Prewired Binnacle Control With or Without Trim
These installation instructions contain information that can help prevent personal injury and damage to equipment. Understand the following symbols before proceeding:
Alerts you to the possibility of danger and identifies information that will help prevent injuries.
Identifies information that will help prevent damage to machinery.
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.
This control is compatible with the 1996 (ED) and newer Modular Wiring System. This control supports the SystemCheck™ engine monitoring system and allows single-lever control of an Evinrude® or Johnson® outboard motor.
Installation of this kit involves procedures for connecting throttle and shift cables to motor, described in detail in 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 Installer and Owner - INSTALLER: Give these instructions to owner. OWNER: Read section Remote Control Operation, and also Operator Tests and Adjustments, located at end of this document, before you operate your boat. Keep these instructions with your Operator's Manual.
If a non-BRP instrument cable is used, it must have equivalent wire type and size, and must meet A.B.Y.C. standards (or standards that apply in your country).
Tools and Lubricants Required For Installation:
- Masking Tape - Tape Measure - Triple-Guard® Grease 0508298 - Needle Nose Pliers - Phillips Screwdriver - 3/8 in. Wrench - Center Punch - Hammer - Electric Drill - 1/8 in. (3,2 mm) Drill Bit - 1/2 in. (12,7 mm) Drill Bit - Saber Saw - Anti-Corrosion Spray 0777193 - Electrical Grease 0503243
Review Contents of Kit and installation procedure.
|Ref.||Name of Part||Qty.|
|8||Control Mounting Screw||4|
|9||Adjustment Screw Cover||1|
|11||Clip and Lanyard||1|
|12||Key - one with molded grip||2|
Remote Control Operation
Key Switch Operation** - Push emergency stop switch clip (A) onto key switch. Attach lanyard (B) securely to clothing. If operator is thrown from helm, lanyard will pull clip off switch and stop motor. In an emergency, a passenger can put remote control in NEUTRAL and restart motor without lanyard.
Do not operate motor with clip removed from switch, except in an emergency. If you do, and if primer is used while motor is running, the starter and flywheel can be damaged by accidental starter engagement.
Shift Disengage - To open throttle without shifting into gear (for easier starting if motor does not have QuikStart™ electronic starting). Push and hold the shift disengage button (A) with handle in NEUTRAL (B), and move handle to either shift detent position, (C) or (D). Release button and move handle more to open throttle for starting and warm-up. The shift will re-engage when the handle is returned to NEUTRAL.
NOTE: Pull handle part way back as soon as motor starts. Do not run a cold motor any faster than necessary to keep motor from stalling. Do not exceed 2500 RPM. Motors with QuikStart , wait until motor is at normal idle RPM before shifting into gear.
(B) Neutral Detent
(C) Forward Gear
(D) Reverse Gear
(E) Forward Throttle Range
(F) Reverse Throttle Range
Trim/Tilt Switch (G) - Push top of switch to trim out and tilt up, or push bottom of switch to tilt down and trim in.
Select Mounting Location
A minimum of 20 in. (508 mm) (H) of fore-and-aft space is needed to operate this control. This will provide 2 3/15 in. (55 mm) (I) hand clearance in front of the handle at wide-open throttle (W.O.T.) in FORWARD, and 1 in. (25 mm) (J) behind the handle at W.O.T. in REVERSE.
  
Remove template from instructions and place at proposed control location. Check handle and hand clearance dimensions in FORWARD and REVERSE W.O.T. positions. Move template until a satisfactory control position is found. Tape template in place with arrow pointing to front of boat.
There must be at least 19 in. (482 mm) (P) of clear space below the mounting surface for the control cables.
The mounting surface must be strong enough to provide rigid support. If not, strengthen as necessary.
Determine Control Cable Length
Route cables so they have fewest number of bends. The bends must never be less than 6 in. (15 cm) radius.
From center of handle at (A) or (B), measure along intended cable route to motor centerline at transom height (C), as illustrated by either dotted line. For Evinrude/Johnson outboards, add 3 ft. 4 in. (1,02 m) to the measurement. This dimension is the required cable length.
(D) Cable length in meters
(E) Cable length in feet
(F) Part Number
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. Pick cables that are equal to your calculated length, or are the next longer available length.
Use the correct cable length. The wrong length cable can bind, causing control to jam during operation.
Determine Which Levers the Cables will be Attached to
Use a 15/16 in. socket to remove key switch retaining nut (G), and push key switch (H) out of control cover (I). Lift cover off remote control (1). Don't lose spacer ring (J) from key switch or rubber boot (K) from shift disengage button.
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 UP.
The control pulls on the cables when the levers move UP.
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.
Therefore, put the control handle in FORWARD detent position. Mark the throttle and shift levers that are now UP. The cables are attached to these levers.
Cables anchor in upper slots.
Both cables attach to handle side of the control levers.
Connect Snap-In Control cables to Remote Control
Lubricate cable ends with Triple-Guard grease.
To install throttle cable, place trunnion anchor (2) into upper slot (A) in front of control.
Install throttle cable trunnion into starboard side of anchor.
Pull cable up to handle side of throttle lever (B), aligning hole in cable with hole in lever.
Install cable pin (3) through the lever first, then the cable. Install cotter pin (4) and secure by spreading ends.
Position anchor retainer (5) onto trunnion anchor and cable trunnion. Install screw (6) and locknut (7). Tighten screw securely.
To install shift cable, place trunnion anchor (2) into upper slot (C).
Install shift cable trunnion into port side of anchor.
Pull cable end up to handle side of shift lever (D), and align hole in cable with inner hole (E) in lever.
Install cable pin (3) through cable and inner hole in shift lever, from handle side. Install cotter pin (4) and secure by spreading ends.
Install anchor retainer (5) onto trunnion anchor and cable trunnion. Install screw (6) and locknut (7). Tighten screw securely.
Install Remote Control
Disconnect battery cables from battery before drilling or sawing near electrical wires to prevent possible injury from shorting a hot wire to ground.
With template at your selected location, center punch and drill 1/8 in. (3,2 mm) and 1/2 in. (12,7 mm) holes through mounting surface, being careful that 1/2 in. (12,7 mm) holes stay inside lines of template. Center punch and drill holes marked with a "T" ONLY IF YOUR CONTROL HAS TRIM.
Use a saber saw to carefully cut out mounting hole, staying INSIDE line. Remove template.
Insert control cables and wires through cutout.
Route control cables aft to motor with no sharp bends. All bends must have a 6 in. (15 cm) or larger radius.
Locate the six-socket plug (A) on instrument cable with the same color wires as the key switch cable, the two-socket plug (B) for the horn connection, and the three-socket plug (C) for trim and tilt. Check mating surfaces of both halves 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 (D), (E) and (F). Align connector halves and push together until latched.
For protection in salt water, spray entire control with anti-Corrosion Spray metal protectant.
Place rubber boot (G) on shift disengage button and spacer ring (H) o key switch. Position cover on control Reinstall nut on key switch and tighten to 24-36 in. lbs. (3-4 Nm).
Secure cover and control with screws (8) provided. Use a manual screwdriver; a power screwdriver could damage cover. Install adjustment screw cover (9).
Check that remote control operates freely and equal friction is felt in FORWARD and REVERSE throttle range of control handle. Any binding could cause remote control to jam when cables are attached to motor.
Install decal (10) in center recess of cover if desired.
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 deform cables.
You must provide a 12 in. (30 cm) minimum diameter loop (A) in cables between last boat fastener 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.
Connect Control Cables to Motor
Refer to your service manual for procedures to connect control cables to motor.
Test Your Installation
Check to be sure cables are attached to 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.
Connect battery cables to battery.
Neutral Start Test
Separate connector between charge coil and power pack, or disconnect all spark plug wires to keep motor from starting. Removing clip from key switch WILL NOT prevent motor from starting.
Running motor out of water even momentarily will damage water pump and eventually cause powerhead damage.
This remote control is designed to crank motor in NEUTRAL only. If control handle is "in-gear," starter will not operate. The lanyard clip (11) may be attached to key switch or may be removed for the following test. Use this test 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 (12) 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.
If trim operates in one direction only or moves in the wrong direction, check of wire colors are the same on both sides of the trim switch connector.
If pressing switch does not operate trim/tilt motor, check switch-to-motor connection. 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.
When testing boat in water, tie it securely to dock to prevent motion. Attach lanyard clip to key switch.
Place control handle in NEUTRAL position.
If motor does not have QuikStart , push and hold the shift disengage button, and move handle to FORWARD detent position. Release button and push handle a little more to open throttle for starting and warm-up.
Turn key ON. The horn should sound momentarily to indicate it is working. Turn key to START position. If priming is required, push and hold key IN and turn to START. Release key as soon as motor starts. Key may be pushed IN momentarily (in ON position) for additional enrichment to keep motor running. DO NOT turn key to START while motor is running.
Pull control handle part way back as soon as motor starts. Do not run a cold motor any faster than is necessary to keep it from stalling. Do not exceed 2500 RPM in NEUTRAL during warm-up. See complete starting instructions in operator's manual.
After motor has warmed up enough to idle smoothly, pull control lever back to NEUTRAL. The shift will re-engage in NEUTRAL.
For motors with _QuikStart_, wait until motor speed drops to a normal idle RPM before shifting into gear.
Check that motor shifts to FORWARD and REVERSE when control is shifted to FORWARD and REVERSE.
Check that remote control operates freely with equal friction in FORWARD and REVERSE throttle range of control handle. Any binding could cause control to jam during operation.
Operator Tests and Adjustments
Test operation of Emergency Stop Switch** - Test stop switch every 30 days. Start motor and check operation of stop switch by pulling lanyard (A) to remove clip from key switch. If motor does not stop, return control to dealer for repair.
Check throttle friction - Move control handle to FORWARD throttle range. When properly adjusted, control handle should have low enough friction to allow easy movement in FORWARD throttle range, yet not allow vibration to change throttle setting.
Adjust throttle friction - Remove adjustment screw cover (B). Turn UPPER adjustment screw clockwise to increase friction.
Adjust detent force - Turn LOWER adjustment screw clockwise to increase detent force. Move handle to FORWARD shift detent, then back to NEUTRAL detent. Readjust until desired detent force is achieved.
Reinstall adjustment screw cover.