REMOTE CONTROL ADAPTOR KIT, P/N 5037454 INSTALLATION INSTRUCTIONS APPLICATION Install remote control adaptor kit on Johnson 4-Stroke 25 HP (32.8 cu. in. / 538 cc) outboards. DO NOT install on any other models. Refer to service manual and installation guides for additional assembly information. SAFETY INFORMATION For safety reasons, this kit should be installed by an authorized Evinrude®/Johnson® dealer. This instruction sheet is not a substitute for work experience. Additional helpful information may be found in other service literature for your engine. Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so to protect yourself, as well as the people around you. This instruction sheet uses the following signal words identifying important safety messages. It is understood that this instruction sheet may be translated into other languages. In the event of any discrepancy, the English version shall prevail. DANGER DO NOT do any repairs until you have read the instructions and checked the pictures relating to the repairs. Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING Indicates a potentially hazardous situation which, if not avoided, CAN result in severe injury or death. CAUTION Be careful, and never rush or guess a service procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol use, to name a few. Damage to a boat and outboard can be fixed in a short period of time, but injury or death has a lasting effect. 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. Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate personal injury or property damage. It also may be used to alert against unsafe practices. Torque wrench tightening specifications must be strictly followed. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts. IMPORTANT: Identifies information that will help prevent damage to machinery and appears next to information that controls correct assembly and operation of the product. If you use procedures or service tools that are not recommended in this instruction sheet, YOU ALONE must decide if your actions might injure people or damage the outboard. These safety alert signal words mean: TO THE INSTALLER: Give this sheet to the owner. Advise the owner of any special operation or maintenance information contained in the instructions. ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! TO THE OWNER: Save these instructions in your owner’s kit. This document contains information important to the future use and maintenance of your engine. Printed in the United States. © 2006 BRP US Inc. All rights reserved. TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates. DSS06248I 1 of 8 COMPONENTS 11 12 25 24 10 15 9 26 30 8 13 2 14 1 3 6 6 20 7 18 3 19 17 16 4 18 27 22 5 17 16 21 21 29 28 23 Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 2 of 8 P/N 5037454 5036959 5036960 5031829 5030056 5035272 5030086 5030990 5036920 5036921 5036922 5036923 5036924 5034142 5030988 5030989 Name of Part Qty REMOTE CONTROL ADAPTOR KIT 1 *LINK, CLUTCH LEVER 1 *LEVER, CLUTCH CONTROL 1 *WASHER, CLUTCH LEVER LINK 5.5x12 2 1 *WASHER, CLUTCH LEVER 6.5x18 *SPACER, CLUTCH LEVER 1 *PIN, CLUTCH LEVER LINK 2 1 *BOLT, CLUTCH LEVER 6x25 *LEVER, THROTTLE CONTROL 1 *LEVER, INTERLINK THROTTLE 1 *SPRING, THROTTLE LEVER 1 *STAY, THROTTLE CABLE 1 *CABLE ASSY, THROTTLE 2 1 *WASHER, THROTTLE LEVER 6.5x20 1 *BOLT, THROTTLE LEVER 6x12 *BOLT, THROTTLE CABLE STAY 6x12 2 Ref 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 P/N 5032155 5031080 5030575 5037083 5037084 5030035 5033017 5037123 5036996 5036992 5031690 5037126 5037085 5037088 5030840 Name of Part *CONNECTOR, R/CON CABLE *WASHER, CONNECTOR 7x12 *CLIP, R/CON CABLE CONNECTOR *HOLDER, SHIFT CABLE *HOLDER, THROTTLE CABLE *BOLT, R/CON CABLE HOLDER 6x15 *GROMMET, R/CON CABLE *WIRE HARNESS ASSY *HOLDER, CONNECTOR *PLUG, STARTING SWITCH HOLE *SCREW, CONNECTOR HOLDER *GROMMET, CABLE *DRAG LINK ASSY *STEERING BRACKET KIT *SEAL, CABLE Qty 2 2 2 1 1 4 1 1 1 1 1 1 1 1 1 DISASSEMBLY INSTALLATION Read and familiarize yourself with the complete installation instructions of the remote control adaptor kit. Always test the operation of remote controls once installed. Install the plug in the lower cover panel to seal start switch hole. WARNING Assemble the throttle control lever, the throttle lever spring, and the throttle interlink lever. Install the assembly on the engine block using the throttle lever bolt and washer. Torque bolt to 100 in. lbs. (11 ± 2.0 N·m). Failure to properly install and test remote control may result in remote control malfunction and loss of control of boat. 1 3 To prevent accidental starting while servicing, disconnect battery leads from battery. Twist and remove all spark plug leads. To prevent injury from contact with a rotating propeller, remove propeller before servicing and when running outboard on a flushing device. 2 1. Throttle control lever 2. Spring 3. Throttle interlink lever 006380 Insert one end of the shift lever link end into the shift shaft. Insert the opposite end of the shift lever link into the hole of the clutch lever. Install a washer and a cotter pin on each end of the link. 1 Nautical Orientation 2 004861 1) Remove lower covers and flywheel cover. 2) Disconnect throttle cable ends from carburetor. 3) Disconnect the engine stop switch wiring from the tiller handle bracket. 3 1. Shift lever link 2. Shift shaft 3. Clutch lever 006381 4) Remove the tiller handle assembly from the outboard. 5) Disconnect the shift lever link from the shift shaft. Remove the shift lever from the outboard. 6) Remove the cable grommet and the start switch from lower cover panel. 7) Remove the adjuster lever assembly and the steering friction plate from the steering bracket. 8) Note the wire harness routing and connections. Remove the wiring harness. 3 of 8 Install the clutch lever on the cylinder block using spacer, washer and bolt. Torque the bolt to 100 in. lbs. (11 ± 2.0 N·m). Install the wire harness connector holder on the cylinder block. 1 1 1. Connector holder 1. Clutch lever 006430 Install the throttle cable stay on the cylinder block using two bolts and torque to 100 in. lbs. (11 ± 2.0 N·m). Install the non-adjustable ends of the throttle cables on the throttle lever and the adjustable ends of the throttle cables on the throttle cam. Position cables in the throttle cable stays. 5 3 1 2 4 1. 2. 3. 4. 5. Throttle cable stay Bolt (2) Throttle cable Throttle control lever Throttle cam 006432 Install the connectors of the wire harness assembly on the connector holder. Install the wire harness assembly following the original routing and connections. Refer to chart below. Connect To Connection Oil pressure switch Temperature switch Neutral switch Rectifier/Regulator Oil pressure indicator CDI Ground Starter motor relay Starter motor Ring terminal, black cover White, 2-pin connector Black, 2-pin connector Green - bullet terminal Red connector Black, 8-pin connector Ring terminal, black wires Clear connector Ring terminal, red wire Clamp the wire harness in the same position as the original harness. 006382 1 006433 1. Throttle cam 4 of 8 006431 Route the shift cable through the shift cable holder. Position the groove of the cable in the retaining slot of the holder. 006434 IMPORTANT: Route wire harness carefully. Do not allow wire harness to contact moving components or to rub against sharp surfaces. REMOTE CONTROL CABLE INSTALLATION IMPORTANT: Before connecting the remote control cables to the engine, the cables must be properly installed in the remote control assembly. Refer to installation instructions for remote control. 1. Shift cable holder 006386 Route the throttle cable through the grommet of the shift cable holder. Next, route the throttle cable through the throttle cable holder. Position the groove of the cable in the retaining slot of holder. Install the throttle cable holder on the lower cover panel using two bolts and torque to 88 in. lbs. (10 ± 2.0 N·m) 2 Insert the remote control cable grommet into the shift cable holder. Install the shift cable holder (with the grommet) on the lower cover panel using two bolts and torque to 88 in. lbs. (10 ± 2.0 N·m). 1 3 1. Grommet 2. Shift cable holder 3. Throttle cable holder 006387 Position cable grommet for the lower engine cover on the remote control cables as shown. 3 1. Grommet 2. Shift cable holder 006383 4 1 2 1. 2. 3. 4. Shift cable Throttle cable Wire harness Battery cable 006435 5 of 8 THROTTLE CABLE ADJUSTMENT IMPORTANT: Remote control throttle cable must not be connected to throttle control lever. Align the alignment mark on the throttle control lever with the rib on the cylinder block. Keep lever in this position. Install the cable connector onto the threaded end of the remote control cable. Screw connector in or out with the inner cable fully pulled out. Align the hole of the connector with the pin of the throttle control lever. Position the cable connector on the pin with flat surface of connector toward cylinder block. Install the washer and clip. Tighten the cable nut against the connector. 2 1 1 1. Cable connector 1. Alignment mark, throttle control lever 2. Alignment mark, cylinder block 006388 006436 Make sure the throttle lever of the carburetor contacts the full throttle stop when the remote control lever is advanced to FULL THROTTLE or highest throttle position and contacts the idle stop when the remote control lever is returned to IDLE or slowest throttle position. IMPORTANT: Adjust throttle linkage cables to remove all slack from cables with all alignment marks aligned as shown. Throttle lever must be in IDLE or slowest throttle position and aligned with the rib on the cylinder block. Adjust the lengths of the throttle linkage cables to align the alignment mark on the throttle cam with the center of the throttle lever roller. 1 2 2 3 1. Full throttle stop 2. Idle stop 1 1. Throttle linkage cables 2. Alignment mark 3. Center, throttle lever roller 006389 IMPORTANT: The cable connector must thread onto threaded end of cable a minimum of 0.5 in. (13 mm). 6 of 8 006390 SHIFT CABLE ADJUSTMENTS STEERING CABLE INSTALLATION Make sure the remote control is in NEUTRAL. Extend the output end of the steering cable and lubricate the inner core and sliding surfaces of cable with Triple-Guard grease. Turn propeller shaft and move the clutch control lever (shift lever). Shift outboard between FORWARD, NEUTRAL and REVERSE. Position lever in NEUTRAL. Make sure outboard is in NEUTRAL and propeller shaft turns freely. Install steering cable through tilt tube and tighten the retaining nut. Install steering cable seal. IMPORTANT: The cable connector must thread onto threaded end of cable a minimum of 0.5 in. (13 mm). Install the cable connector onto the threaded end of the remote control cable. Screw connector in or out with the inner cable fully pushed in. Align the hole of the connector with the pin of the clutch control lever. Position the cable connector on the pin with flat surface of connector towards cylinder block. Install the washer and clip. Tighten the cable nut against the connector. 5 1 6 1 2 1. Retaining nut 2. Steering cable seal 2 006392 STEERING ATTACHMENT KIT INSTALLATION Install the steering attachment kit on the outboard’s steering bracket. Use the bolts and the lock washers supplied in the kit. Torque bolts to 37 ft. lbs. (50 ± 5.0 N·m) 3 1. 2. 3. 4. 5. 6. Cable connector Inner cable Clutch control lever Washer Clip Nut DRAG LINK INSTALLATION 4 Connect drag link to the steering cable with washers and self-locking nut as shown. Tighten the nut to 88 in. lbs. (10 N·m), then back the nut off 1/8 of a turn. 006391 Turn propeller shaft and check shift operation. Make sure the shift lever moves the clutch to engage the forward and reverse gears completely. IMPORTANT: Make sure the neutral switch is depressed when the remote control lever is in neutral position. N 1. 2. 3. 4. Drag link Steering cable Washers Nut 004824 7 of 8 Move the steering cable until hole of drag link aligns with the rear hole on the steering bracket. Connect the drag link to rear hole of bracket using the bolt, spacer, and washers as shown. Torque the bolt to 25 ft. lbs. (34 N·m). Install self-locking nut and torque to 25 ft. lbs. (34 N·m). NEUTRAL START TEST WARNING Make certain starter will not operate when the outboard is in gear. The start-in-gear prevention feature is required by the United States Coast Guard to help prevent injuries. Use this “non running” test to make certain the starter motor will NOT operate when control lever is in FORWARD or REVERSE. The lanyard clip may be attached to key switch or removed for the following test. IMPORTANT: Disconnect all spark plug wires to prevent outboard from starting during test procedure. 006394 IMPORTANT: After assembly, turn the steering wheel all the way to PORT and to STARBOARD to check for smooth and unrestricted steering operation. With control handle in NEUTRAL position, turn key switch to START. The starter should operate. With the key switch in START position and the starter cranking the engine, move control handle to FORWARD. The starter should stop as handle leaves NEUTRAL. REMOTE CONTROL WIRE HARNESS CONNECTION Release key and move control handle to NEUTRAL. Turn key to START. The starter should operate. Connect the remote wire harness to the connectors of the engine wire harness assembly. Position the connectors in the holder. Route the remote control wire harness through the cable grommet. With key switch in START position and the starter cranking the engine, move control handle to REVERSE. The starter should stop as handle leaves NEUTRAL. 1 CHECK OPERATION Start the engine and check shift and throttle control operation by moving the remote control lever to FORWARD and then REVERSE position. Check emergency stop function. With outboard running at IDLE, pull safety lanyard from emergency stop switch. Outboard must stop immediately. 2 1. Connector holder 2. Grommet Reinstall flywheel cover and lower covers. 8 of 8 006437 Make sure throttle advances to FULL THROTTLE position and returns to IDLE or slow speed position and operates smoothly. LUBRICATION Apply Triple-Guard grease to all moving parts, including throttle cables, the throttle lever, and the throttle drum.