Prewired Binnacle Mount 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 BMCA 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 the 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 Test, located at the 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 - Phillips Screwdriver - 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.|
|4||Clip and Lanyard Assembly||1|
|5||Key - one with molded grip||2|
Remote Control Operation
Emergency Stop Switch Operation - Push clip (A) onto emergency stop switch. Attach lanyard (B) securely to clothing. If operator is thrown from helm, lanyard will pull clip off stop switch and stop motor. In an emergency, a passenger can put remote control in NEUTRAL, hold stop switch button IN, and restart motor without lanyard.
Shift Disengage - Use to open throttle without shifting into gear (for easier starting if motor does not have QuikStart™ electronic starting). With control in NEUTRAL (A), pull handle out and move to shift detent position (B) or (C). Move handle more to open throttle for starting and warm-up. The shift will re-engage when the handle is returned to NEUTRAL.
Turn key (D) ON. The horn will beep 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. Push key IN momentarily (in ON position) for additional enrichment to keep motor running; DO NOT turn key to START.
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 slows to normal idle RPM before shifting into gear.
(A) Neutral Detent
(B) Forward Gear
(C) 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 19 in. (482 mm) (H) of fore-and-aft space is needed to operate this control This will provide 2 3/8 in. (60 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. Note additional clearance (P) that is required to get maximum throttle in REVERSE.
  
Remove template from instructions and place at proposed location. Check handle and hand clearance dimensions in FORWARD and REVERSE W.O.T. positions. Move template until a satisfactory control position is found, and tape template in place with arrow pointing to front of boat.
There must be at least 20 3/4 in. (527 mm) (Q) 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 control at (A) or (B), measure along intended cable route to motor centerline (C) at transom height - as illustrated by dotted lines. Add 3 ft. 4 in. (1,02 m) to measurement. This dimension is the required cable length.
(D) Cable length in meters
(E) Cable length in feet
(F) Part Number
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 correct length cables. The wrong length cable can bind, causing control to jam during operation.
Connect Cables to Remote Control
Lubricate shift and throttle cable ends with Triple-Guard grease.
Remove tray screw and cover tray (G) to expose shift and throttle levers.
Insert the shift cable trunnion into the port trunnion pocket ** (H)**.
Shift control into REVERSE. Insert clevis pin (2) through shift lever (I) and cable end. Head of pin (J) must be toward the center of remote control. Clevis pin must snap into the plastic bushing, or pin could fall out or jam control.
Insert throttle cable trunnion into the starboard trunnion cavity (A).
Pull control handle to three-quarter throttle in REVERSE and insert clevis pin (2) through throttle lever (B) and cable end. Head of pin (C) must be toward center of remote control. Clevis pin must snap into the plastic bushing or pin could fall out of jam control.
With control handle in full-throttle REVERSE position, the control levers and cables should be as shown.
Replace cover tray with center web of tray between shift and throttle levers. Replace cover tray screw and tighten securely.** The cover tray holds the cable trunnions in the trunnion pockets and the clevis pins in the shift and throttle levers. If the cover tray is not in place and secured, the trunnions or clevis pins can come out and the operator would not be able to control motor speed or direction of thrust.
Check that remote control handle operates freely and equal friction is felt in FORWARD and REVERSE throttle range of handle. Any binding could cause control to jam.
Install Remote Control
Always disconnect 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 control location, center punch and drill 1/8 in. (3,2 mm), and 1/2 in. (12,7 mm) through mounting surface, being careful that the 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 the line. Remove template.
Insert control cables and wires through cutout.
Route control cables aft to motors 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.
Position remote control in cutout and secure cover and control with mounting screws (3) provided.
Use a manual screwdriver - a power screwdriver could damage cover.
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 squeeze cable out-of-round.
You must provide a 12 in. (30 cm) minimum loop (G) in cables between last boat fastener and motor anchoring point.
Before connecting cables to motor, check that control operates freely, and shift re-engages in NEUTRAL after disengaging for warm-up. Check that 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 service manual for cable connection procedures.
Test Your Installation
Check to be sure cables are attached on the correct lever. Place control handle in NEUTRAL. Pull out on control handle and 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
Remove clip (4) from emergency stop switch, separate connector between charge coil and ignition module, or disconnect all spark plug wires to keep 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. 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 (5) 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 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 (4) to stop switch.
Place control handle in NEUTRAL position. If motor does not have _QuikStart_, pull control handle out and move handle to FORWARD shift detent position. Move handle more to open throttle for starting and warm-up.
Turn key (5) ON. The horn will beep 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. Push key IN momentarily (in ON position) for additional enrichment to keep motor running - - DO NOT turn key to START with motor 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 when control is shifted to FORWARD, and shifts to REVERSE when control is shifted to REVERSE.
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 ignition switch. If motor does not stop, return control to dealer for repair.