These installation instructions contain information that can help prevent personal injury and damage to equipment. Understand the following symbols before proceeding:
Safety Warning: Alerts you to the possibility of danger and identifies information that will help prevent injuries.
NOTE: Identifies information that will help prevent damage to machinery.
IMPORTANT: 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 kit converts a 1995 (EO) or newer 9.9/15, four-stroke tiller electric model to a remote electric start.
Contents of Kit
|Ref.||Name of Part||Qty.|
|4||Switch Mounting Screws||2|
|5||Switch Mounting Locknuts||2|
|6||Engine Wiring Harness||1|
|7||Key Switch Wiring Harness||1|
|8||Key Switch Panel Screws||2|
Installation of this kit involves procedures described in detail in your Service Manual.
To avoid accidental starting of engine while servicing, twist and remove all spark plug leads.
Shift motor into NEUTRAL.
Refer to your service manual and remove the manual starter, flywheel, and lower engine covers.
NOTE: Retain all hardware and parts that are removed. Replace any damaged parts before installing.
Remove screw retaining the shift detent spring. Remove springs.
Remove screws retaining the rectifier to the powerhead and place off to side.
Remove clip (A) retaining the rectifier to the powerhead and place off to side.
Remove screw and washer retaining the shift lever. Remove lever.
Slide shift shaft, with bushing, out of powerhead flanges.
Apply Triple-Guard 0508298® grease to inside of bushings.
Install new shift shaft (1), with bushings, into flanges. Install shift lever, washer, and screw on shaft. Torque screw to 15-17 ft. lbs. (20-23 Nm).
Slide gearcase shift rod on shift lever pin and secure with retaining clip.
Place rectifier in position and install small screw through lower flange into middle boss. Torque to 36-60 in. lbs. (4-7 Nm).
Install switch (2) on bracket (3) using screws (4) and locknuts (5). Tighten finger tight.
Place switch bracket between top rectifier flange and detent spring boss. Install original screw through bracket and top rectifier flange. Do not tighten.
Loosely install original screw through lower hole in switch bracket and shift detent springs. Position springs in NEUTRAL position. Adjust switch as follows:
Adjust switch bracket to position switch pin horizontally in the middle of the shift cam. Tighten switch bracket mounting screws to 108-132 in. lbs. (12-15 Nm).
Position switch approximately horizontal, with switch pin at center of cam, and switch body 3/32 in. (2,4 mm) from cam. Tighten switch-to-bracket screws to 35-40 in. lbs. (4,0-4,6 Nm).
Remove oil pressure sender wire, large black wire at powerhead, and large red wire, small black wire, and yellow/red wire at starter solenoid.
Disconnect both Amphenol connectors and red wire bullet connector. Remove engine harness but retain fuse.
Install new engine wiring harness (6). Connect red wire bullet connector. Connect both Amphenol connectors and secure with retainers. Place 3-wire connector in retainer bracket.
Attach the small black wire, yellow/red wire, and large red wire (with positive battery cable) to solenoid. Torque small nuts with lock washer to 12-24 in. lbs. (1,4-2,8 Nm). Torque large nut with starwasher to 60-84 in. lbs. (7-9 Nm). Apply Black Neoprene Dip to connections.
Attach large black wire (with negative battery cable) to powerhead. Apply Nut Lock to screw and torque to 60-84 in. lbs. (7-9 Nm). Apply Black Neoprene Dip 0909570 on connection. Attach wire to oil pressure sender and secure with screw and lock washer. Place boot over sender.
Attach key switch wiring harness (7) to engine wiring harness. Connect 2-pin and 6-pin waterproof connectors. Before joining the connectors, apply a light coat of Electrical Grease 0503243 to their seals.
Verify protective cap is on purple bullet end.
Install lower engine covers. Route battery cable and harness through grommet. Install grommet in lower engine cover.
Install manual starter.
Install fuse in engine harness receptacle. Snap connection into manual starter.
Select appropriate location for key switch panel. Use 15/16 in. socket to remove nut and panel from switch.
Use panel as template to mark mounting screw holes and switch hole.
Drill three 3/32 in. (2,4 mm) pilot holes. Drill the 1/12 in. (40 mm) switch hole with a hole saw.
Insert switch through dash and reattach panel to switch.
Secure panel to dash with screws (8).
Support cable within 12 in. (30 cm) of switch and at 24 in. (60 cm) intervals back to motor. Allow sufficient cable slack to connect to the motor and to allow the motor to turn and tilt. Secure excess cable out of the way with tie straps or clamps (not included).
Put motor in water or connect to flushing adapter. Put motor in FORWARD gear and use key to see if motor will start. Repeat test in REVERSE gear. If motor starts, check adjustment of neutral start switch. If motor still starts in gear, return motor to dealer for repair before operating boat.
Put motor in NEUTRAL and start motor using key switch and electric starter. Check that motor stops when key switch is turned OFF or when emergency stop lanyard is pulled off. Return motor to dealer if motor does not stop when key is turned OFF or when lanyard is pulled.
 Unplug key switch cable (A) and start motor with original start switch on shift bracket (B). Stop motor by pulling emergency stop switch lanyard. If motor does not stop when lanyard is pulled, return motor to dealer for repair before operating boat.