ELECTRIC START KIT, P/N 5037559 INSTALLATION INSTRUCTIONS
This electric start kit is designed for use on 2005 (SO) and newer 15 HP
Johnson® (4S) outboards. DO NOT install on any other models.
For safety reasons, this kit 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.
IMPORTANT: 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 and the operating instructions 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.
ELECTRIC START KIT
|Ref||P/N||Name of Part||Qty|
|1||5007559||ELECTRIC START KIT||1|
|3||5036244||*STARTER MOTOR AY||1|
To prevent accidental starting while servicing, twist and remove all spark plug leads.
Refer to the appropriate service manual for additional information.
Remove engine covers and recoil starter.
Disconnect stop switch wire connector. Remove stator and stator base.
Position grommet on starter motor.
Position starter motor at front of crankcase. Install starter motor bracket. Do not tighten bracket screws at this time.
Install battery cable grommet and cable clamp and screw.
Install rectifier/regulator on bottom of stator base as shown. Use screws provided and position clamp as shown. Tighten screws to 84 in. lbs. (10 Nm).
Remove wiring harness and install replacement wiring harness. Position harness with tie straps and clamp as shown.
Install stator base. Apply nut lock to threads and tighten screws as follows:
- 8 mm screws: 16.5 ft. lbs. (23 Nm)
- 6 mm screws: 84 in. lbs. (10 Nm)
IMPORTANT: Do not pinch wiring during installation.
Route wiring and battery cables to starter motor as shown.
Tighten starter motor band screws to16.5 ft. lbs. (23 Nm).
Install starter switch with nut on steering bracket. Route wiring to motor cover grommet as shown.
Connect stop switch connector and starter switch connectors and to engine wire harness at stator base.
Install protective sleeve and tie strap as shown.
IMPORTANT: Position wiring to prevent interference with shift linkage.
Route wire harness through the electrical bracket and behind CDI unit. Position starter relay with holder and fuse case in electrical bracket.
Connect rectifier/regulator wiring connectors and neutral switch wiring connector.
Connect coil wiring connector, oil pressure sending unit wire and oil pressure caution lamp connector.
Connect electrical connectors to CDI unit and position in electrical bracket.
Clean flywheel and crankshaft mating surfaces with cleaning solvent. Use flywheel holder to hold flywheel. Tighten flywheel nut to 58 ft. lbs. (78.4 Nm).
Install recoil starter and tighten screws securely.
Secure wiring to prevent contact with moving parts. Keep wiring away from shift lever/lockout assembly. Contact can cause outboard damage or personal injury.
Reinstall engine covers and spark plug leads.
Run outboard and test operation. Check for proper operation of electric start, start-in-gear protection, emergency stop switch, battery charging and stop switch.
Check operation of start-in-gear protection. Improper operation can lead to outboard damage or personal injury.
IMPORTANT: Instruct owner on the operation of the electric start and charging features. Advise owner to refer to an Operator’s Guide with electric start operating instructions.
Reference View – Port Side
Reference View – Starboard Side