Electric Start Kit
These instructions will alter you to certain things you should do very carefully. If you don't, you could...
- hurt yourself or bystanders
- hurt boat operator, passengers
- damage the machinery
appears next to information important to prevent you and others from being hurt.
appears next to information important to keep machinery from being damaged.
The important safeguards and instructions appearing in these directions cannot cover all possible conditions or situations that occur. The person following these directions must use common sense, caution and care.
Product Reference & Illustration
When reference is made to brand name, product or specific tool, an equivalent product may be used in place of the referred to product. Substitute products used must have equivalent characteristics, including type, strength, and material. Incorrect substitution may result in product malfunction and possible injury to the operator and/or passengers.
All photographs and illustrations used may not necessarily depict actual models or equipment, but are intended only for reference. Specifications used are based on the latest product information available at the time of publication.
This kit adds electric starting and 5-amp battery charging to 1993 (ET) and newer 9.9/15 Evinrude® and Johnson® manual start models.
Call-out NUMBERS (1), (2), etc, in the text and illustrations refer ONLY to the specific items in the Contents of Kit illustration and list. Call-out LETTERS (A), (B), etc. are used over and over - on different items in other illustrations.
Installation of this kit involves procedures that require special training for the installer. The installation may also require special tools, supplies and/or Service Manuals and other literature.
Service Technicians at your Dealer have received special training and have the special tools, supplies, and reference literature to service this product. We recommend that you have this kit installed by your Dealer.
Contents of Kit
|Ref.||Name of Part||Qty.|
|2||Screw, 1/4-20 x 9/16 in., Hex Head||1|
|5||Screw, 1/4-20 x 2 3/8 in., Hex Head||2|
|7||Screw, 10-24 x 1/2 in., Hex Head||1|
|10||Screw, 10-24 x 3/4 in., Slot Head||1|
|13||Screw, 5/16 Dia.||2|
|16||Screw, 10-24 x 1/2 in., w/ Starwasher||1|
|17||Screw, 1/4-20 x 5/8 in., w/ Starwasher||1|
|18||Starwasher, 1/4 in.||1|
|23||Screw, 10-24 x 1/2 in., Slot Head||2|
To prevent accidental starting, disconnect spark plug wires.
Remove lower motor cover screws, and remove covers.
Remove manual starter mounting screws, Lift starter, and disconnect starter lockout link (A).
Remove flywheel. See Section 3 - Flywheel Servicing in Service Manual.
Cut tie strap, remove retainer, and unplug 5-pin Amphenol connector (B).
Place plug against motor and push "E" terminal (C) out with Socket Removal Tool, P/N 0322699.
Loosen ignition plate screws until they are out of retainer plate. Lift off and discard ignition plate. Save the throttle cam (D).
Apply Moly Lube™ to the crankcase boss (A).
Lubricate ignition plate bearing groove (B) with Moly Lube.
Apply Nut Lock™ to ignition plate screws (C).
Squeeze ignition plate bearing onto support plate, and guide new ignition plate (1) down over bearing.
Align ignition plate screws with retainer plate. Position the throttle cam (D) with the bosses in the retaining plate, and start all screws. Tighten screws to a torque of 25-35 in . lbs. (2.8-4.0 Nm).
Install Electrical Bracket
Remove and discard two ignition coil mounting screws (E). Save all other hardware.
Insert electrical bracket screw (2) into electrical bracket (3) and secure with nut (4).
Install electrical bracket and reinstall coil with screws (5). See Section 3 - Ignition Coil Replacement in Service Manual for correct washer location on coil screws. Tighten screws to a torque of 48-96 in. lbs. (5,4-10,8 Nm).
Install Start Switch
Remove air silencer screws and washers (A), and lift off the air silencer.
Pry plug (B) out of panel bracket.
Remove the shift handle pivot screw (C) and washers (D).
Remove the steering handle pivot screw (E) and locknut (F) and lay steering handle aside.
Insert the start switch (6) wires back through the steering bracket (A), and pull them out through hole (B).
Secure the switch in place with screw (7).
Place grommet (8) on start switch wires and insert into panel bracket.
Fit start button (9) over shift handle boss and secure temporarily with screw (10) and locknut (11).
Reinstall pivot screw (C) and washers in shift handle and tighten screw securely.
Reinstall pivot screw (D) and locknut (E) in steering handle. Tighten just enough to hold handle in any position.
Make sure shift lever is in NEUTRAL, move start button (A) exactly in line with start switch (B), and tighten screw securely.
Install starter (12) with screws (13) and flat washers (14). Torque screws to 10-12 ft. lbs. (14-16 Nm).
Install rectifier (15) to starter with screws (16) and (17). Tighten small screw (16).
Snug inner nut on starter terminal. Install starwasher (18), shorter start switch wire (C), and nut. Tighten nut securely.
Connect battery cable (19) black wire to rectifier with large rectifier screw (D). Tighten screw to a torque of 48-96 in. lbs. (5.4-10.8 Nm).
Place red battery cable, rectifier red wire, start switch wire, starwasher (20), and nut (4) on electrical bracket screw (E). Tighten nut to a torque of 48-96 in. lbs. (5.4-10.8 Nm).
Coat cable terminals (A), (B), and (C) with Black Neoprene Dip.
Connect rectifier wires to the same color alternator wires. The extra yellow/gray wire (D) is for a tachometer.
Push cap (21) over extra yellow/gray wire bullet connector.
Press each connector into a slot in the electrical bracket, and push wires neatly in place.
Install cover (22) on electrical bracket with screws (23).
Push socket terminal (A) removed from original 5-pin plug into "E" terminal position with Insert Took, P/N 0322697. To avoid injury, securely hold insert tool against shoulder of terminal and plug against motor while inserting terminal.
Connect 5-pin connectors (B) and reinstall the retainer (C).
Secure the 5-pin connector to the coil boss and the ignition plate wires together with tie straps (24) as shown.
Remove blank grommet from front panel. Install grommet (25) on battery cable and fit grommet into front panel.
Reinstall lower motor covers.
Install flywheel (26). See Section 3 - Flywheel Servicing in Service Manual.
Recheck Synchronization and Linkage Adjustments, See Section 1 - in Service Manual.
Reinstall air silencer.
Hook up starter lockout link (A), and reinstall manual starter. Tighten screws to a torque of 60-84 in. lbs. (7-9 Nm). Check if starter lockout prevents manual cranking with motor in gear.
Connect a 5 amp ammeter between red battery cable and battery. Battery must not be completely charged for test. Reconnect spark plug wires. Start motor manually. Ammeter should read up to 5 amps, depending on battery state of charge.
Connect positive battery cable to battery. Turn propeller and put motor in gear. Check to see that start button does not work in either FORWARD or REVERSE gear. Put motor in NEUTRAL, and start motor with electric starter. Push stop button to stop motor. If motor does not perform as described, repair as necessary before delivering motor to customer.