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Remote Control Concealed Side Mount With and Without Trim Switch

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.

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

Installation of this kit involves procedures for connecting throttle and shift cables to motor, described in detail in the 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 the Remote Control Adjustments, located at end of this document, before you operate your boat. Keep these instructions with your Operator's Manual.

Tools and Lubricants Required for Installation:

- Tape Measure - Triple-Guard® Grease - Phillips Screwdriver - 3/8 in. Wrench - Needle-Nose Pliers - Masking Tape - Center Punch - Hammer - Electric Drill - 1/8 in. (3,2 mm) Drill Bit - 1 in. (25 mm), 1 3/4 in. (45 mm), and 2 3/4 in. (70 mm) Hole Saws - Electrical Grease - Anti-Corrosion Spray - Torque Wrench - 7/64 Allen Wrench
 

Prepare for Installation

[1]
Review Contents of Kit and installation procedure.

Ref. Name of Part Qty.
1 Control Assembly 1
2 Trunnion Anchor 2
3 Trunnion Retainer 2
4 Retainer Screw 2
5 Retainer Locknut 2
6 Cable Pin 2
7 Cotter Pin 2
8 Long Retainer Screw 1
9 Mounting Plate 1
10 Plate Mounting Screw 5
11 Receptacle Wedge 1
12 Receptacle 1
13 Control Mounting Screw 3
14 Control Handle 1
15 Shift Disengage Button 1
16 Shift Disengage Screw 1
17 Shift Disengage Boot 1
18 Plate Cover 1
19 Tie Strap 1


Remote Control Operation

[2] [4]
Neutral Lock
- To shift from NEUTRAL (A) to either FORWARD (B) or REVERSE (C), lift neutral lock lever (D) and move control handle quickly into gear.

[3] [2]
Shift Disengage
- To open throttle without shifting into gear, push and hold shift disengage button (E) with control handle in NEUTRAL. Lift neutral lock lever (D) and move handle to either "in-gear" position. Release shift disengage button and move control handle further to open throttle. The shift will re-engage when the control handle is returned to NEUTRAL.

[4]
Control Handle Positions

(A) Neutral Detent
(B) Forward Gear
(C) Reverse Gear
(F) Forward Throttle Range
(G) Reverse Throttle Range

[2]
Trim/Tilt Switch (H)
- 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]
This remote control can be mounted on the starboard (I) or the port (J) side. This instruction sheet shows a starboard installation.

[6]
Allow a minimum of 4 in. (10,2 cm) clearance around handle in all positions for safe and efficient operation.

[7]
The panel thickness (K) must not exceed 1 in. (2,5 cm). The panel thickness plus the space behind the panel (L) must be at least 3 1/2 in. (8,9 cm).

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

[8]
Control cables must have at least 20 1/2 in. (52 cm) clear space from the control handle center line for the first bend.

[8]
The control assembly may be tipped up or down 15° from horizontal for cable clearance, and still have the control handle vertical in NEUTRAL.
 

Determine Control Cable Length

Plan cable route so cables have fewest possible number of bends. The bends must never be less than 6 in. (15 cm) radius.

[9]
From center of handle, at (A) or (B), measure along intended cable route to motor centerline (C) at transom height - as illustrated by either dotted line.

  • For Evinrude/Johnson outboard motors: Add 3 ft. 4 in. (1.02 m).
     
  • For other motors and propulsion units, use the manufacturer's recommended cable length.

[10]
Snap-In®
cables:

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

[11]
Snap-In/SAE
cables:

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

[10]
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.

[11]
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

  • 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 FORWARD.
     
  • The control pulls on the cables when the levers move FORWARD.
     
  • When you pull the throttle cable on Johnson® and Evinrude® outboard motors 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] [13]
Therefore, put control handle in FORWARD detent position. Mark the two levers (A) and (B) that are not FORWARD. The cables are attached to the outside of these levers.

[14]
BRP cable trunnions always anchor in forward crescent holes (C). The rear holes are for SAE cables.

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 FORWARD.

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

Snap-In® Cables - Installation

Throttle Cable

[16]
Place the trunnion anchor (2) on the control side of the throttle cable trunnion, and the trunnion retainer (3) over the outside of the trunnion.

[17]
Fit the trunnion anchor into the crescent hole behind the throttle lever you marked. Secure trunnion retainer with screw (4) and locknut (5). Tighten screw securely.

[18]
Pull cable end forward, outside the throttle lever, aligning cable end with hole in throttle lever. Install cable pin (6) and insert cotter pin (7). Secure by spreading end of cotter pin.

[19] [20]
If relocating the throttle cable will result in a better installation, the throttle cable can be moved from bottom to top (or vice versa). Remove screw and washer (D). Turn throttle lever (E) to move pin (F) from top throttle cam slot to bottom slot (G). Reinstall screw and washer. Determine "which lever" again.
 

Shift Cable

[21] [22]
Place the trunnion anchor (2) on the control side of the shift cable trunnion and the trunnion retainer (3) over the outside of the trunnion. Fit the trunnion anchor into the crescent hole behind the shift lever you marked. Secure trunnion retainer with screw (4) and locknut (5). Tighten screw securely.

NOTE: If throttle cable and shift cable are both at top or both at bottom; the two trunnion anchors, two cable trunnions, and two trunnion retainers are all secured to the control back-to-back with one long retainer screw (8), and a locknut (5).

[23]
BMCA motors and others that require 2.9 in. (74 mm) forward-to-reverse shift stroke, use hole (A) in the shift lever. Motors that require 3.1 in. (79 mm) use SAE cables and hole (B). Pull cable end forward, outside the shift lever, aligning cable end with inner hole (A). Install cable pin (6) with the head against the cable and insert cotter pin (7). Secure by spreading end of cotter pin.

[24]
Always attach the control cables (C) and (D) to the outside of the shift and throttle levers (E) and (F). Failure to attach control cables correctly can cause interference and binding.
 

Install Remote Control

Remove the starboard or port template from the back of these instructions and tape it to the boat in the position selected with the handle centerline vertical. Check that you have correct template.

[25]
With the template positioned as shown, the control can still be mounted with the control mechanism rotated 15° in either direction and the handle will be vertical in NEUTRAL.

[25] - [27]

  • Center punch and drill the five 1/8 inch (3,2 mm) mounting holes, and three 1/8 inch (3,2 mm) pilot holes for hole saw.
     
  • Cut trim/tilt wire clearance hole (G) using a 1 in. (25 mm) hole saw if your control has a trim switch.
     
  • Cut mounting flange hole (H) using 2 3/4 in. (70 mm) hole saw.
     
  • Cut friction and detent adjustment hole (I) using 1 3/4 inc. (45 mm) hole saw.
     
  • Remove template.

[28]
Position the control mounting plate (9), aligned with the five drilled holes. Secure plate with the five mounting screws (10).

NOTE: Do not use power screwdriver to avoid damage to the mounting plate.

[29]
For controls with trim switch, insert trim/tilt wires through lower opening in mounting plate.

[30]
For Evinrude/Johnson outboards, remove wedge (11) from waterproof connector receptacle (12) with needle-nose pliers. Inject a small amount of Electrical Grease in the three corners of the connector and insert trim wires in receptacle. Place green wire in "A" position. Place blue wire in "B" position. Place red wire in "C" position. Twist wire slightly if any pin does not latch into place. Insert receptacle wedge and push in until it latches in place.

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

[31]
Connect one yellow/red neutral start switch wire (A) from remote control to key switch "S" terminal.

[31]
Connect second yellow/red neutral start switch wire (B) from remote control to key switch cable bullet connector (C).

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

[32]
Place control assembly (1) in position behind panel and insert shaft through mounting plate. Control may be rotated 15° in either direction to improve control cable routing. Align control and mounting screw holes. Install three control mounting screws (13) and tighten to a torque of 60-80 in. lbs. (7-9 Nm).

[33] [34]
Temporarily place handle on control and move control to NEUTRAL position (shift levers (D) at mid position as shown). Remove and reinstall control handle (14) in VERTICAL position.

[35]
Move control handle to full throttle in reverse. Tighten handle locking hex screw to a torque of 25-35 in. lbs. (2,8-4,0 Nm).

[36]
Install shift disengage button (15) and screw (16) and tighten screw securely.

[37]
Install boot (17) over button.

[38]
Install plate cover (18) on mounting plate.

[39]
Loop trim switch wires between control assembly and mounting surface to the switch guard. Secure wires to guard with tie strap (19). Make sure wires to not interfere with shift cable/lever.

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.

[40]
You must provide a 12 in. (30 cm) minimum diameter loop (A) in cables between last boat fastener (B) 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.

[41]
Waterproof Connectors
: Check mating surfaces of connectors for dirt or other contaminates. Remove all dirt, old lubricant, etc. Immediately before joining, apply a light coat of Electrical Grease to seal (C) on three-socket plug on instrument cable. Align plug with three-pin remote control receptacle (D) and push connector halves together until latched.
 

Connect Control Cables to Motor

Refer to the Service Manual for procedures to connect control cables to motor.
 

Test Your Installation

Check to be sure cables are attached on 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

To prevent Evinrude/Johnson outboard motors from starting, separate the connector between the charge coil and the power pack, or disconnect all spark plug wires. To prevent stern drives and other outboard motors from starting, follow procedure in service manual.

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

Connect battery cables to battery.

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

  • 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 remote 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.

[42]
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 that all the pins and sockets are in place in the trim switch connector. 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 just enough friction to prevent vibration from changing throttle setting and yet allow easy handle movement in forward throttle range.

[43] [44]
Adjust throttle friction
- Pry out at back to remove plate cover (18). Turn adjustment screw closest to handle (A) clockwise to increase friction.

[45]
Adjust detent tension
- move handle to FORWARD shift detent, then back to NEUTRAL detent. Turn adjustment screw furthest from handle (B) clockwise to increase detent tension. Readjust until desired tension is achieved.

Reinstall plate cover.

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