Pulse Transformer Kit P/N 433659
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
To the Installer
installation instructions to the future owner. The instructions contain Safety
Warnings and other information vital to the continued safe use of the product.
To the New Owner
Retain these installation instructions with your Owner's/Operator's manual.
They contain installation, adjustment and operating information for future
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
Review components in kit:
|Ref.||Name of Part||Qty.|
|1||Pulse Transformer Assembly||1|
|8||Heat shrink tube||1|
Step 2. Removal
Before working on or removing any electrical parts, disconnect the battery cables at battery to prevent electrical sparks.
IMPORTANT: 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.
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.
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
For horizontal mounting of bracket, remove the exhaust cover screw (B).
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).
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).
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 4. Wire Installation
Remove 1/4 in. (6.3 mm) of wire covering from the coil primary wire.
Crimp and solder butt splice (7) onto wire end.
Remove terminal from engine positive wire.
Remove 1/4 in. (6.3 mm) of wire covering from wire.
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.
Remove 1/4 in. (6.3 mm) of wire covering. Spread high tension wires flat on wire covering.
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.
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® grease to the transformer terminal.
Install cover assembly firmly onto transformer terminal.
Reconnect battery cables to battery.
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.