THROTTLE POSITION SENSOR, P/N 5006484 INSTALLATION INSTRUCTIONS
This kit is designed for use on 2004 and newer Evinrude® E-TEC® outboards.
For safety reasons, this part should be installed by an authorized Evinrude®/Johnson® dealer. This instruction sheet is not a substitute for work experience. Additional helpful information may be found in other service literature for your engine.
This instruction sheet uses the following signal words identifying important safety messages.
Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, CAN result in severe injury or death.
Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate personal injury or property damage. It also may be used to alert against unsafe practices.
Indicates an instruction which, if not followed, could severely damage engine components or other property.
Identifies information that will help prevent damage to machinery and appears next to information that controls correct assembly and operation of the product. These safety alert signal words mean:
YOUR SAFETY IS INVOLVED!
Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so to protect yourself, as well as the people around you.
It is understood that this instruction sheet may be translated into other languages. In the event of any discrepancy, the English version shall prevail.
DO NOT do any repairs until you have read the instructions and checked the pictures relating to the repairs.
Be careful, and never rush or guess a service procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol use, to name a few. Damage to a boat and outboard can be fixed in a short period of time, but injury or death has a lasting effect.
When replacement parts are required, use Evinrude/ Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Using substandard parts could result in injury or product malfunction.
Torque wrench tightening specifications must be strictly followed. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts.
If you use procedures or service tools that are not recommended in this instruction sheet, YOU ALONE must decide if your actions might injure people or damage the outboard.
TO THE INSTALLER: Give this sheet to the owner. Advise the owner of any special operation or maintenance information contained in the instructions.
TO THE OWNER: Save these instructions in your owner's kit. This sheet contains information important to the future use and maintenance of your engine.
The replacement throttle position sensor (TPS) must be correctly aligned on the throttle lever bushing. Carefully follow these instructions to ensure correct procedure.
Refer to the appropriate Evinrude E-TEC Service Manual before attempting any service repairs or part replacement.
Disconnect battery cables at the battery.
Remove engine cover.
Remove lower engine cover screws, including one at inside, top rear, and remove lower engine covers.
Remove the air silencer.
Remove the electrical connector from the TPS.
Remove the TPS.
|Screw Mounted||2004 to 2005 40 - 90 HP|
|Stud Mounted||2006 and newer 40 - 90 HP|
|ALL 15 - 30 HP|
|ALL 115 - 130 HP|
|ALL 150 - 300 HP|
Screw Mounted — For screw-mounted sensors, reuse the existing screws and washers. DO NOT use additional fastener components included in kit.
Stud Mounted — For stud-mounted sensors, use the fastener components provided in kit.
Do NOT lubricate the throttle lever bushing to throttle shaft surface.
Some 2006 model year 40 – 90 HP outboards have washers under the throttle arm studs. If the washers are present, DO NOT use washers supplied in kit.
Rotate sensor on throttle shaft lever. This will allow the sensor and throttle shaft lever to align sensor mounting bracket holes over studs (or screw holes). There will be tension on the sensor, as it turns on the throttle shaft lever.
The new sensor must be aligned on studs (or on screw holes) with the throttle shaft lever on the throttle lever bushing.
Correct alignment — Throttle plates MUST be opened so throttle shaft lever seats.
The sensor and throttle shaft lever WILL NOT seat if not aligned correctly. Correct alignment will allow for installation of push nuts (for stud mounted), or screws (for screw mounted).
Screw Mounted — Do not use washers from the kit. Reuse the original mounting hardware. Adding washers will not allow screws to set. Install new TPS with screws.
Stud Mounted — Install new TPS using washers and push nuts. Do not press the push nut past the retaining groove in top of stud.
Use Evinrude Diagnostics software to set TPS calibration. Refer to TPS Calibration in the appropriate service manual.
ICON Models: Use Evinrude Diagnostics software to calibrate throttle actuator stroke. Refer to Calibrate Actuator Stroke in the appropriate service manual.
Reinstall air silencer and lower and upper engine covers.