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.