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TILLER HANDLE KIT, P/N 5007118 INSTALLATION INSTRUCTIONS

Crowley Marine

APPLICATION

Use this instruction sheet when installing the above tiller handle kit on 2004 (SR) and newer Evinrude® E-TEC™ outboards, 40 – 60 HP. DO NOT install on any other models.
 

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.

This instruction sheet uses the following signal words identifying important safety messages.


Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.


Indicates a potentially hazardous situation which, if not avoided, CAN result in severe injury or death.


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.

IMPORTANT: Identifies information that will help prevent damage to machinery and appears next to information that controls correct assembly and operation of the product. These safety alert signal words mean:

ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!

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.

It is understood that this instruction sheet may be translated into other languages. In the event of any discrepancy, the English version shall prevail.

 DO NOT do any repairs until you have read the instructions and checked the pictures relating to the repairs.

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.

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.

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.

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 to the future use and maintenance of your engine.


Do not install this kit unless you have the ability to communicate with the engine using Evinrude E-TEC Diagnostics Software. Complete installation of this kit requires reprogramming the Engine Management Module (EMM) to provide start-in-gear protection.
 

TILLER CONVERSION KIT (Evinrude E-TEC 40 – 60 HP)

Ref P/N Name of Part Qty
1 352290 STEERING HANDLE, Blue 1
2 329878 STEERING HANDLE, Inner 1
3 352292 BRACKET, Steering handle 1
4 352291 HANDLE, Shift 1
5 329885 SCREW, Shift handle mount 1
6 313607 LUBE FITTING 1
7 327400 WASHER, Shift handle 2
8 334815 BUSHING, Shift handle 1
9 318626 BALL 1
10 327178 GUIDE 1
11 309247 SPRING 1
12 351932 PIN, Shift handle to cable 1
13 303049 COTTER PIN 1
14 351995 RETAINER, Shift cable 1
15 336481 SCREW, Retainer 2
16 352293 COVER, Steering handle 1
17 336481 SCREW, Cover 7
18 333499 CLIP, Emergency stop 1
19 583830 STOP SWITCH Assy 1
20 514679 *PIN, Terminal 2
- 514696 CONNECTOR, 2 pin receptacle                  NS     1
- 514697 LOCKWEDGE, 2 pin receptacle                 NS 1
21 336481 SCREW, Stop switch 3
22 398602 CLIP & LANYARD Assy 1
23 336481 SCREW, Inner handle retaining 1
24 394522 THROTTLE FRICTION CONTROL 1
25 332089 RETAINER CLIP 1
26 339722 HELIX, Twist grip 2
27 329880 PIN 1
28 329879 GUIDE 2
29 329881 ROLLER, Helix to cable 2
30 352104 GUIDE, Wire 1
31 352813 TWIST GRIP, Assy 1
32 324967 SCREW 2
33 352103 HOUSING, Trim switch 1
34 352270 SWITCH, Trim & Tilt 1
35 514686 CONNECTOR, Trim & Tilt 1
36 514682 LOCKWEDGE, 3 pin receptacle 1
37 586827 START SWITCH Assy 1
38 514679 *PIN, Terminal 2
- 514696 CONNECTOR, 2 pin receptacle                 NS  1
- 514697 LOCKWEDGE, 2 pin receptacle                 NS 1
39 327805 NUT, Start switch 1
40 350310 SLEEVE 1
41 5006160 CABLE, Shift 1
42 333774 RETAINER CLIP 1
43 328702 WASHER 1
44 5006159 CABLE, Throttle 1
45 334083 ANCHOR, Throttle cable 1
46 328739 WASHER, Anchor to bracket 1
47 329160 SCREW, Anchor to bracket 1
48 334153 CONNECTOR, Throttle cable 1
49 350989 SCREW, Steering handle to bracket 1
50 328733 WASHER, Spring 1
51 307160 LOCKNUT, Steering handle screw 1
52 313609 LUBE FITTING 1
53 352295 THUMBSCREW, Height adjustment 1
54 203470 RETAINER CLAP 1
55 325729 SCREW, Bracket to steering arm 2
56 333374 SHIM, Steering arm extension 1
57 325452 BUSHING, Steering handle to brkt. 2
58 352625 PLATE, Angle adjustment 1
59 315077 NUT, Steering bracket 1
60 5005800 SWITCH, Ignition & key assy 1
61 127251 SPACER 1
62 127237 NUT, Keyswitch 1
63 582262 HARNESS, Keyswitch 1
64 514679 *TERMINAL 5
65 514688 *CONNECTOR, 6 Pin receptacle 1
66 910446 *TERMINAL, Socket 5
67 514684 *LOCKWEDGE, 6 Pin receptacle 1
68 514690 *SEAL PLUG 1
69 551113 SPRING, Steering friction 1
70 332945 SCREW, Steering friction 1
71 586895 HARNESS, Tiller handle 1
- 176295 *CONNECTOR, 2 Socket plug                 NS 2
- 514685 *CONNECTOR, 3 Socket plug                 NS 2
- 514687 *CONNECTOR, 6 Socket plug                 NS 1
- 514688 *CONNECTOR, 6 Pin receptacle              NS 1
- 514690 *SEAL PLUG                                       NS 5
- 335299 DECAL, Emergency stop clip                  NS 1
- 333978 DECAL, Start warning (blue)                  NS 1
- 333979 DECAL, Gear shift (blue)                       NS 1
- 320107 TIE STRAP                                         NS 12
- 317893 TIE STRAP                                         NS 2
72 328739 WASHER 1

NS Not Shown


Improper installation of this kit could result in personal injury due to loss of boat control.

A boat designed for remote steering might have a lower maximum rated horsepower for a tiller-steered outboard than shown on the certification plate. To avoid overpowering a boat designed and rated for remote steering, contact boat manufacturer for tiller-steered maximum rated horsepower.

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.
 

INSPECTION

Before installation, check boat for obstructions that could interfere with free movement of tiller handle when steering or tilting outboard.


To avoid damaging the tiller handle when tilting the outboard up, position the outboard to clear obstacles in the motor well and boat.
 

INSTALLATION

Disconnect the battery cables at the battery.

Remove any screws from steering arm holes. Make sure all paint or locking material is cleaned from threads.

Place angle adjustment plate in pocket of steering arm bracket.

The steering arm can be positioned straight, or angled 15° port or starboard by moving the adjustment plate.

Place shim plate on bottom of tiller handle. Insert steering arm screws through plate and handle.

Place tiller handle on steering arm from the bottom. Thread steering arm screws into steering arm and tighten to a torque of 18 to 20 ft. lbs. (25 to 27 Nm).

IMPORTANT: Be sure that wires are not pinched.

Install locknuts on screws on top of steering arm. Hold screws with a wrench and tighten locknuts to 18 to 20 ft. lbs. (25 to 27 Nm).


 

CONTROL CABLE INSTALLATION

IMPORTANT: DO NOT complete final attachment of cables to shift and throttle levers until all cables, wires, and hoses have been routed and grommet has been placed into the lower engine cover.

Remove cable retainer from anchor block.

Remove grommet from lower engine cover and insert shift cable through opening.

Pull firmly on shift cable casing to remove backlash. With outboard and tiller handle shift lever in NEUTRAL, place the cable trunnion into the lower anchor pocket. Adjust the trunnion nut so the casing fits onto the shift lever pin.

Use Ball Socket Installer tool, P/N 342225, to snap throttle cable connector onto throttle cam pin. (Use Remover tool, P/N 342226, to remove cable.)

Place throttle cable in upper anchor pocket. Install cable retainer and anchor bracket on anchor block using screw supplied with kit. Tighten screw 60 to 84 in. lbs. (7 to 9 Nm).

Adjust cable anchor so throttle cam is against stop when twist grip is at IDLE. Install washer, cable anchor, and cable anchor screw. Tighten screw securely.

Apply soapy water to the inside surfaces of grommet and install cables and fuel line as shown:

Place the grommet into position in the lower motor cover.

When grommet is in place and all cables have been installed, tighten a tie strap, P/N 500081, around the outside of the grommet to form a watertight seal around the cables.

Secure control cables to the throttle and shift lever pins. For proper installation of shift cable, review the following steps:

  • Place washer on pin.
     
  • Position retainer clip with straight section on the bottom and angled section on the top.
     
  • Use long noses pliers to insert straight section of clip into linkage pin hole.

  • Push the clip towards the hole while lifting on the curved end with the pliers.
     
  • Be sure retainer clip fully engages the pin.
     
  • Lock the retainer by moving the angled section behind the straight section.


 

ELECTRICAL CONNECTIONS

Remove electrical cover.

Route wiring harnesses from tiller handle through channel in flywheel cover.

Apply Electrical Grease to connector seals, then connect tiller handle wiring harness to engine harness.

Arrange connectors in flywheel cover, as shown, and install electrical cover. Seal unused SystemCheck connector with 6-Pin Connector Seal, P/N 586076 (not included with kit).

Use tie straps to secure harness to throttle body bracket.

IMPORTANT: Route and secure all wires to avoid contact with moving parts.

Use Evinrude E-TEC Diagnostics Software to reprogram Engine Management Module (EMM) for Tiller Model start-in-gear protection.


After installation, dealer must use Evinrude E-TEC Diagnostics Software to reprogram Engine Management Module (EMM) to provide start-in-gear protection. Failure to provide start-in-gear protection could create a risk of personal injury or property damage.
 

STEERING FRICTION

Remove plug from port side of swivel bracket.

Apply Triple-Guard® grease to threads of steering friction adjustment screw. Install spring and screw.

Steer outboard from side to side. Adjust steering friction screw until steering effort is comfortably stiff with only slight drag.


Steering friction device is not intended to hold boat on a set course. DO NOT overtighten steering friction screw for “hands-off” steering. Reduced control of the boat could result in loss of control by the operator, creating a risk of personal injury or property damage.
 

CHECK INSTALLATION

Make sure the following operate properly before returning outboard to customer:

  • Engine stop circuit
     
  • Emergency stop switch and lanyard
     
  • Steering movement and friction control
     
  • Throttle control (IDLE to WIDE OPEN)
     
  • Shift control and proper gear engagement
     
  • Start-in-gear protection
     
  • Trim and tilt control


Only shift outboard with throttle in IDLE position. If outboard is shifted into gear with throttle setting above IDLE speed, the boat could accelerate suddenly, injuring boat occupants and bystanders.
 

OPERATING INSTRUCTIONS

IMPORTANT: Store these instructions onboard the boat with the operator’s guide.
 

SAFETY INFORMATION

DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.

Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off. Always shut off the engine when near people in the water.


The engine cover is a machinery guard. DO NOT operate your outboard with the cover off unless you are performing maintenance or emergency starting, and then be careful to keep hands, hair, and clothing clear of all moving parts. Contact with moving parts could cause injury.

Always shut off the outboard when your boat is near people who are in the water.

Be familiar with the waters you are operating in. The gearcase of this outboard extends below the water surface and could potentially come in contact with underwater obstructions. Contact with underwater obstructions may result in loss of control and personal injury.
 

ENGINE STARTING

Refer to the Routine Inspection Checklist in the Evinrude E-TEC Operator’s Guide for pre-launch checks before using your outboard.

You MUST supply water to the engine before starting. Engine damage can occur quickly.

Connect the clip to the emergency stop switch. Snap the lanyard to a secure place on the operator’s clothing or life vest — not where it might tear away instead of activating the stop switch.

IMPORTANT: The operator should always use the clip and lanyard anytime the engine is running.


Always use the safety lanyard when operating your boat to help prevent a runaway boat and reduce the risk of personal injury or death.

Avoid knocking or pulling the clip off the stop switch during normal boating. The resulting unexpected loss of forward motion can throw occupants forward, causing injury.

Your emergency stop switch can be effective only when in good working condition. At each outing, inspect clip and lanyard for cuts, breaks, or wear. Replace worn or damaged parts.

Keep the lanyard free from obstructions and entanglements.

At each outing, test the system’s operation. With the engine running, remove the clip from the switch by pulling the lanyard. If the engine does not stop running, see your Dealer.

If clip and lanyard should be lost overboard, a spare clip can be found on the bottom of the tiller handle.

IMPORTANT: Spare clip is for emergency use only. Clip with lanyard should always be attached to operator during normal operation.

Move the shift lever to NEUTRAL. Refer to Shifting and Speed Control.


Always shift to NEUTRAL before starting the outboard to prevent sudden boat movement, which can cause injury.

Twist throttle grip to slowest IDLE position. Refer to Speed Control.

DO NOT advance the throttle before start-up. Advancing the throttle overrides the electronic idle control system. After the engine starts, the engine management module (EMM) will automatically increase idle speed slightly. Idle speed will decrease as the engine warms up.

If the outboard is started at wide open throttle, twist the throttle grip back to IDLE before shifting.
 

Key Switch

While seated, turn the key switch fully clockwise to the START position. Crank the engine no longer than 20 seconds.

IMPORTANT: The starter motor can be damaged if operated continuously for more than 20 seconds.

Upon start-up, release the key.

If the engine did not start, release the key momentarily, then try again.

IMPORTANT: Engine will crank but will not start if outboard is in gear.
 

Start Button

While seated, press the start button. (Key switch must be in the ON position.) Crank the engine no longer than 20 seconds.

IMPORTANT: The starter motor can be damaged if operated continuously for more than 20 seconds.

Upon start-up, release the start button.

If the engine did not start, release the start button momentarily, then try again.

IMPORTANT: Engine will crank but will not start if outboard is in gear, or if key switch is in OFF position.
 

After Engine Starts

Check the water pump indicator. A steady stream of water indicates the water pump is working. If a steady stream of water from the water pump indicator is not visible, stop the engine. Refer to Engine Overheating in the Evinrude E-TEC Operator’s Guide.


 

ENGINE STOPPING

Twist the throttle grip to IDLE position.

Move shift lever to NEUTRAL.

Outboard may be stopped by turning the key switch to the OFF position, or by pressing the STOP button until the outboard stops running.

IMPORTANT: Be sure to turn key OFF when outboard is not in use to avoid discharging the battery.
 

SHIFTING AND SPEED CONTROL

IMPORTANT: Carefully check the function of all control and engine systems before leaving the dock. DO NOT shift the outboard into FORWARD or REVERSE while it is shut OFF.
 

Shifting

With engine running, twist the throttle grip to IDLE position.

Move the shift lever briskly and decisively to FORWARD or REVERSE.

IMPORTANT: When shifting from FORWARD to REVERSE or from REVERSE to FORWARD, pause at NEUTRAL until the engine is at idle speed and the boat has slowed.

Speed Control With the outboard running, twist throttle grip:

  • Clockwise to decrease speed; or
     
  • Counterclockwise to increase speed.

Tiller is equipped with a throttle friction adjustment knob. Tighten the knob to reduce the effort required to hold a throttle setting.


Tighten knob only enough to hold throttle at a constant engine speed. Overtightening will prevent quick throttle change in case of emergency.
 

TRIM CONTROL

Tiller includes a handle mounted trim/tilt switch.


If tiller kit is installed on a manual tilt outboard, DO NOT use tiller as a lever to help tilt the outboard. Damage can result.
 

TILLER HEIGHT

The angle of the tiller handle can be raised or lowered by adjusting a thumbscrew under the handle.


 

STORAGE (WINTERIZATION)

You can winterize your outboard either in the water or on a trailer. DO NOT start the outboard once winterization is completed.
 

In the Water

Prepare your outboard for the off-season by following these steps:

1) Make sure that the throttle is in NEUTRAL and the water intake screens are completely submerged.

2) Add 2+4® Fuel Conditioner to the fuel tank and fill it with fuel.

3) Advance the throttle to 1/2 throttle position and start the outboard. The outboard will run at idle speed.

4) After approximately 15 seconds, move the throttle to IDLE position. Run the outboard at idle for another 15 seconds, then advance the throttle again to 1/2 throttle position.

5) The outboard will automatically go to fast idle and fog itself. Allow the outboard to run until it shuts itself off (about one minute).

6) Top off the oil reservoir and inspect the fuel filter. If there is debris in the fuel filter, it must be replaced.

IMPORTANT: When finished, leave the outboard in a vertical position long enough to completely drain the water from the powerhead.

7) If equipped, disconnect the speedometer pickup at the upper connection and blow all water out of the hose using air pressure of 25 psi (172 kPa) or less. Reconnect the speedometer pickup after all of the water has been removed.
 

On a Trailer


To prevent injury from contact with rotating propeller, remove the propeller before servicing and when running the outboard with a flushing device.

Prepare your outboard for the off-season by following these steps:

1) Make sure that the throttle is in NEUTRAL. Remove the propeller.

2) Add 2+4® Fuel Conditioner to the fuel tank and fill it with fuel.

3) Attach a garden hose to the flushing port and turn on the water.

4) Advance the throttle to 1/2 throttle position and start the outboard. The outboard will run at idle speed.

5) After approximately 15 seconds, move the throttle to IDLE position. Run the outboard at idle for another 15 seconds, then advance the throttle again to 1/2 throttle position.

6) The outboard will automatically go to fast idle and fog itself. Allow the outboard to run until it shuts itself off (about one minute).

7) After the outboard shuts itself off, detach garden hose.

8) Top off the oil reservoir and inspect the fuel filter. If there is debris in the fuel filter, it must be replaced.

9) Apply the recommended lubricant to the propeller shaft splines, then install the propeller.

IMPORTANT: When finished, leave the outboard in a vertical position long enough to completely drain the water from the powerhead.

10) If equipped, disconnect the speedometer pickup at the upper connection and blow all water out of the hose using air pressure of 25 psi (172 kPa) or less. Reconnect the speedometer pickup after all of the water has been removed.

When using this winterization procedure, engine oil may appear on the skeg below the gearcase area. This is normal. Avoid potential oil stains by placing a shop towel or suitable container under the propeller and skeg for the duration of the storage.
 

OPTIONAL ACCESSORIES

Owners of tiller equipped outboards may be interested in adding the following additional equipment:

Modular Wiring System (MWS) Harness Kit, P/N 586853—Allows addition of a SystemCheck warning system gauge.

Quick Disconnect Hose Kit, P/N 398339— Provides easy connection to a portable fuel tank.

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