Service Manual 5008334_200-300 HP 90° V6 Remote Control System [Component Servicing]

To prevent accidental starting while servicing, disconnect the battery cables at the battery.

Disconnect the battery cables at the battery.

Removal

Disconnect the:
• ICON buss cable from ESM
• ESM CAN bus harness from EMM
• ESM throttle actuator harness
• ESM shift actuator harness
• ESM power supply harness from solenoid and ground stud
Remove the ESM from studs.

1. Retainer mechanism

008506

Install grommets on ESM. Apply soapy water to grommets and push assembly on to studs.

1. Grommets
   007500

1. Studs

008506

Route the CAN bus harness from the ESM to the EMM as shown on the starboard side of outboard. Install grommet in notch on the electrical bracket.

1. CAN bus harness
2. Grommet
   007495

Continue harness routing under pressure relief valve hoses to EMM connector. Clip connector to
fuel rail. Make sure harness is not strained and does not rub against EMM mounting boss.

1. CAN bus harness
2. Connector clip
   007502

Route ESM to actuator harnesses between actuator plate and engine electrical bracket as shown.

1. ESM to actuator harnesses

007496

Route the throttle actuator harness behind and over the oil recirculation hose as shown. Connect to harness from ESM and attach to clip on mounting plate.

Make sure the oil recirculation hose is not pinched during assembly.

1. Harness
2. Hose
   007497

Secure ESM to throttle actuator harness with tie strap, P/N 320107. Route ESM to shift actuator harness behind throttle actuator and over throttle actuator harness. Attach to clip on mounting plate. Install clamp over actuator motor and secure to plate with screw. Tighten screw to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Throttle harness tie strap
   007498

Secure shift actuator harness with tie strap, P/N 317893.

1. Shift harness tie strap
   008514

Route ESM power supply harness behind trim relay harness. Route negative (–) terminal to battery ground stud and positive (+) terminal to solenoid

1. ESM Power supply harness
2. Ground stud
3. Solenoid

007499

Install ESM ground, star washer, battery cable, and nut on main ground stud. Tighten to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

1. ESM Ground
   007507

Install copper crush washer over ESM positive ring terminal. Then, install star washer, battery cable, and nut. Tighten nut to a torque of 60 to 84 in. lbs (7 to 9.5 N·m).

1. Copper washer
   007508

007526

Connect ESM harness to engine harness key switch and trim/tilt connectors. Secure connectors in bracket as shown and install connector cover.

1. Key switch connector
2. Trim/tilt connector
3. System Check connector
   008507

Route all ESM harnesses as shown and secure to shift actuator with tie straps, P/N 907833.

1. Large tie straps
   008508

Install electrical bracket cover.

007525

IMPORTANT: Calibrate shift and throttle actuators. Refer to Calibrate Actuator Stroke on p. 205.

Removal

Disconnect the battery cables at the battery. Remove electrical bracket cover. Observe and note all wire routings before disassembling.

007525

Remove clips and washers from the shift link. Remove the shift link.

008509

Remove the shift actuator connector from the clip on the mounting plate. Disconnect the shift actuator harness.

1. Shift actuator connector

   007498

Remove the clamp retaining screw.

1. Clamp retaining screw

007301

Remove the four shift actuator retaining screws.

1. Shift actuator retaining screws

008505

Remove old adhesive from clamp retaining screw and shift actuator retaining screws. Apply Nut Lock to the threads of the screws. Install shift actuator on mounting plate with three long screws and one short screw. Tighten screws to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Long screws
2. Short screw

008505

Place clamp over actuator motor. Install and tighten screw to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Clamp retaining screw

007301

Connect the shift actuator harness. Attach to clip on mounting plate.

1. ESM to shift actuator harness

007498

Secure shift actuator harness with tie strap, P/N 317893.

1. Shift harness tie strap

007872

Route all ESM harnesses as shown and secure to shift actuator with tie straps, P/N 907833.

1. Large tie straps

008508

IMPORTANT: Do not install shift link until the calibration procedure has been completed. Refer to Calibrate Actuator Stroke on p. 205.

Removal

Disconnect the battery cables at the battery. Remove the flywheel cover. Remove the electrical bracket cover. Observe and note all wire routings before disassembling.

007525

Remove the throttle actuator connector from the clip on the mounting plate. Disconnect the throttle actuator harness.

1. Throttle actuator connector

007497

Remove the clamp retaining screw.

1. Clamp retaining screw

   007498

Use Ball Socket Remover tool, P/N 342226, to remove throttle link from actuator arm.

008034

Remove the four throttle actuator retaining screws.

1. Throttle actuator retaining screws

007302

Remove old adhesive from clamp retaining screw and shift actuator retaining screws. Apply Nut Lock on the threads of the screws. Install throttle actuator on mounting plate with three long screws and one short screw. Tighten screws to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). Do not install clamp until wiring harnesses have been secured.

1. Long screws
2. Short screw

007302

Use Ball Socket Installer tool, P/N 342225, to snap throttle link onto actuator arm.

007303

Secure ESM to throttle actuator harness with tie strap, P/N 320107. Route ESM to shift actuator harness behind throttle actuator and over throttle actuator harness. Place clamp over actuator motor. Install and tighten screw to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Tie strap
2. ESM to shift actuator harness
3. Clamp retaining screw
   007498

Route the throttle actuator harness behind andover the oil recirculation hose as shown. Connect
the throttle actuator harness. Attach to clip on mounting plate

Make sure the oil recirculation hose is not pinched during assembly

1. Throttle actuator harness
2. Oil recirculation hose
   007497

IMPORTANT: Calibrate actuator. Refer to Calibrate Actuator Stroke on p. 205.