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ELECTRIC START KIT, P/N 5007995

Crowley Marine

APPLICATION

This electric start kit is designed for use on 2009 (SE) through 2011 (II) 25-30 HP Evinrude® E-TEC® outboards. DO NOT install on any other models.
 

SAFETY INFORMATION

The following symbols and/or signal words may be used in this document:


Indicates a hazardous situation which, if not avoided, will result in death or serious injury.


Indicates a hazardous situation which, if not avoided, could result in death or serious injury


Indicates a hazardous situation which, if not avoided, could result in minor or moderate personal injury.

NOTICE: Indicates an instruction which, if not followed, could severely damage engine components or other property.

These safety alert signal words mean:

ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!

For safety reasons, this kit must 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.

DO NOT perform any work until you have read and understood these instructions completely.

Torque wrench tightening specifications must strictly be adhered to.

Should removal of any locking fastener (lock tabs, locknuts, or patch screws) be required, always replace with a new one.

When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Use of substandard parts could result in injury or product malfunction.

Always wear EYE PROTECTION AND APPROPRIATE GLOVES when using power tools.

Unless otherwise specified, engine must be OFF when performing this work.

Always be aware of parts that can move, such as flywheels, propellers, etc.

Some components may be HOT. Always wait for engine to cool down before performing work.

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.

This instruction sheet may be translated into other languages. In the event of any discrepancy, the English version shall prevail.

TO THE INSTALLER: Give this sheet and the operating instructions to the owner. Advise the owner of any special operation or maintenance information contained in the instructions.

TO THE OWNER: Save these instructions in your owner’s kit. This sheet contains information important for the use and maintenance of your engine.
 

ELECTRIC START KIT

Ref P/N Name of Part Qty
1 587045 STARTER MOTOR Assy 1
2 386721 CABLE Assy - 6 GA 1
3 328701 LOCK WASHER, Starter cable & ground 2
4 328740 NUT, Starter cable to starter motor 1
5 353735 WASHER, Starter mounting 3
6 353554 SCREW, Starter mounting - 8 x 30 mm 3
7 353589 SCREW, Harness ground - 6 x 16 mm 1
8 587102 FLYWHEEL Assy 1
9 586995 CABLE Assy, Start switch 1
10 587012 CABLE Assy, Battery 1
11 586906 BATTERY CHARGE MODULE Assy 1
12 338558 SPACER FLANGED 2
13 333040 ISOLATOR 2
14 353761 WASHER, Battery charge module (large) 2
15 353553 SCREW, Battery charge module - M6X30 2
16 354130 BRACKET, Starter solenoid 1
17 587020 STARTER SOLENOID Assy 1
18 353590 SCREW, Solenoid to bracket - 6 x 25 mm 2
19 331259 LOCK WASHER, Starter solenoid 2
20 354046 WASHER, Retaining - starter solenoid 1
21 321472 NUT, Starter solenoid 2
22 320107 TIE STRAP 6
23 353917 HOSE 1
24 353918 HOSE 1


REQUIRED TOOLS

Universal puller set, P/N 378103 13 mm combination wrench
Flywheel holder #2 pozidriver
9/16" combination wrench #0 phillips bit screwdriver
7/8" socket and socket wrench 22 mm open end wrench
28 mm socket and breaker bar 75 ft. lb (100 Nm) torque wrench
10 mm socket and socket wrench 50 in. lb (12 Nm) torque wrench
8 mm socket and socket wrench 150 in. lb. (200 Nm) torque wrench
11 mm combination wrench Diagonal cutting pliers


INSTALLATION

Refer to the appropriate service manual for additional information.

Remove lower engine covers.


To prevent accidental starting during installation, twist and remove all spark plug leads.

Remove the electrical connectors from the recoil starter housing.

On 2010 or older models, remove the touch troll connector and retainer from the cooling hose.

Remove cooling hose from the EMM and the overboard indicator. Remove tie straps and discard cooling hose.

Remove the Electronic Management Module (EMM) mounting screws. Remove the EMM. Position the EMM to the side.

Remove the vapor separator vent hose and wiring from the recoil starter housing.

Remove the recoil starter mounting screws and remove recoil starter assembly.

Remove flywheel nut and washer. Use universal puller, P/N 387103, to remove flywheel.

Lightly coat threads of flywheel nut with Triple Guard grease. Align the flywheel key in groove of crankshaft.

Install new flywheel (with ring gear). Install washer and nut and tighten to a torque of 66 to 70 ft. lbs. (90 to 95 Nm)

Position the wiring in the retaining bracket of recoil starter housing.

Install recoil starter assembly. Tighten mounting screws to a torque of 31 to 48 in. lbs. (3.5 to 5.5 Nm).

IMPORTANT: Prevent damage to wiring from rotating flywheel, make sure stator connector is securely fastened to the starter housing.

Install stator connector in retainer groove of starter housing.

Position the vapor separator vent hose and wiring in the retainers on the recoil starter housing.

Install the isolators and flanged spacers on the battery charge module as shown.

Cut the existing tie strap holding the engine harness and insert a new tie strap as shown. Install the battery charge module on the crankcase assembly with 6 x 30 mm screws and the large 6 mm washers. Tighten screws to a torque of 31 to 48 in. lbs. (3.5 to 5.5 Nm). Tighten tie strap to secure both the engine harness and the battery charge harness.

Connect battery charge module harness to engine wiring harness. Route harness under the EMM and over the recoil starter housing.

Position the charge module harness, connectors and wiring as shown. Assemble and tighten tie straps through the tie strap slots of the recoil housing. Attach fuse holder to retainer. Attach remaining connectors to retainers on recoil housing as shown.

Install the electric starter on the crankcase assembly. Install and tighten the front screw first. Torque all three screws to 128 to 146 in. lbs. (14.5 to 16.5 Nm).

IMPORTANT: Check the oil hoses are NOT pinched behind the electric starter.

Remove the screws from the intake manifold. Install the solenoid bracket as shown using the same screws. Tighten screws to a torque of 84 to 106 in. lbs. (9.5 to 12 Nm). Install negative battery cable using the 6 x 16 mm screw and lock washer. Tighten screw to a torque of 31 to 48 in. lbs. (3.5 to 5.5 Nm).

Install starter solenoid on solenoid bracket with two 6 x 25 mm screws. Tighten screws to 31 to 48 in. lbs. (3.5 to 5.5 Nm).

Install the battery charge wire, positive battery cable, lock washer, and solenoid nut on upper solenoid terminal.

Install protective cover on positive battery cable. Tighten solenoid nut securely.

Install the starter cable, lock washer, and nut on the lower solenoid terminal. Install starter cable, lock washer, cable and nut on the starter terminal. Tighten solenoid and starter terminal nuts and apply liquid neoprene to seal terminals.

Remove solenoid connector from storage location and connect to starter solenoid. Use a tie strap to secure the cables as shown.

Position the EMM on the starter housing. Install and tighten self-taping screws carefully.

IMPORTANT: Turn self-tapping screws counter clock-wise to start the threads and clockwise to tighten. Failure to follow this procedure can damage the threads of the housing.

Connect the cooling hose (P/N 353918) from the EMM to the battery charge module as shown. Secure with tie straps.

Connect the cooling hose (P/N 353917) from battery charge module to the overboard indicator fitting (exhaust grommet fitting). Secure with tie straps. On 2010 and older models, attach touch troll connector and retainer to straight hose.

Install lower engine covers. Route battery cables through port lower engine cover.

Remove steering arm cover screws (8) and cover.

Remove start switch cover and stop switch assembly.

Slide start switch wiring through slot and install start switch.

Reinstall stop switch assembly. Route wiring as shown. Check wiring is not pinched.


Secure wiring to prevent contact with moving parts. Contact can cause outboard damage or personal injury.

Install steering arm cover and screws (8).

IMPORTANT: Turn self-tapping screws counter clock-wise to start the threads and clockwise to tighten. Failure to follow this procedure can damage the threads of the housing.

Reinstall spark plug leads.

Reinstall lower engine covers. Route battery cables through the grommet on the port side of the lower engine cover.

Secure MWS connectors to starboard cover with tie straps. Seal tie strap holes with tape.

Use the “Engine Options” feature of Evinrude Diagnostics software to select “Install” Battery Module.


Check operation of start-in-gear protection. Improper operation can lead to outboard damage or personal injury.

Run outboard and test operation. Check for proper operation of start-in-gear protection, emergency stop switch, battery charging and stop switch, and electric start.

IMPORTANT: Instruct owner on the operation of the electric start and battery charging features. Advise owner to refer to the operating instructions in the operator’s guide.
 

Reference View – Top


 

Reference View – Port Side


 

Reference View – Starboard Side

Related Products

5007995 - Electric Start Kit 25-30 HP Evinrude® E-TEC®

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