PREWIRED SURFACE MOUNT REMOTE CONTROL INSTALLATION INSTRUCTIONS

APPLICATIONThis surface mount remote control assembly isdesigned for use on Evinrude ® and Johnson ®

outboards.

SAFETY INFORMATIONFor safety reasons, this kit should be installed byan authorized Evinrude ® / Johnson ® dealer. Thisinstruction sheet is not a substitute for work experi-ence. Additional helpful information may be foundin other service literature for your engine.This instruction sheet uses the following signalwords identifying important safety messages.

IMPORTANT: Identifies information that willhelp prevent damage to machinery and appearsnext to information that controls correct assem-bly and operation of the product.

These safety alert signal words mean:ATTENTION!BECOME ALERT!YOUR SAFETY IS INVOLVED!

Always follow common shop safety practices. Ifyou have not had training related to commonshop safety practices, you should do so to pro-tect yourself, as well as the people around you.

It is understood that this instruction sheet may betranslated into other languages. In the event of anydiscrepancy, the English version shall prevail.DO NOT do any repairs until you have read the in-structions and checked the pictures relating to therepairs.Be careful, and never rush or guess a service pro-cedure. Human error is caused by many factors:carelessness, fatigue, overload, preoccupation,unfamiliarity with the product, and drugs and alco-hol use, to name a few. Damage to a boat and out-board can be fixed in a short period of time, butinjury or death has a lasting effect.When replacement parts are required, useEvinrude/Johnson Genuine Parts or parts withequivalent characteristics, including type, strengthand material. Using substandard parts could resultin injury or product malfunction.Torque wrench tightening specifications must bestrictly followed. Replace any locking fastener(locknut or patch screw) if its locking feature be-comes weak. Definite resistance to turning must befelt when reusing a locking fastener. If replacementis specified or required because the locking fasten-er has become weak, use only authorizedEvinrude/Johnson Genuine Parts.If you use procedures or service tools that are notrecommended in this instruction sheet, YOUALONE must decide if your actions might injurepeople or damage the outboard.TO THE INSTALLER: Give this sheet to the owner.Advise the owner of any special operation or main-tenance information contained in the instructions.TO THE OWNER: Save these instructions in yourowner’s kit. This sheet contains information impor-tant to the future use and maintenance of your out-board.

DANGER

Indicates an imminently hazardous situa-tion which, if not avoided, WILL result indeath or serious injury.

WARNING

Indicates a potentially hazardous situationwhich, if not avoided, CAN result in severeinjury or death.

CAUTION

Indicates a potentially hazardous situationwhich, if not avoided, MAY result in minoror moderate personal injury or propertydamage. It also may be used to alertagainst unsafe practices.

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Printed in the Japan.© 2005 BRP US Inc. All rights reserved.TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

CONTENTS OF KIT

004865

Ref P/N Name of Part Qty* 5006180 REMOTE CONTROL w/ TRIM SW* 5006181 REMOTE CONTROL 1 NA *REMOTE CONTROL AY 12 176360 *HORN 13 175974 *SWITCH, KEY & LANYARD 14 176288 **LANYARD Assy. 15 514696 *CONNECTOR, 3-Pin 16 514697 *LOCK WEDGE, 3-Pin connector 17 5006550 *MOUNTING BOLT & SPACER KIT 1

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REMOTE CONTROL FEATURES

List of Features• Neutral Lock• “Start in gear prevention” switch• Warning horn included• Adjustable throttle friction• Pigtail wiring harness – correct ignition wir-

ing harness must be ordered separately• Uses standard Evinrude / Johnson control

cables (1979 and newer type)

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7

6

1

7

1

2

3

4

5

8

3

6

1. Trim and tilt switch2. Remote control lever3. Fast idle lever4. Emergency stop / key switch5. Clip and lanyard assembly6. Adjusting screw, remote control lever friction7. Neutral lock lever8. Shift position label9. Handle, shift and throttle

004849

Nautical Orientation 004861

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REMOTE CONTROL OPERATION

Read and familiarize yourself with the completeoperation of the remote control before attemptingto start the outboard.

IMPORTANT: The operation of this remote con-trol may vary from one outboard model to anoth-er. Refer to outboard’s operator’s guide forspecific instructions related to outboard.

Emergency Stop Feature of Key SwitchPush clip of emergency stop lanyard onto keyswitch as shown.

Lanyard MUST be securely attached to operator.

If operator is thrown from helm, lanyard will pullclip from key switch to stop outboard.

IMPORTANT: In an emergency, a passengercan put control handle in NEUTRAL and restartoutboard without lanyard.

Fast Idle LeverUse of the fast idle lever is not required on allmodels. Refer to operator’s guide for outboard.

The fast idle lever can be used to open throttlewithout shifting into gear. With control handle inNEUTRAL, lift fast idle lever to open throttle forstarting and warm-up. The control is locked inNEUTRAL when fast idle lever is raised toprevent shifting into gear at higher than IDLERPM. The control handle is unlocked when fastidle lever is all the way down.

Key SwitchTurn key switch from OFF to ON position. Thewarning horn should sound momentarily toindicate it is working. Turn key to STARTposition. To use PRIME feature, push and holdkey IN and turn switch to START position.

Release key as soon as motor starts. DO NOTturn key to START while outboard is running.

Push key IN momentarily (in ON position) foradditional enrichment (PRIME) to keep outboardrunning. Not used on all models.

DO NOT run a cold outboard any faster thannecessary to keep it from stalling. DO NOTexceed 2500 RPM in NEUTRAL. If raised forstarting, push fast idle lever part way down assoon as outboard starts. For outboards withQuikstart™, wait until engine slows to IDLE RPMbefore shifting into gear. Refer to operator’s guidefor specific instructions related to outboard.

1. Emergency stop clip 004848

1. Key switch2. Lanyard

004850

WARNING

Lanyard MUST be securely attached tooperator, and clip MUST be installed onkey switch. DO NOT operate outboard withclip removed from switch, except in anemergency.

1

21

1. Fast idle lever 004851

004852

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Control Handle

IMPORTANT: Outboard must be OFF. If remotecontrol cables are connected to outboard, turnpropeller shaft while shifting remote control.

With control handle in NEUTRAL and fast idlelever DOWN, lift the neutral lock lever, and movecontrol handle to FORWARD gear or REVERSEgear position. Release neutral lock lever andcontinue movement of control handle in samedirection to open (advance) throttle.

Refer to Remote Control Configuration forremote control handle set-up.

Control Lever Friction Adjustment

Move the control lever to FORWARD throttlerange. Control lever should move freely. Adjustcontrol lever friction adjustment to preventvibration from changing throttle setting.

Use a flat head screwdriver to adjust controllever friction adjustment screw. This adjustmentis used to increase or reduce the force requiredto move the control lever.

Turn adjustment screw clockwise to increase thefriction or counterclockwise to reduce the friction.

Warning HornThe warning horn sounds to alert operator whencertain engine problems occur. A 1/2-secondself-test beep should sound when the key switchis turned ON.IMPORTANT: The warning horn must connectto wiring harness with a SystemCheck™ gaugeor an audible horn driver module to be functional.Refer to Operator’s Guide and instrumentationinstructions for additional information related tothe outboard’s warning system.

Trim/Tilt SwitchPush top of switch to trim out and tilt up, or pushbottom of switch to trim in and tilt down.

1. NEUTRAL2. Fast idle lever3. Neutral lock lever

004853

Remote Control Handle Positions 004854

WARNING

DO NOT adjust control lever frictionadjustment screw with outboard running.

3

1

2

1. Adjustment screw, throttle friction 004856

1. Warning horn2. 2 in. SystemCheck gauge3. 3 in. Tachometer / SystemCheck gauge

004857

1. Trim/Tilt switch2. Top – Trim out / tilt up3. Bottom – Trim in / tilt down

004853004860

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32

1

3

2

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INSTALLATION INSTRUCTIONS

Read and familiarize yourself with the completeinstallation instructions of the remote controlbefore attempting to install the remote control.Always test operation of remote control onceinstalled.

IMPORTANT: Refer to specific outboard instal-lation instructions for information related to con-necting remote controls to outboard.

Select Mounting Location

This remote control can be mounted on thestarboard side of the boat, or port side of centerconsole. In the “starboard side mount” position,the starboard side of the control is next to theboat mounting surface.

The control can be mounted on the port side ofthe boat, or starboard side of center console ifthe control handle is relocated to the oppositeside on control. In the “port side mount”position, the port side of the control is next to theboat mounting surface.

Refer to Remote Control Configuration.

IMPORTANT: Remote control MUST be mount-ed where the key switch is readily accessible. Al-so, the mounting location must be a flat surfaceand must be strong enough to provide a rigidsupport. Strengthen mounting surface as neces-sary.

Place remote control at proposed location andcheck clearance around remote control handle atfull throttle in FORWARD and then at full throttlein REVERSE. There must be at least 4 in. (10cm) of clearance between the handle and anypart of the boat throughout the control handletravel.

There must be at least 12 in. (30.5 cm) of clearspace behind the remote control for cablerouting. Control cables must be straight as theyexit the remote control. Allow at least 6 in. (15.2cm) to the beginning of the first bend of controlcables.

WARNING

Failure to properly install and test remotecontrol may result in remote control mal-function and loss of control of boat.

1. Starboard side mount2. Port side mount

004855

2 1

1 2

1. Remote control2. 4 in. (10 cm) clearance line

004858

1. 12 in. (30.5 cm) clear space 004859

22

1

12 in.

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Determine Cable LengthMeasure from center of control handle withremote control in mounting position, alongintended cable route to engine centerline attransom height as illustrated by dotted lines indiagram. Add 40 in. (1.0 m) to the measurement.This dimension is the required cable length.

Evinrude/Johnson Genuine Parts outboard con-trol cables are available in one-foot incrementsfrom 5 ft. to 20 ft. lengths and two-foot incre-ments from 20 ft. to 50 ft. lengths. Use cablesthat are equal to your calculated length, or arethe next longer available length.

IMPORTANT: Route cables with fewest numberof bends. Bends must never be less than 6 in.(15 cm) radius.

Remote Control ConfigurationThe remote control lever can be positioned oneither side of remote control, and the trim/tiltswitch can be oriented to face the port orstarboard side of remote control.

IMPORTANT: Determine the required controlhandle orientation prior to installing remote con-trol cables.

004884

Starboard Side Mount 1. Port side trim/tilt switch (standard configuration)2. Starboard side trim/tilt switch

004862

Port Side Mount1. Port side trim/tilt switch2. Starboard side trim/tilt switch

004863

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Remote Control Configuration DiagramsIMPORTANT: Refer to the following diagrams for proper trim/tilt switch wire routing. Route the trim/tilt wiring through the correct hole in control housing to allow proper movement of lever and to preventtrim/tilt switch wire damage.

Starboard Mount w/Port Side Trim/Tilt Switch

(Standard/Original Configuration)

2 1

3

1. Port side view of remote control2. Forward view of remote control3. Shield

004882

Shield 004916004919

004918

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Starboard Mount w/Starboard Side Trim/Tilt Switch

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3

1. Port side view of remote control2. Forward view of remote control3. Shield

004883

Shield 004921004919

004918

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Port Mount w/Starboard Side Trim/Tilt Switch

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3

1. Starboard side view of remote control2. Forward view of remote control3. Shield

004892

004922 Shield 004925004269

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Port Mount w/Port Side Trim/Tilt Switch

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3

1. Starboard side view of remote control2. Forward view of remote control3. Shield

004893

004927 Shield 004928004929

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Control Lever Removal

IMPORTANT: Refer to Trim/Tilt Switch WireRouting. Route trim/tilt wiring carefully when re-mote control lever and trim/tilt switch wiring arerepositioned.

Refer to Remote Control ConfigurationDiagrams before performing the following steps.Remove back control cover. Compress tabs oftrim wire cover to remove cover. Remove cover(standard configuration) and trim wire andretainer from remote control.

Loosen control lever retaining screw (12 mm)three to four rotations counterclockwise.

Support the remote control housings. Strike thescrew head with a center punch and hammer tounseat control lever.

Remove the screw and washer. Detach remotecontrol lever and joint from remote control. Placeflat tip screwdriver in notch of joint to pry fromcontrol.

Loosen and remove two screws and neutral lockplate from remote control housing.

Position neutral lock plate on appropriate side ofremote control housing. Install two screws withlock washers through plate and torque screws to35 in. lbs. (4 N·m).

1. Trim/tilt wire cover2. Retainer

004868

1. Lever retaining screw 004875

004874

12

1

1. Lever2. Joint3. Notch

004878004911

004876

004877

2

13

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Trim/Tilt Switch Wire RoutingRefer to Remote Control ConfigurationDiagrams. Note wire positions and routings.

Remove control lever cover and note wire posi-tion and routing and position of wiring shield.Route wire based on diagram for your specificcontrol lever configuration. The standard config-uration is shown below (starboard side mountwith port side trim/tilt switch).

Route trim/tilt switch wires based on diagram foryour specific control lever configuration. Use thetrim/tilt wire retainer in all configurations. Routewire through the correct cutout of control housingcover. Refer to Remote Control ConfigurationDiagrams.

IMPORTANT: Remote control cables must beinstalled to check routing of tilt/trim wiring. Referto Install Remote Control Cables.

Torque screws to 36 in. lbs. (4 N·m). Installremote control lever joint. Wire shield must be inposition as shown. Solid side of shield must bedown.

CAUTION

To prevent trim tilt switch wiring frombeing damaged, route wires carefully andprovide adequate slack in wiring. Refer toRemote Control Configuration Diagrams.

1. Cover2. Wire routing3. Shield

004879

Starboard Mount Wire Routing1. Retainer, trim/tilt wire

004918

2

3

1

1

1. Cover, trim/tilt wire 004920

1. Wire cutout, control housing cover2. Joint, control lever

004929004919

1. Screws (2)2. Shield

004928

1

1 2

2

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Position lever on remote control joint. Alignsplines of lever with splines of joint. Neutral locklever must align with neutral lock plate. Securelever with screw and washer. Torque screw to 7ft. lbs. (10 N·m).

Align wire and shield to prevent rubbing beforeinstalling control lever cover.

IMPORTANT: Trim/tilt wire must be routed asshown in diagrams. Refer to Remote ControlConfiguration Diagrams.

Install Remote Control CablesRemove two screws and back cover from remotecontrol housing.

Use Triple-Guard ® grease to lubricate all movingmechanisms, trunnion pockets, and remotecontrol cables.

Install shift cable and flat washer on to shift pinand secure with new cotter pin. Bend cotter pinas shown.

004887

1. Shield, solid side down 0049306

1

004867

004910

WARNING

Always use new cotter pins and bend bothsides of cotter pin as shown to preventinterference with remote control housingor possible dislodging of cotter pin frommounitng pin.

1. Shift cable 004885, 004889

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IMPORTANT: Use Evinrude/Johnson GenuineParts or parts with equivalent characteristics, in-cluding type, strength, and material.

Install throttle cable and flat washer on to throttlepin and secure with new cotter pin. Bend cotterpin as shown.

IMPORTANT: Refer to Trim/Tilt Switch WireRouting before installing the remote controlhousing’s rear cover.

Make sure shift and throttle cables are in thetrunnion pockets, and trim and tilt wire is properlyinstalled and does not rub or interfere withmovements of control box components.

Align throttle cable trunnion and wiring grommetwith back cover. Install back cover and screws.Apply Triple-Guard grease to assembly screws.Torque screws to 36 in. lbs. (4 N·m).

If removed, position remote control joint on driveassembly and install remote control lever.

Align splines and position lever on joint. Neutrallock lever must align with neutral lock plate.Make sure trim/tilt wire shield is in position.

Secure lever with screw and washer. Torquescrew to 7 ft. lbs. (10 N·m). Align wire and installcover.

Check operation and movement of controllevers. Make sure control locks in NEUTRALposition and shift and throttle functions operatesmoothly. Refer to REMOTE CONTROLOPERATION TEST.

1. Throttle cable 004885, 004890

Port Mounting Configuration1. Trunnion pockets

004922

Starboard Mounting Configuration (Standard)1. Trunnion pockets

004918

1

1

1

1. Shield 004887

004899

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Install Remote Control in BoatHold remote control(s) in selected position. Re-fer to specific outboard installation instruc-tions for information related to connectingremote controls to outboard. Mark threemounting hole locations on mounting surface.Refer to profile drawing and use drill template ifneeded.

Drill three 1/4 in. (6 mm) holes.

Fasten control box in position with mountinghardware provided. Install using three each ofscrews, spacers, washers, lock washers, andnuts. Tighten mounting screws to 7 ft. lbs. (10N·m).

IMPORTANT: After remote control is installed,check that at least three threads of the mountingscrews are extended beyond the nut. Be sure re-mote control assembly is secure and does notmove during operation.

Electrical ConnectionsInstall trim and tilt wiring into electrical connector.Position wiring terminals in connector housing asindicated:

• Terminal for green/white wire in position “A”• Terminal for blue/white wire in position “B”• Terminal for red/white wire in position “C”

Insert lock, wedge after terminals are positionedin connector.

IMPORTANT: Apply a light coat of ElectricalGrease™ onto the electrical connector seals.Push connectors together until latched.

Fasten warning horn bracket to mounting stud ofgauge, or tie strap it to wiring harness. Carefullyroute wiring and connect two-pin position hornconnector to two-socket horn connector ofignition harness. Connect six-pin key switchharness connector to six-socket connector ofignition harness.

1. Mounting holes, standard configuration 004900

004897

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1. Electrical connector2. Lock, wedge

004901

1. Lock, wedge 004903

1. Horn connector2. Key switch harness connector

004902

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21

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REMOTE CONTROL OPERATION TEST

IMPORTANT: Disconnect all spark plug wiresand/or disconnect crankshaft position sensor(CPS) connector to prevent outboard from start-ing during test procedure. If remote control ca-bles are connected to outboard, turn propellershaft while shifting remote control.

Depress neutral lock lever and shift control leverinto FORWARD and advance throttle to FULLTHROTTLE. Next, move lever back to IDLE po-sition and then back into NEUTRAL. Notice shiftdetent function of lever and make sure control le-ver locks at NEUTRAL position. Repeat processmoving control lever into REVERSE.

Remote control must shift smoothly and accu-rately into FORWARD, NEUTRAL, and RE-VERSE and throttle must move smoothlythrough the entire throttle range from IDLE toFULL THROTTLE (WOT). Check throttle opera-tion in both FORWARD and REVERSE.

NEUTRAL START TEST

Remote control is designed to crank outboard inNEUTRAL only.

Use this “non running” test to make certain thestarter motor will NOT operate when control leveris in FORWARD or REVERSE.

The lanyard clip may be attached to key switch orremoved for the following test.

IMPORTANT: Disconnect all spark plug wiresand/or disconnect crankshaft position sensor(CPS) connector to prevent outboard from start-ing during test procedure.

With control lever in NEUTRAL position, turn keyswitch to START. The starter should operate.

With the key switch in START position and thestarter cranking the engine, lift the neutral locklever and move control lever to FORWARD. Thestarter should stop as lever leaves NEUTRAL.

Release key and move control lever toNEUTRAL. Turn key to START. The startershould operate.

With key switch in START position and startercranking engine, lift neutral lock lever and movecontrol lever to REVERSE. The starter shouldstop as lever leaves NEUTRAL.

1. Neutral lock lever 004896

004904

1

WARNING

Make certain starter will not operate whenthe outboard is in gear. The start-in-gearprevention feature is required by theUnited States Coast Guard to help preventinjuries.

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OPERATOR TESTS AND ADJUSTMENTS

IMPORTANT: Test operation of emergencystop switch at each outing. Refer to EMERGEN-CY STOP SWITCH TEST. If outboard does notstop, return control to dealer for repair.

Check throttle friction. When properly adjusted,control lever should have low friction to alloweasy movement in FORWARD throttle range,and not allow vibration to change throttle setting.Refer to Control Lever Friction Adjustment.

ON-WATER TEST

Secure boat to dock to prevent motion. Attachlanyard to key switch. Place control lever inNEUTRAL position. If needed, use fast idle lever.Turn key ON. Warning horn should soundmomentarily as self-test. Turn key to START.Release key as soon as outboard starts. Push inon key for enrichment function if outboard isequipped. Do not turn key to START whileoutboard is running. Refer to outboard’soperator’s guide.

IMPORTANT: Do not exceed 2500 RPM inNEUTRAL during warm-up.

With fast idle lever all the way down, check shiftoperation. Check that motor shifts to FORWARDwhen control is shifted to FORWARD, and shiftsto REVERSE when control is shifted toREVERSE.

Check that remote control operates freely andequal friction is felt in FORWARD and REVERSEthrottle range of control lever.

EMERGENCY STOP SWITCH TEST

Check emergency stop function. Install lanyardclip on key switch and start outboard.

With outboard running, remove emergency stoplanyard. Outboard must STOP. If outboard doesnot stop, check key switch and wiring. Repair asneeded.

WARNING

Always use the safety lanyard when oper-ating boat to help prevent a runaway boatand reduce the risk of personal injury ordeath. Check emergency stop functionoften.

004848

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MAINTENANCE

Check mounting of remote control. Tightenscrews or secure as needed.

While turning propeller, check for smooth andcorrect operation of remote control. Observelinkages at outboard and be sure shift andthrottle linkages move accurately and completelyfor each remote control setting.

If an abnormal condition is found, repair asneeded. Replace all damaged parts. Recheckoperation of remote control after servicing.Remote control must shift smoothly andaccurately into FORWARD, NEUTRAL, andREVERSE, and throttle must move smoothlythrough the entire throttle range from IDLE toFULL THROTTLE (WOT). Check throttleoperation in both FORWARD and REVERSE.

Check remote control for looseness, damage,and corrosion. Clean and replace parts asneeded.

Use Triple-Guard grease to lubricate all movingmechanisms and remote control cables.

Reassemble all components disassembled forinspection and servicing. Check operation ofremote control.

Start outboard and check shift and throttleoperation.

With outboard running, remove emergency stoplanyard. Outboard must STOP. If outboard doesnot stop. Check key switch and wiring. Repair asneeded.

CAUTION

Inspection and maintenance must be per-formed with outboard stopped. Disconnectemergency stop lanyard, disconnect bat-tery cables, and remove spark plug wiresfrom spark plugs to prevent accidentalstarting of outboard.

Port Mounting Configuration1. Screws (3)

004912

1

1

004914

004915

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