This kit will service all Evinrude® and Johnson® outboard tiller handle steering models with the emergency ignition stop switch installed on the side of the tiller steering handle.
BMCA Special Tools Required
To avoid accidental starting of engine while servicing, twist and remove all spark plug leads.
This kit includes a pin terminal and a socket terminal to be installed into the Amphenol plug. Install the same type of terminal into plug as removed. Discard other terminal. Use the appropriate Special Tool for removal.
Review contents of kit:
|Ref.||P/N||Name of Part||Qty|
|1||584260||Stop Switch Assembly||1|
Remove the wire retainer and separate the 1-pin Amphenol connector. Remove the stop switch pin or socket terminal from the Amphenol plug using a socket or a pin removing tool.
Remove the stop switch ground ring terminal (A) from the ignition coil mounting screw. Retain the mounting screw.
Remove the three stop switch assembly mounting screws. Retain screws for reassembly.
Cut both wires from stop switch assembly. Discard switch assembly.
Tape both wires from new stop switch assembly to existing wires. Pull the old wires out of protected sleeve and pull new wires through sleeve.
Install new stop switch to handle using three mounting screws. Tighten screws securely.
Touch-Trim Control Models Only
Before installing stop switch assembly into handle, you must remove the rib from the stop switch plate. This will allow the stop switch mounting plate to fit on the handle without interfering with the Touch-Trim™ lever and grommet inside the handle.
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Remove rib by cutting rib from plate or cut plate just behind the rib. Remove all burrs and shavings before installing. Install stop switch assembly, tighten screws securely.
Compare wire lengths of old stop switch and new stop switch. If wires on new switch are longer cut them to length of old switch wires.
Strip about 3/16 inch (5 mm) of insulation from both wires. Select terminal from kit that are the same as those on the old stop switch wires.
Attach the pin terminal (4) or socket terminal (5) to one of the switch wires using crimping pliers.
Attach the ring terminal (3), (using crimping pliers) to the second wire (ground wire).
Using Insert Tool, install the stop switch terminal (pin or socket) into the Amphenol plug. Connect the 1-pin Amphenol connector to the plug. Secure connector with wire retainer.
Secure stop switch ring terminal (ground wire) to bottom ignition coil mounting screw. Tighten screw to a torque of 48-96 in. lbs. (5,4-10,8 Nm).
If you are not sure you have a good mechanical and electrical connection on any of the terminals, solder the terminals to the wires.
Reinstall all spark plug leads.
Attach lanyard clip (2) to switch button. Start motor and push stop button to stop motor. Restart motor and pull lanyard to stop motor. If motor does not stop in each test repair as required.