ELECTRIC START KIT, P/N 5037453 INSTALLATION INSTRUCTIONS
This electric start kit is designed for use on 2006 (SD) and newer 25 HP Johnson® (4S) outboards. DO NOT install on any other models.
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.
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:
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.
ELECTRIC START KIT
|Ref||P/N||Name of Part||Qty|
|5037453||ELECTRIC START KIT||1|
|2||5036981||*STATOR and CKP SENSORS AY||1|
|3||5036972||*STARTER MOTOR AY||1|
|4||5036978||*BRACKET, STARTER AY||1|
|12||5031021||*NUT, STARTER TERMINAL||1|
|14||5037065||*PLUG, MOTOR COVER EMBLEM||1|
|16||5036977||*GROMMET, STARTER DAMPER||1|
|19||5031828||*NUT, START SWITCH||1|
|20||5032042||*PLUGS, REG/RECT LEADS||2|
|21||5033258||*GROMMET RELAY HOLDER||1|
|22||5030995||*SCREW, STARTER BRACKET||2|
|23||5030996||*SCREW, STARTER BRACKET||2|
|24||5030994||*SCREW, STARTER BAND||2|
To prevent accidental starting while servicing, twist and remove all spark plug leads.
Refer to the appropriate service manual for additional information.
Remove engine covers and recoil starter.
Disconnect 6 pin connector from CDI unit. Remove CKP sensor mounting screws and stator retainer screws. Remove stator and sensors.
Disconnect wire harness from oil pressure switch, temperature switch, neutral switch, stop switch, ignition coils and CDI unit and remove wire harness from engine.
Install rectifier regulator assembly on intake manifold with screws provided. Tighten screws to 84 in. lbs. (10 Nm)
Remove front panel screws to allow installation of starter band screw. Install starter band and inner screw. Do not tighten at this time.
Install the starter grommet on starter housing and wire lead on “S” terminal of starter assembly.
Install starter bracket on starter assembly with screws provided.
Install the two locating pins into crankcase as shown.
Position starter assembly with grommet in starter band. Grommet must be positioned on band and starter bracket must be positioned on locating pins.
Tighten all four (4) starter bracket screws to 16.5 ft. lbs. (23 Nm).
Install wire clamp on PORT starter band screw. Tighten starter band screws to 16.5 in. lbs. (23 Nm).
Position front panel and re-install the two front panel screws.
Install replacement wiring harness. Connect all switches and clamps. Refer to wire routing diagram on next page.
Install stator and CKP sensors. Apply nut lock to threads and tighten screws as follows:
8 mm screws: 16.5 ft. lbs. (23 Nm)
6 mm screws: 84 in. lbs. (10 Nm)
Do not pinch wiring during installation.
Route wiring into electrical parts holder as shown. Connect starter relay to harness. Install grommet on relay. Position relay and grommet and fuse holder in electrical bracket.
Connect wire harness connectors to CDI unit. Position CDI Unit with grommet in electrical bracket.
Install positive battery cable on “B” terminal of starter assembly and negative cable under front starboard starter bracket screw.
Open oval shaped hole in motor cover grommet. Route battery cables through oval hole in grommet. Position wiring to prevent interference with shift linkage.
Clean mating surfaces of new flywheel and crankshaft with cleaning solvent. Install new flywheel. Use flywheel holder and tighten bolt to 142 ft. lbs. (196 Nm).
Perform final check of wire routing and check all screws are tight. All wires must be clamped properly to prevent contact with rotating flywheel. Refer to wire routing diagram.
Mark port side lower motor cover as shown. Carefully drill a 9/16 in (14 mm) hole through motor cover. Install start switch and nut in hole. Tighten nut to hold switch securely. Connect start switch wiring.
Install air silencer on new flywheel cover. Install flywheel cover.
Connect the outlet hose to carburetor adaptor. Connect breather hose.
Install lower covers. Connect water hose from starboard cover.
Secure wiring to prevent contact with moving parts. Keep wiring away from shift lever/lockout assembly. Contact can cause outboard damage or personal injury.
Reinstall spark plug leads. Install plug (emblem) in upper motor cover. Reinstall upper engine cover.
Run outboard and test operation. Check for proper operation of electric start, start-in-gear protection, emergency stop switch, battery charging and stop switch.
Check operation of start-in-gear protection. Improper operation can lead to outboard damage or personal injury.
: Instruct owner on the operation of the electric start and charging features. Advise owner to refer to an Operator’s Guide with electric start operating instructions.