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Crowley Marine: serving boaters for over 40 years Crowley Marine: serving boaters for over 40 years
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Binnacle Control, With or Without Trim

Crowley Marine

SAFETY

These installation instructions contain information that can help prevent personal injury and damage to equipment. Understand the following symbols before proceeding:

(Safety Warning):  Alerts you to the possibility of danger and identifies information that will help prevent injuries.

NOTE:  Identifies information that will help prevent damage to machinery.

IMPORTANT:  Appears next to information that controls correct assembly and operation of the product.
 

TO THE OWNER

The assembly procedures outlined in this sheet should be performed by a skilled technician. If you have questions, see your DEALER. Save these instructions in your owner's kit. This sheet contains information important to the future use and maintenance of your engine.
 

TO THE INSTALLER

Give this sheet to the owner. Advise the owner of any special operation or maintenance information contained in the instructions.
 

PREFACE

This control is compatible with the 1996 (ED) and newer Modular Wiring System. This control supports the SystemCheck™ engine monitoring system and allow single-lever control of an Evinrude® or Johnson® outboard motor.

Installation of this kit involves procedures for connecting throttle and shift cables to motor, described in detail int he Service Manual for your product. If you do not have the required literature and do not wish to purchase it, have this kit installed by your Evinrude/Johnson Dealer.

Call out NUMBERS (1), (2), etc. in text and illustrations refer ONLY to specific items in Contents of Kit illustration and list. Call out LETTERS (A), (B), etc. are used over and over - on different items on other pages.

To the Installer and the Owner - INSTALLER: Give these instructions to owner. OWNER: Read the section Remote Control Operation, and also Remote Control Adjustments, located at end of this document, before you operate your boat. Keep these instructions with your Operator's Manual.

If a non-BRP instrument cable is used, it must have connections for the "start-in-gear-prevention" switch in this control. It must also have a key switch, (and for an Evinrude/Johnson outboard motor, a primer switch, and a warning horn). It must have equivalent wire type and size, and must also meet U.S. Coast Guard safety regulations and A.B.Y.C. standards (or standards that apply in your country).

[1]
Review Contents of Kit and installation procedure.

Ref. Name of Part Qty.
1 Control Assembly 1
2 Control Cover 1
3 Rubber Boot 1
4 Trunnion Anchor 2
5 Cable Pin 2
6 Cotter Pin 2
7 Anchor Retainer 2
8 Retainer Screw 2
9 Retainer Locknut 2
10 Control Mounting Screw 4
11 Adjustment Screw Cover 1

Tools and Lubricants Required for Installation:

- Masking Tape - Tape Measure - Triple-Guard® Grease - Needle Nose Pliers - Phillips Screwdriver - 3/8 in. Wrench - Center Punch - Hammer - Electric Drill - 1/8 in. (3,2 mm) Drill Bit - 1/2 in. (12,7 mm) Drill Bit - saber Saw - Anti-Corrosion Spray - Electrical Grease
 

Remote Control Operation

[2] [3]
Shift Disengage
- To open throttle without shifting into gear (for easier starting of motor does not have QuikStart™ electronic starting). Push and hold the shift disengage button (A) with control handle in NEUTRAL (B), and move handle to either shift detent position, (C) or (D). Release button and move handle more to open throttle for starting and warm-up. The shift will re-engage when the handle is returned to NEUTRAL.

NOTE: Pull lever part way back as soon as motor starts. Do not run a cold motor any faster than necessary to keep motor from stalling. Do not exceed 2500 RPM in NEUTRAL. For motors with QuikStart, wait until motor drops to a normal idle RPM before shifting into gear.

[3]
Handle Positions

   (B) Neutral Detent
   (C) Forward Gear
   (D) Reverse Gear
   (E) Forward Throttle Range
   (F) Reverse Throttle Range

[4]
Trim/Tilt Switch (G)
- Push top of switch to trim out and tilt up, or push bottom of switch to tilt down and trim in.
 

Select Mounting Location

[5]
A minimum of 20 in. (508 mm) (H) of fore-and-aft space is needed to operate this control This will provide 2 3/16 in. (55 mm) (I) hand clearance in front of the handle at wide-open throttle (W.O.T.) in FORWARD, and 1 in. (25 mm) (J) behind the handle at W.O.T. in REVERSE.

[36] [6] [5]
Remove template from instructions and plate at proposed control location. Check handle and hand clearance dimensions in FORWARD and REVERSE W.O.T. positions. Move template until a satisfactory control position is found, and tap template in place with arrow pointing to front of boat.

[7]
There must be at least 19 in. (482 mm) (P) of clear space below the mounting surface for the control cables.

The mounting surface must be strong enough to provide rigid support. If not, strengthen as necessary.
 

Determine Control Cable Length

Route cables so they have fewest number of bends. The bends must never be less than 6 in. (15 cm) radius.

[8]
From center of handle at (A) or (B), measure along intended cable route to motor centerline at transom height (C), as illustrated by either dotted line.

  • For Evinrude/Johnson outboards, add 3 ft. 4 in. (1,02 m) to these measurements. These dimensions are the required cable lengths.
     
  • For OMC Cobra® engines, see the product service manual for control cable lengths.

[9]
Snap-In® cables:

   (D) Cable length in meters
   (E) Cable length in feet
   (F) Part Number

[10]
Snap-In/SAE cables

   (G) Cable length in meters
   (H) Cable length in feet
   (I) Part Number

[9]
Snap-In remote control cables are available in one foot increments from five foot to twenty foot length, and in two foot increments to fifty foot length.

[10]
Snap-In/SAE cables have a Snap-In type input end and a standard SAE output end. They are available in one foot increments from eight foot to twenty foot length. and in two foot increments to thirty foot length.

Pick cables that are equal to your calculated length, or are the next longer available length.

Use the correct length cable. The wrong length cable can bind, causing control to jam in operation.
 

Determine Which Levers the Cables will be Attached to

[11]
Lift cover (2) off remote control (1) if installed. Don't lose rubber boot (3) from shift disengage button.

Note which is front and rear sides of control as installed in boat (handle is on port side).

  • To determine which levers the control cables will be attached to, and to provide some clearance around them for control cable installation, the correct levers will be moved UP.
     
  • The control pulls on the cables when the levers move UP.
     
  • When you pull the throttle cable on Johnson and Evinrude outboard motors and on OMC Cobra engines, the throttle CLOSES, and when you pull on the shift cable the motor goes into FORWARD GEAR.
     
  • The THROTTLE is CLOSED and the motor is in FORWARD GEAR when the control lever is in the FORWARD detent position.

[12]
Therefore, put control handle in FORWARD detent position. Mark the two levers (A) and (B) that are not UP. The cables are attached to the handle side of these levers.

For Other Propulsion Units: Determine what control position will pull the shift and throttle cables.

  • Does it pull the throttle to W.O.T. (Wide Open Throttle), or to close the throttle?
     
  • Does it pull the shift to FORWARD, or to REVERSE?
     
  • Put control in position that will pull both cables.
     
  • Attach the control cables to the levers that are UP.
     

Connect Snap-In or Snap-In/SAE Control Cables to Remote Control

[13]
Lubricate shift and throttle cable ends with Triple-Guard grease.

[14]
To install throttle, cable, place trunnion anchor (4) into upper slot (C).

[15]
Install throttle cable trunnion into starboard side of anchor.

[16]
Pull cable up to handle side of throttle lever (D), aligning hole in cable with hole in lever.

[17]
Install cable pin (5) through the lever first, then the cable. Install cotter pin (6) and secure by spreading ends.

[18]
Position anchor retainer (7) onto trunnion anchor and cable trunnion. Install screw (8) and locknut (9). Tighten screw securely.

[19]
To install shift cable, place trunnion anchor (4) into upper slot (A).

[20]
Install shift cable trunnion into port side of anchor.

Pull cable end up to handle side of shift lever (B), and align hole in cable with inner hole (C) in lever.

[21]
Install cable pin (5) through cable and inner hole in shift lever. from handle side. Install cotter pin (6) and secure by spreading ends.

[22]
Install anchor retainer (7) onto trunnion anchor and cable trunnion. Install screw (8) and locknut (9). Tighten screw securely.
 

Install Remote Control

Disconnect battery cables from battery before drilling or sawing near electrical wires to prevent possible injury from shorting a hot wire to ground.

[23]
With template at your selected location, center punch and drill 1/8 in. (3,2 mm) and 1/2 in. (12,7 mm) holes through mounting surface, being careful that 1/2 in. (12,7 mm) holes stay inside lines of template. Center punch and drill holes marked with a "T" ONLY IF YOUR CONTROL HAS TRIM.

Use a saber saw and carefully cut out mounting hole, staying INSIDE line. Remove template.

Insert control cables and wires through cutout.

Route control cables aft to motor with no sharp bends. All bends must have a 6 in. (15 cm) or larger radius.

[24]
Connect the yellow/red neutral start switch wire (A) from remote control to key switch "S" terminal (B).

[25]
Connect second yellow/red neutral start switch wire (C) from remote control to key switch cable bullet connector (D).

[26]
Locate the six-socket plug (E) on instrument cable with the same color wires as the key switch cable. Check mating surfaces of six-pin and three-pin connectors for dirt or other contaminants. Remove all dirt, old lubricant, etc. Immediately before joining, apply a light coat of Electrical Grease to seal (F), and also on seal (G) if control has trim and tilt.

[27]
Align six-socket plug on instrument cable with key switch receptacle. Push connector together until latched. Align three-socket plug on instrument cable with control receptacle. Push connector together until latched.

For installations not using the Modular Wiring System, cut off terminal pins and crimp on suitable terminals.

For protection in salt water, spray entire control with Anti-Corrosion Spray metal protectant.

[28]
Place rubber boot (3) over shift disengage button and position cover (2) on control. Secure cover and control with screws (10) provided.

NOTE: Use a manual screwdriver - a power screwdriver could damage cover.

Check that remote control operates freely and equal friction is felt in FORWARD and REVERSE throttle range of control handle. Any binding could cause remote control to jam when cables are attached to motor.

[29]
Install adjustment screw cover (11).

Route cables in a straight line, without sags, and secure to boat every 24 in. (61 cm). Place first fastener 24 in. (61 cm) behind remote control. If you use cable clamps, do not squeeze cable out-of-round.

[30]
You must provide a 12 in. (30 cm) minimum diameter loop (A) in cables between last boat fastener and motor anchoring point.

Before connecting cables to motor, check that control operates freely, that shift re-engages in NEUTRAL after disengaging for warm-up, and equal friction is felt in FORWARD and REVERSE throttle range of control handle. Any binding could cause control to jam when cables are attached to motor.
 

Connect Control Cables to Motor

Refer to your service manual for procedures to connect control cables to motor.
 

Test Your Installation

Check to be sure cables are attached to the correct lever. Place control handle in NEUTRAL. Depress and hold shift disengage button. Move handle to FORWARD or REVERSE detent. No cable should move. Continue moving handle to wide-open-throttle position. Only the throttle cable should move.
 

Neutral Start Test

Evinrude/Johnson outboard motors: Separate connector between charge coil and ignition module, or disconnect all spark plug wires to keep motor from starting. OMC Cobra engines: See service manual.

Connect battery cables to battery.

This remote control is designed to crank motor in NEUTRAL only. If control handle is "in-gear," starter will not operate. Test to make certain starter motor will NOT operate when control handle is in FORWARD or REVERSE and WILL operate when handle is in NEUTRAL.

NOTE: Running motor out of water even momentarily will damage water pump and eventually cause powerhead damage.

  • Move control handle to NEUTRAL.
     
  • Turn key to START position. The starter should operate.
     
  • With key still in START position and starter cranking motor, move control handle to FORWARD. The starter should stop as control leaves NEUTRAL.
     
  • Release key and move control handle to NEUTRAL.
     
  • Turn key to START position. The starter should operate.
     
  • With key still in START position and starter cranking motor, move control handle to REVERSE. The starter should stop as control leaves NEUTRAL.

If starter operates with control IN GEAR, return complete remove control to your dealer for further tests and/or service.
 

Trim/Tilt Switch Test

Press top of switch to trim motor out and tilt motor up. Press bottom of switch to tilt motor down and trim motor in.

[32]
If trim operates in one direction only and/or moves in the wrong direction, check if wire colors are the same on both sides of the trim switch connector.

If pressing switch does not operate trim/tilt motor, check switch-to-motor connection. Operate trim with lower motor cover switch (if on your motor). If trim does not work, have trim unit checked. If trim works with lower motor cover switch but not with remote control switch, have your dealer inspect remote control.
 

Remote Control Adjustments

Check throttle friction - Move control handle to FORWARD throttle range. When properly adjusted, control handle should have low enough friction to allow easy movement in FORWARD throttle range, yet not allow vibration to change throttle setting.

[33] [34]
Adjust throttle friction
- Remove adjustment screw cover (A). Turn UPPER adjustment screw clockwise to increase friction.

[35]
Adjust detent force
- Turn LOWER adjustment screw clockwise to increase detent force. Move handle to FORWARD shift detent, then back to NEUTRAL detent. Readjust until desired detent force is achieved.

Reinstall adjustment screw cover.

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