Remote Electric Start Kit 1
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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 kit converts a 1993 or newer 9.9/15 two-stroke Evinrude® or Johnson® tiller electric outboard to remote electric starting with included key switch. An accessory dash mounted emergency stop switch kit is available and can be installed if necessary.
The installation of this kit requires special tools and/or special lubricants and involves procedures described in detail in the Service Manual for your product. If you do not have the special tools, supplies, and literature required, and do not wish to purchase them, have this kit installed by your dealer.
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.
Contents of Kit
|Ref.||Name of Part||Qty.|
|1||Neutral Start Switch||1|
|2||Neutral Start Switch Bracket||1|
|3||Screw - 6-32 x 3/4 in. (19 mm)||2|
|4||Nut - 6-32||2|
|7||Shift Lever Bushing||1|
|8||Shift Lever Screw||1|
|9||Fuel Hose - 1 in. (25 mm) long||1|
|11||Fuel "T" Fitting||1|
|13||Primer Hose - 3 1/2 in. (89 mm) long||1|
|14||Tie Strap - 4 in. (100 mm)||4|
|15||Primer Nipple Cap||1|
|16||Screw - 10-24 x 1/2 in. (13 mm)||2|
|17||Solenoid-to-Starter Cable - 3 1/2 in. (89 mm)||1|
|18||Battery-to-Solenoid Cable 8 1/2 in. (216 mm)||1|
|20||Solenoid Screw - 10-24 x 1/2 in. (13 mm) w/ Washer||2|
|22||One-Wire Amphenol Plug||1|
|24||Key - one with finger grip||2|
|25||Fuse - 20 Amp||2|
|27||Star Lock Washer||3|
|28||Hex Nut - 1/4-20||2|
|29||Tie Strap - 8 in. (200 mm)||4|
|30||#10 Split Ring Lock Washer||2|
|31||Nut - 8/32||2|
|32||Key Switch Cable||1|
Disconnect battery cables from battery.
Remove the manual starter (A). See Service Manual - Section 7 - Manual Starter Servicing.
Remove lower engine cover starboard screws (B). Remove inlet hose from fuel pump (C) and port lower engine cover screws (D). Remove lower engine covers.
Remove mounting screws (E) and air silencer (F).
Remove screws (G) and electrical bracket cover (H).
Install Neutral Start Switch
Attach the neutral start switch (1) to the neutral start switch bracket (2) with the screws (3) and nuts (4). Tighten screws carefully.
Loosen the top coil mounting screw (I) a couple of revolutions. Remove and discard throttle lever screw (J). Save washer (K).
Position shift link (5) vertically and insert end in shift lever cam (L). Rotate link back to horizontal position.
Place shift lever (6) on link.
Insert slotted end of neutral start switch bracket between steel washer and screw head (M).
Place saved washer (K) and shift lever bushing (7) on shift lever screw (8). Lubricate throttle lever bushing (N), shift lever bushing (7), and screw threads (O) with Triple-Guard grease.
Insert screw and bushing through shift lever, through neutral start switch bracket (2), and throttle lever bushing (P). Thread screw into block until almost tight.
With outboard in NEUTRAL, push switch forward until switch body (A) is about 3/32 in. (2,5 mm) from shift lever cam (B) and tighten shift lever screw (8). Tighten top coil screw (C) to 48-96 in. lbs. (5,4-10,8 Nm)
Push 1 in. fuel hose (9) onto primer (10) inlet nipple.
Push fuel "T" fitting (11) into hose.
Hold primer and clamp (12) against manifold with primer positioned as high as possible.
Turn primer until primer hose is angled about 30° off a fore-and-aft line. Mark the fuel hose (D) where it crosses the primer hose. This is where the fuel hose will be cut and the "T" inserted.
Cut fuel hose at mark and insert "T" into hose.
Remove cap (E) from carburetor primer nipple and discard. Push primer hose (13) onto carburetor nipple.
Carefully push primer hose onto starboard primer nipple. Install 4 in. tie straps (14) on fuel hose connections. Push cap (15) onto other primer nipple (F).
Start one primer screw (16) in starboard side of primer mount and hook clamp (12) on screw.
Insert primer in clamp, and start second primer screw (16) with black primer wire under screw head. Hold primer boss up against clamp and tighten screws only until primer is held firmly in place.
Remove starter terminal nut (A). One end of the 3 1/2 in. solenoid-to-starter cable (17) has a smaller hole. Place smaller end on starter stud with existing wire, and reinstall nut.
Remove battery cable retaining nut (B). Scrape off all Black Neoprene Dip from battery cable terminal. Place battery-to-solenoid cable (18) on stud with existing wire, and reinstall nut.
Push solenoid (19) onto bosses on block. secure solenoid with thread forming screws with washers (20). Tighten screws securely.
Install Engine Harness
Remove tie strap (C) and retainer (D). Disconnect Amphenol connector (E).
Push existing black/yellow lead socket terminal out of "E" position in plug (F). Insert socket terminal on black/yellow lead of engine harness (21) into "E" position just vacated in plug (F). See Service Manual - Section 3 - Amphenol Connector Servicing Information.
Reconnect plug and receptacle. Reinstall retainer.
Install socket terminal just removed from 5-socket plug into one-wire Amphenol plug (22).
Connect plug (22) to one-wire receptacle (G) on engine harness. Install one-wire retainer (23).
Connect two-wire receptacle (H) on engine harness to two-wire plug (I) on neutral start switch. See Service Manual - Section 8 - Deutsch Connector Servicing.
Insert fuse (25) into fuse holder (A) on engine harness and insert fuse holder into socket (B) in electrical bracket.
Route engine harness forward under ignition coil, starter, solenoid, and fuel pump.
Connect engine harness purple/white and primer purple/white wires to primer boss with self-tapping screw (26).
Connect solenoid-to-starter cable to lower terminal of solenoid with a star lock washer (27) and hex nut (28).
Use one of the 8 in. tie straps (29) to loosely tie together all of the wires and cables under the solenoid.
Connect the engine harness yellow/red wire to the solenoid forward stud and the short black wire to the aft stud with lock washers (30) and nuts (31).
Connect battery-to-solenoid cable (18) and engine harness red wire (C) to top solenoid stud with star lock washer (27) between wires and with hex nut (28). Tighten nut securely.
Connect engine harness black ground wire (D) to battery cable ground on lower rectifier screw with star lock washer (27) under black ground wire terminal. Tighten screw securely.
Secure five-wire and one-wire connectors, plus alternator wires, to ignition coil post with 8 in. tie strap **(29).
Tighten tie strap **(29) holding wires together under solenoid.
Cut out upper hole (E) in control panel grommet, and cut through grommet at (F). Reinstall grommet on battery cable and in front panel.
Coat all new terminals with Black Neoprene Dip.
Push alternator terminals (A) firmly into the slots and reinstall electrical bracket cover.
Reinstall air silencer (B). Tighten screws securely. Readjust primer solenoid (C), if necessary.
Reinstall manual starter. Insert interlock rod into cam and turn in interlock screw (D) gently, only until head of screw is seated. See Service Manual - Section 7 - Manual Starter Servicing.
Pull engine harness connector up between solenoid and fuel pump. Adjust position of primer, primer wires, battery cable, etc., as required to clear the lower engine cover.
Reinstall lower engine covers, leaving port side screws loose and front port side screw (E) out until key switch cable is installed and connected. Place spare fuse (25) in fuse plug (34). Insert fuse plug in electrical bracket pocket (F).
Install Key Switch in Boat
Remove nut and panel (G) from key switch cable (32) with 15/16 in. socket.
Select appropriate location for key switch panel. Use panel as template to mark mounting screw holes and switch hole.
Drill three 3/32 in. (2,4 mm) pilot holes. Drill the 1 1/2 in. (40 mm) switch hole with a hole saw.
Insert switch through dash and reattach panel to switch.
Secure panel to dash with screws (33) provided.
Support cable within 12 in. (30 cm) of switch and at 24 in. (60 cm) intervals back to engine. Allow sufficient cable slack to connect to the engine and to allow the engine to turn and tilt. Secure excess cable out of the way with tie straps or clamps (not included).
Place key switch cable in the port side grommet and connect cable receptacle to engine plug. Finish installing and tightening lower engine cover screws. Secure key switch cable to starter post with tie strap (29). Adjust so cable wires (A) stay below flywheel/starter cover lower edge (B). Tighten tie strap securely.
Put outboard in water or connect to flushing adapter. Put engine in FORWARD gear and use key (24) to see if engine will start. Repeat test in REVERSE gear. If engine starts, check adjustment of neutral start switch. If engine still starts in gear, repair before operating boat.
Put outboard in NEUTRAL and start engine using key switch, electric primer, and electric starter. Check that engine stops when key switch is turned OFF. If engine does not stop when key is turned OFF, repair before operating boat.
Start engine with original start switch (C) on shift bracket.Stop engine by pulling emergency stop switch lanyard (D). If engine does not stop when lanyard is pulled, repair before operating boat.