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Crowley Marine: serving boaters for over 40 years Crowley Marine: serving boaters for over 40 years
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Electric Start & Battery Charging Kit

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 kit converts a 1993 (ET) and newer 40 thru 50 Evinrude® or Johnson® manual start outboard to tiller electric start with non-regulated 4-amp battery charging.

[1] Contents of Kit

Ref. P/N Name of Part Qty.
1 343160 Start Button Body 1
2 343435 Start Button Spring 1
3 343161 Start Button 1
4 328480 Start Switch Mounting Ring 1
5 583929 Start Switch 1
6 328169 Start Switch Nut 1
7 123739 "Start" Decal 1
8 310928 J-Clamp 1
9 582926 Stator Assembly 1
10 337522 Stator Mounting Screws 3
11 583482 Starter Motor 1
12 306470 Starter Lock Washers 3
13 302479 Starter Mounting Screws 3
14 512762 Terminal Block 1
15 309483 Terminal Block & Rectifier Mounting Screw 1
16 306644 Terminal Block Mounting Screw 1
17 329182 Terminal Block Screws 4
18 581778 Rectifier 1
19 303701 Rectifier Mounting Lock Washer 1
20 306644 Rectifier Mounting Screw 1
21 317893 Tie Strap 1
22 395419 Solenoid Assembly 1
23 311217 Solenoid Sleeve 1
24 330112 Solenoid Clamp 1
25 306010 Solenoid Mounting Screws 2
26 328701 Solenoid & Power Pack Lock Washer 2
27 331259 Solenoid, Large Lock Washer 3
28 311349 Solenoid, Large Nut 3
29 331259 Solenoid, Large Lock Washer 2
30 304454 Solenoid, Small Lock Washer 2
31 306556 Solenoid, Small Nut 2
32 328701 Ground Wire Lock Washer 1
33 580733 Solenoid Ground to Cylinder Block Wire 1
34 583674 Terminal Block-to-Solenoid Wire 1
35 583692 Starter Motor-to-Solenoid Wire 1
36 395390 Battery Cable 1
37 512682 Battery Cable Cover 1
38 320107 Tie Strap 1
39 337548 Start Button Screw (not shown) 1
40 343159 Start Button Cap (not shown) 1

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.

Installation of this kit involves procedures described in detail in Service Manual.

To avoid accidental starting of engine while servicing, twist and remove all spark plug leads.

[2]
Remove lower retaining screw from lower engine cover.

[3]
Remove rear retaining screws from lower engine cover.

[4]
Remove front retaining screw from lower engine cover.

[5]
Remove both sides of lower engine covers.

[6] [7]
Following the instructions supplied with the Start Button Kit, install the start button parts into the shift bracket.

[8]
Remove backing from START decal (7). Place decal on shift lever.

[9]
Place shift lever in FORWARD. Install start switch mounting ring (4) over start switch leads until mounting ring seats on back of start switch (5). Insert start switch cable through start switch hole in steering bracket behind bottom of shift lever.

[10]
Seat start switch in hole in steering bracket. Place start switch nut (6) on start switch and tighten securely.

[11]
Torque shift lever screw to 18-20 ft. lbs. (25-27 Nm).

[12]
Remove the rear screw and nut (A) from the steering housing.

[13]
Install the J-clamp (8) onto the steering housing screw and reinstall screw into steering housing. Secure start button cable in J-clamp. Install nut and torque to 18-20 ft. lbs. (25-27 Nm).

[14]
Remove manual starter (B) and flywheel (C).

[15]
Remove ignition plate top clamp, retain clamp and screws.

[16]
Loosen the five screws retaining the ignition plate to the retainer plate. Lift the ignition plate from the powerhead.

[17]
Turn ignition plate over and remove bottom cover and screw (D).

[18]
Install wires of stator assembly (9) through opening in ignition plate. Apply Ultra Lock™ to the three stator mounting screw (10) threads. Install screws finger tight.

[19]
Reinstall top clamp and screws. Tighten screws securely.

[20]
Reinstall bottom cover and screw. Tighten securely.

NOTE: Make sure wires are not pinched after cover is installed. The tab on the cover should fit inside the groove of the ignition plate.

[20] [21]
Apply Moly Lube™ to the crankcase boss (pilot for ignition plate). Lubricate the groove in the ignition plate bearing (A) with a light coating of Johnson or Evinrude TC-W3® Outboard Lubricant. Hold ignition plate bearing compressed on the support plate with needle-nose pliers. Install the ignition plate down over the bearing.

[22]
Place Coil Locating Ring, P/N 334994 (B), over machined surfaces on ignition plate. Push stator against coil locating ring. Tighten screws to a torque of 15-22 in. lbs. (1,6-2,4 Nm).

Reinstall the flywheel and manual starter housing.

[23]
Apply Nut Lock™ to threads of the three starter motor screws (13). Place the starter motor (11) in position against the powerhead. Install the three mounting screws with starter lock washers (12). Tighten the front screw first. Tighten all screws to a torque of 14-16 ft. lbs. (19-22 Nm).

[24]
Remove and save the two screws (C), washers, and cover from electrical box.

[25]
Remove the screw, washer, and ground terminal (D). Discard screw and washer. Remove the black lead from terminal "E" of stator 5-pin Amphenol connector. Remove the wire harness and plug from hole (E).

[26]
Route rectifier through back of electrical bracket hole locating the rectifier mounting holes with the electrical bracket holes.

[26]
Install lock washer (19) onto screw (20). Coat threads of screw with Ultra Lock and install screw into bracket hole and rectifier (18). Tighten screw finger tight.

[27] [28]
Coat threads of screws (15) and (16) with Nut Lock and install screws into mounting holes of terminal block (14) and into rectifier. Tighten rectifier and terminal block mounting screws securely.

[28]
Route power pack, stator wires, and terminal block-to-solenoid wire (34) through slot in front of electrical bracket. Install ground terminal and one washer (26) under head of the upper power pack retaining screw. Torque screw to 60-84 in. lbs. (7-0 Nm).

Install black lead back into stator 5-pin connector.

[29]
Secure rectifier yellow wire (A) and stator yellow wire (B) to terminal block using terminal block screw (17).

[30]
Secure rectifier yellow/gray wire (C) and stator yellow/gray wire (D) to terminal block using terminal block screw (17).

[31]
Secure rectifier yellow/blue wire (E) and stator yellow/blue wire (F) to terminal block using terminal block screw (17).

[32]
Secure rectifier red wire (G) and terminal block-to-solenoid wire (34) to terminal block using terminal block screw (17).

[33]
Route wires neatly inside of electrical bracket, as shown. Secure tie strap (38) around the power pack wires, stator wires, and terminal block-to-solenoid wire.

Coat terminal block screws (17) with Black Neoprene Dip, P/N 909570.

Reinstall electrical box cover.

[34]
Install solenoid sleeve (23) on solenoid assembly (22).

[35]
Install clamp (24) on starter solenoid. Place 1/4-20 x 1/2 in. mounting screws (25) through clamp. Install large-ring terminal of solenoid ground wire (33) then lock washer (32) on bottom mounting screw. Mount starter solenoid to port rear of powerhead. Tighten screws to a torque of 60-84 in. lbs. (7-9 Nm).

[36]
Attach starter motor-to-solenoid wire (35) to solenoid bottom terminal with lock washer (27) and nut (28). Tighten nut to a torque of 120-140 in. lbs. (14-16 Nm).

[37]
Route starter motor-to-solenoid wire (35) to starter motor terminal. Attach wire to starter motor using nut (A) supplied with starter. Tighten nut to a torque of 60-84 in. lbs. (7-9 Nm).

[38]
Place small terminal of solenoid ground wire (33) onto starter solenoid lower terminal. Use nut (31) and lock washer (30).

[39]
Place start switch yellow/red wire (B) on starter solenoid top terminal. Use nut (31) and lock washer (30). Tighten both ground and start switch nuts to a torque of 25-35 in. lbs. (3-4 Nm).

[40]
Place red start switch wire (C) and terminal block-to-solenoid wire (34) on starter solenoid top terminal. Secure wires with 5/16-18 nut (28) and lock washer (27). Tighten nut to a torque of 120-140 in. lbs. (14-16 Nm).

[41]
Place one lock washer (27) on starter solenoid top terminal.

[41]
Place red battery cable (36) on starter solenoid top terminal. Install a lock washer (29) and 5/16-18 nut (28). Tighten nut to a torque of 120-140 in. lbs. (14-16 Nm).

[42]
Route black battery lead (36) to double-end bolt (D). Place terminal on bolt. Secure with nut and starwasher provided with engine. Tighten nut to a torque of 60-84 in. lbs. (7-9 Nm).

[43]
Place rubber boot (E) over starter solenoid top terminal. Coat starter solenoid smaller terminals with Black Neoprene Dip.

[44]
Using pliers, remove the lower flange from the manual primer housing. This will allow the electrical cables to be routed through the front of the lower engine cover. Reinstall the port lower engine cover.

[45]
Route the battery cable and start button wires to the front of the lower engine cover and through the opening.

[46]
Install the manual primer switch into the opening in the lower engine cover.

Reinstall the starboard lower engine cover.

[47]
To slip battery cable terminal cover (37) over the red battery cable, split the sleeve on the terminal cover. Cut a slot on the inner edge of the sleeve. Use the tie strap (21) supplied to fasten the battery terminal cable cover to the red battery cable next to the white sleeve. Pull the tie strap tight and trim off excess length.

Install spark plug lead on spark plugs.

Refer to Section 8 in service manual for Battery Specifications and Battery Installation.

NOTE: DO NOT connect any electrical equipment directly to the motor's charging system. If the motor is run without a battery, the equipment could be damaged.

To start engine electrically, put shift lever in NEUTRAL and depress start button to crank engine.

Use stop button to stop engine.

Test for proper operation of stator and rectifier/regulator. Refer to Running Test, Alternator Output, Section 8, in service manual.

NOTE: If a tachometer is required, be sure to use only one of the recommended five pulse-type tachometers. Use of an incorrect tachometer will result in improper propeller selection and engine overspeeding. Engine overspeeding will result in serious damage to the powerhead.
 

To the New Owner

Always place terminal cove over end of positive battery cable whenever cable is removed from battery. Do not run motor with cable disconnected and unshielded against possible grounding. Electrical sparks and possible fire and explosion can occur.

NOTE: DO NOT use wing nuts on battery connections even if they come with the battery. Wing nuts can loosen and cause errant warning signals of electrical system damage.

Keep the battery connections, clean, tight, and insulated to prevent their shorting or arcing and causing an explosion. If the battery mounting system does not cover the connections, install protective covers. Check often to see that connections stay clean and tight.

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