0.8

Oil Level Switch F443 1.3

Oil Tank Vent Valve F444 0.5

5
Powerhead (SAP System Code 21)
DESCRIPTION NOTE CODE TIME

Powerhead - Replace (RPH) 1,2,6,12 P401 13.5

Cylinder Head and O-ring (One) 12 P402 2.7

Cylinder Head and O-ring (Both) 12 P403 3.7

Thermostat (One) 12 P406 1.7

Thermostat (Both) 12 P407 2.0

Cylinder and Crankcase - Reseal 1,6, 12 P409 6.2

Cylinder and Crankcase - Rebuild 1,6, 12 P410 16.0

Crankshaft - Replace 1,6 P411 9.5

Upper Crankshaft Seal 6 P412 3.3

Lower Crankshaft Seal 12 P413 4.2

Upper Main Bearing 6 P414 3.0

Lower Main Bearing 12 P415 4.8

O-rings - Powerhead to Adapter 12 P417 2.5

Water Pressure Valve Assembly 12 P421 1.5

Flywheel air duct and extension (volute) 12 P422 3.0

Water filter (to EMM/DPS module) 12 P423 1.3

Water filter (to water valve 250 H.O./300) 12 P424 1.0

Cooling Water Hose (Water valve to T-fitting /T-fitting to exhaust runner) (one or all) 12 P425 1.0

Water Fitting (Water valve) (one or both) 12 P426 1.0

Cooling Water Hoses (Thermostat to T-fitting to adapter) (one or all) 12 P427 1.0

Cooling Water Hoses (Cylinder head to Y-fitting to adapter) (one or all) 12 P428 3.0

Cooling Water Hoses (Block water filter to t-fitting /t-fitting to EMM) (one or both) 12 P429 1.5

Cooling Water Hoses (T-fitting to DPS Module to adapter) (one or both) 12 P430 1.0

Cooling Water Hose and Water Fitting (Block flushing) (one or both) 12 P431 1.5

Cooling Water Hose (EMM to vapor separator) 12 P432 3.0

All Other Powerhead Hoses 12 P433 1.0

6
 Midsection (SAP System Code 23)
DESCRIPTION NOTE CODE TIME

Steering Shaft End Cap Assembly 16 H402 4.5

Thrust Ramps (Both) H406 1.0

Stern Brackets (One or Both) H407 1.5

Lever - Tilt Lock H419 0.5

Upper Mount H421 4.6

Exhaust Housing - Outer 1 H422 6.5

Inner Exhaust Adaptor 1 H423 6.5

Water Tube and/or Upper Grommet 1 H425 6.5

Lower Mounts 12 H426 2.25

Exhaust Back Pressure Nipple H427 1.2

Exhaust Water Valve (250 H.O./300) H428 1.5

Stern and Swivel Ay 1,2,16 H429 4.0

Steering Bleed H430 0.7

Seal, exhaust housing to frames H432 0.6

Cooling Water Hose (Muffler to exhaust pipe) H433 1.0

Cooling Water Hose (Exhaust adapter to exhaust housing - rear) H434 1.0

Cooling Water Hose (Exhaust adapter to exhaust housing - front) H435 1.0

Lower Mount Bracket H436 2.25

7
Power Trim (SAP System Code 27)
TIME
DESCRIPTION NOTE CODE
(HRS)
Power Trim and Tilt Manifold- Replace 2 T401 3.0

Motor and Cable - Replace T403 2.0

Reservoir - Replace T407 5.0

Trim Cylinder – Replace (Rod, Roller & Cap Ay) (Both) T408 1.5

Power Trim and Tilt – Drain / Flush / Bleed T409 1.0

Manual Release Valve T412 1.0

Relay or Module Assembly T415 1.3

Trim and Tilt Switch Engine Cover T417 0.8

Sending Unit T421 2.0

Trim Bleed T431 1.5

Dynamic Power Steering (SAP System Code 29)

TIME
DESCRIPTION NOTE CODE
(HRS)
Motor and Cable - Replace S401 2.0

Manifold - Replace S402 5.0

DPS Sensor Assembly S404 1.0

Filter (all) S405 5.0

DPS 1-Helm Pressure Sensor Replace S406 5.0

DPS 1-Pump Pressure Sensor Replace S407 5.0

DPS 2-Pressure Sensor Replace (Either) S408 5.0

Steering Pressure Sensor Replace S409 5.0

8
 Gearcase (SAP System Code 22)
TIME
DESCRIPTION NOTE CODE
(HRS)
Gearcase Assembly 1,2 G401 2.5

Gearcase Assembly - Reseal (Complete) 1 G402 3.8

Gearcase Housing Only - Replace 1 G403 5.0

Pinion Bearing - Replace 1 G404 5.4

Propshaft Bearing Housing - Replace G405 1.2

Propshaft Bearing Housing - Rebuild 7 G406 1.4

Reverse Gear Only - Replace 1 G407 1.3

Lower Driveshaft or Upper Bearing Housing Replace (requires shimming) 1 G408 4.0

Propshaft or Shifter Clutch Dog 1 G410 4.0

Forward and/or Pinion Gear 1, 14 G411 5.0

Shift Housing and/or Forward Bearing Assembly 1 G412 5.0

Water Pump 1, 13, 15 G413 3.0

Additional Time for Pressed Rear Bearing Carrier G414 0.4

Shift Actuator Assembly 13 G415 3.0

9
VOUCHERS - FLUID AND MISCELLANEOUS
The following part numbers have been established to issue credit vouchers. These part numbers
represent an average amount of dollars for bulk fluids, and motor oil used when making warranty
repairs. Select the correct part number from the following list and enter it in the “List All Parts Used in
Repair” section of the warranty claim form.

Part Number Category Dealer Net U.S. Dealer Net CA

090105 V6 Gearcase Oil $9.00 $11.48

090301 Degreaser or Marine Cleaner $6.50 $6.95
090302 Heli – Coil Insert $1.00 $1.20
090303 E-TEC Engine Oil $7.05 $7.75
090304 Trim & Tilt Oil $2.50 $2.95
090306 Fuel Hose $2.00 $2.40

ADDITIONAL ALLOWANCE
Description Note Code Time

Saltwater Allowance (for major assembly only) 1 Y102 0.30

Heli-Coil Repair (One) Y104 0.30

1. Y102 Saltwater allowance may not be used on new motors.

10
CUSTOMER COMMENT CODES
BRP has revised the customer comment codes to assist our Quality Assurance Department. This
change will help to identify and correct any problem areas in a timely manner. New numbers have
been assigned to these codes. We now have fewer codes to make your selection easier.

These comment codes are to be used to describe the condition of the failing part number used on the
claim. Choose the comment code from the list that is best suited for the failure.

Shipping/Packaging General
210 - Missing part in package 208 - Missing part on engine
211 - Wrong part in package 209 - Wrong part on engine
212 - Damaged in shipment 213 - Grounded/Shorted
214 - Open circuit
Shipping/Packaging 215 - Burned
210 - Missing part in package 216 - High output
211 - Wrong part in package 217 - No/Low output
212 - Damaged in shipment 218 - Warning malfunction
219 - Erratic/Intermittent
220 - Adjustment
221 - Foreign material
222 - Noisy
223 - Mis-machined
224 - Mis-assembled
225 - Tight/Sticking
226 - Kinked/Bent
227 - Seized/Scuffed
228 - Restricted
229 - Pinched
230 - Fractured/Broken
231 - Split
232 - Stripped
233 - Loose
234 - Leaking
235 - Cut
236 - Deformed/Warped
237 - Rounded
238 - Software Revision
239 - Field Campaign

11
REQUEST FOR REVIEW OF FLAT RATE TIME STANDARD
Dealer Sender’s
Dealer Name: Code: Name:

Address: Phone:

City, State, Zip: Date:

Engine Model #: Serial Number

What do you feel time
Flat Rate Code: Time from manual: allowed should be?

Did the type of boat significantly affect repair time?

If the answer above is yes, please give the following information:

Make of Boat: Model: Year:

Comments:
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Fax to 262-884-5381 or Email warrantyauthos.mps@brp.com
In House use only:
Models Years Affected______________________________________________________
Authorization______________________________________________________________

12
 Guide des barèmes forfaitaires

Evinrude E-TEC G2
200, 225, 250, 300 HP, 74°V6 (3.4 L)

© 2014 Bombardier Recreational Products Inc. All rights reserved. ®, TM and the BRP logo are trademarks of Bombardier Recreational Products or its affiliates