Emergency Ignition Stop Switch Kit P/N 584267

Safety Considerations

These instructions will alter you to certain things you should do very carefully. If you don't, you could...

• hurt yourself or bystanders
• hurt boat operator, passengers
• damage the machinery

Safety symbol, , appears next to information important to prevent you and others from being hurt.

Note symbol, Note, appears next to information important to keep machinery from being damaged.

IMPORTANT: The important safeguards and instructions appearing in these directions cannot cover all possible conditions or situations that occur. The person following these directions must use common sense, caution and care.

Product Reference & Illustration

When reference is made to brand name, product or specific tool, an equivalent product may be used in place of the referred to product. Substitute products used must have equivalent characteristics, including type, strength, and material. Incorrect substitution may result in product malfunction and possible injury to the operator and/or passengers.

All photographs and illustrations used may not necessarily depict actual models or equipment, but are intended only for reference. Specifications used are based on the latest product information available at the time of publication.

Installer:  Before starting work, read entire instruction sheet. After completing work, place instruction sheet with the owner's manual for future reference.
 

Preface

This kit will service all Evinrude® and Johnson® outboard tiller handle steering models with the emergency ignition stop switch installed on the side of the tiller steering handle.

BMCA Special Tools Required

• Socket Removal Tool P/N 322699 or Pin Removal Tool P/N 322698
   
• Insert Tool P/N 322697

To avoid accidental starting of engine while servicing, twist and remove all spark plug leads.

This kit includes a pin terminal and a socket terminal to be installed into the Amphenol plug. Install the same type of terminal into plug as removed. Discard other terminal. Use the appropriate Special Tool for removal.

[1]
Review contents of kit:

All Models

[2]
Remove the wire retainer and separate the 1-pin Amphenol connector. Remove the stop switch pin or socket terminal from the Amphenol plug using a socket or a pin removing tool.

[2]
Remove the stop switch ground ring terminal (A) from the ignition coil mounting screw. Retain the mounting screw.

[3]
Remove the three stop switch assembly mounting screws. Retain screws for reassembly.

[4]
Cut both wires from stop switch assembly. Discard switch assembly.

[5]
Tape both wires from new stop switch assembly to existing wires. Pull the old wires out of protected sleeve and pull new wires through sleeve.

[6]
Install new stop switch to handle using three mounting screws. Tighten screws securely.
 

Touch-Trim™ Control Models Only

Before installing stop switch assembly into handle, you must remove the rib from the stop switch plate. This will allow the stop switch mounting plate to fit on the handle without interfering with the Touch-Trim™ lever and grommet inside the handle.

[7] - [9]
Remove rib by cutting rib from plate or cut plate just behind the rib. Remove all burrs and shavings before installing. Install stop switch assembly, tighten screws securely.
 

All Models

Compare wire lengths of old stop switch and new stop switch. If wires on new switch are longer cut them to length of old switch wires.

Strip about 3/16 inch (5 mm) of insulation from both wires. Select terminal from kit that are the same as those on the old stop switch wires.

[10]
Attach the pin terminal (4) or socket terminal (5) to one of the switch wires using crimping pliers.

[10]
Attach the ring terminal (3), (using crimping pliers) to the second wire (ground wire).

[11]
Using Insert Tool, install the stop switch terminal (pin or socket) into the Amphenol plug. Connect the 1-pin Amphenol connector to the plug. Secure connector with wire retainer.

[12]
Secure stop switch ring terminal (ground wire) to bottom ignition coil mounting screw. Tighten screw to a torque of 48-96 in. lbs. (5,4-10,8 Nm).

If you are not sure you have a good mechanical and electrical connection on any of the terminals, solder the terminals to the wires.

Reinstall all spark plug leads.
 

Test Switch

Attach lanyard clip (2) to switch button. Start motor and push stop button to stop motor. Restart motor and pull lanyard to stop motor. If motor does not stop in each test repair as required.