PREFACE
This kit provides the necessary hardware to replace the pulse transformer on 1967 and 1968 100 Evinrude® and Johnson® outboard models.
Step 1. Prepare for Installation
[1]
Review components in kit:
| Ref. | Name of Part | Qty |
|---|---|---|
| 1 | Pulse Transformer Assembly | 1 |
| 2 | Bracket | 1 |
| 3 | Bracket screws | 2 |
| 4 | Nuts | 2 |
| 5 | Terminal cover | 1 |
| 6 | Terminal spring | 1 |
| 7 | Butt splice | 1 |
| 8 | Heat shrink tube | 1 |
| 9 | Star Washers | 2 |
| 10 | Flat Washers | 2 |
Step 2. Removal
Before working on or removing any electrical parts, disconnect the battery cables at battery to prevent electrical sparks.
The pulse transformer will be mounted either in a vertical or horizontal position on the powerhead. Install the new pulse transformer in the same position using existing mounting holes.
[2] [3]
Remove the pulse transformer high tension wire (A), two mounting screws (B) (vertical mounting), three mounting screws (B) (horizontal mounting), mounting bracket (C) and pulse transformer from powerhead, discard bracket.
[4]
Remove the two ground terminals (D) and one positive terminal (E) from the bottom of the pulse transformer, discard transformer.
The two ground terminal holes will have to be enlarged to fit onto the new mounting screws. Use a file to enlarge holes to size required.
Step 3. Installation
[5]
For horizontal mounting of bracket, remove the exhaust cover screw (B).
[6]
Install the three mounting screws and bracket (2) to the exhaust cover, torque screws to 16-18 ft. lbs. (22-24 Nm).
When installing bracket vertical install the two mounting screws and bracket, torque screws to 16-18 ft. lbs. (22-24 Nm).
[7]
Install pulse transformer (1) onto bracket. Install screw (3), flat washer (10) start washer (9), coil ground strap (F) from transformer and nut (4). Tighten screw to a torque of 48-96 in. lbs. (5,4-10,8 Nm).
[8]
Install screw (3), flat washer (10), star washer (9), two ground terminals (G) and nut (4), tighten screw to a torque of 48-96 in. lbs. (5,4-10,8 Nm).
Step 3. Installation
[9]
Remove 1/4 in. (6.3 mm) of wire covering from the coil primary wire.
[10]
Crimp and solder butt splice (7) onto wire end.
Remove terminal from engine positive wire.
[9]
Remove 1/4 in. (6.3 mm) of wire covering from wire.
[10] [11]
Install shrink tubing (8) onto wire. Crimp and solder butt splice onto wire end.
Slide heat shrink tube over soldered wires than using radiant heat source approximately 200° F (93° C) shrink the tube.
Remove the high tension lead cover and terminal from end of the wire.
[12]
Remove 1/4 in. (6.3 mm) of wire covering. Spread high tension wires flat on wire covering.
[13]
Insert terminal spring (6) into center of lead, piercing inside wire (A) and contacting strands (B) at the end of lead.
Apply isopropyl alcohol to the inside of the cover.
[14]
Insert spring and lead into cover (5) making sure opening of spring lines up with opening (C) in cover.
Apply a light coating of Triple-Guard® 0508298 grease to the transformer terminal.
Install cover assembly firmly onto transformer terminal.
Reconnect battery cables to battery..
Test
Start the engine following the procedures in your Owner's/Operator's manual. If engine will not start, check all electrical connections making sure connections are tight. If engine still will not start, refer to the appropriate service manual for testing of the pulse transformer or see your dealer to correct the problem.