CONCEALED SIDE MOUNT REMOTE CONTROLINSTALLATION AND USER’S GUIDE

APPLICATIONUse for Evinrude® E-TEC™ concealed sidemount remote control assemblies designed forEvinrude ® 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 booklet to the own-er. Advise the owner of any special operation ormaintenance information contained in the instruc-tions.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.

DSS06234I REV 1 1 of 21

Printed in Japan.© 2006 BRP US Inc. All rights reserved.TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

CONTENTS OF KITS – CONCEALED SIDE MOUNT REMOTE CONTROL, P/N 5006561

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CONCEALED SIDE MOUNT REMOTE CONTROL FEATURES

List of Features• Neutral Detent / Neutral Lock• “Start in gear prevention” switch• Adjustable throttle friction• Uses standard Evinrude / Johnson control

cables (1979 and newer type)

2

1

3

4

5

1. Trim and tilt switch2. Handle, shift and throttle3. Adjustment screw, remote control handle friction4. Fast idle button5. Neutral Lock Lever

006302

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 IdleUse of fast idle feature is not required onEvinrude E-TEC outboards. Refer to operator’sguide for specific outboard.

The fast idle button can be used to advancethrottle without shifting into gear. With controlhandle in NEUTRAL, push on fast idle button(cover) to open throttle for starting and warm-up.

Key SwitchRefer to operator’s guide for specific startinginstructions related to outboard.

Turn key switch from OFF to ON position. Thewarning horn should sound momentarily toindicate it is working. Turn key to STARTposition. Release key as soon as motor starts.DO NOT turn key to START while outboard isrunning.

PRIME feature is NOT used on Evinrude E-TECoutboards. To use PRIME feature, momentarilypush key IN with key in ON position.

DO NOT run a cold engine any faster thannecessary to keep it from stalling. DO NOTexceed 2500 RPM in NEUTRAL. If throttle isadvanced for starting, reduce idle speed settingas soon as outboard starts. For outboards withQuikstart™, wait until engine slows to IDLE RPMbefore shifting into gear.

1. Emergency stop clip 006155

1. Key switch2. Lanyard

006153

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

1

2

1. Fast idle button (push on cover) 006157

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1

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

With control handle in NEUTRAL and fast idlefeature not activated, move control handle toFORWARD gear or REVERSE gear position.Continue movement of control handle in samedirection to open (advance) throttle.

Control Handle Friction Adjustment

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

Use a flat head screwdriver to adjust controlhandle friction adjustment screw. Thisadjustment is used to increase or reduce theforce required to move the control handle.

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

Remote Control Handle Positions 006158

WARNING

DO NOT adjust control lever frictionadjustment screw with outboard running.

53°

35°

53°

NEUTRAL

FORWARD REVERSE

REVERSE

35°FORWARD

1. Adjustment screw, throttle friction 006159

1

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Warning Horn – SystemCheck™ InstallationsThe 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 gauge oran 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.

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.

Mounting LocationSelect the appropriate location based on boatconfiguration.

IMPORTANT: The mounting location must be aflat surface and must be strong enough to pro-vide a rigid support. Strengthen mounting sur-face as necessary. Remote control cannot beinstalled if thickness of mounting surface ex-ceeds 1.2 in. (30 mm).Refer to “PROFILE DIMENSIONS -CONCEALED SIDE MOUNT REMOTECONTROL” on page 18 and “DRILLTEMPLATE - CONCEALED SIDE MOUNTREMOTE CONTROL” on page 20.

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.(102 mm) of clearance between the handle and

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

006159004860

32

1

3

2

1

WARNING

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

1. Port side (See Port Side Mounting instructions)2. Starboard side

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1

2

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any part of the boat throughout the controlhandle travel.

There must be at least 18 in. (457mm) of clearspace from center of remote control handle forcable routing. Control cables must be straight asthey exit the remote control. Allow at least 6 in.(152 mm) to the beginning of the first bend ofcontrol cables.

The remote control can be mounted at a 30°angle above or below the standard horizontalmounting position.

Cut Mounting Holes

IMPORTANT: Make sure the selected mountinglocation has all the required clearances beforedrilling or cutting. Disconnect battery to preventaccidental shock from electrical wiring.

Use “DRILL TEMPLATE - CONCEALED SIDEMOUNT REMOTE CONTROL” on page 20 forcutting mounting holes.

Remote control comes from factory in starboardside mounting configuration. Port side mountingrequires reconfiguration of remote control. Referto “Port Side Mounting” on page 14.If remote control must be mounted at a 30° angleabove or below the standard horizontal mountingposition, rotate template 30° in the requireddirection.

Position template on mounting surface. Mark thecenters of all drill locations.

1. 4 in. (102 mm) clearance line 006160

006279

006304

1

18 in. / 457 mm

30°

30°

006305

006338

30°30°

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Cut along the outer line of shaded area. Useappropriate cutting tools. A 2 7/8 in.(73mm) holesaw can be used for main through hole. Notchbottom of hole for trim and tilt wiring. Drill ONLYone 1/2 in. (12 mm) hole at upper location. Referto diagram below and “DRILL TEMPLATE -CONCEALED SIDE MOUNT REMOTECONTROL” on page 20.

Select proper fasteners and drill bit size. Deter-mine thickness of mounting surface.• Less than 0.8 in. (20 mm) thickness: Drill

three (3) 9/32 in. (7 mm) diameter holes touse 8 mm bolts and nuts and washersprovided.

• 0.8 in. - 1.2 in. (20 - 30mm) thickness: Drillthree (3) 1/8 in. (3 mm) holes to use screwsprovided.

Drill three holes at mounting hole locations.

Determine Remote Control 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.(150 mm) radius.

Install Remote Control CablesRemove screws and side cover from remotecontrol housing.

1. Shaded area2. Drill for STARBOARD side mounting ONLY3. Drill for PORT side mounting ONLY

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006339

23

1

006152

1. Side cover 006356

1

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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.

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

Foot Throttle Note: If foot throttle will be in-stalled, install trunnion, P/N 126034 as a spacer,in place of the throttle cable.

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

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 frommounting pin.

1. Shift cable 006375

1

1. Trunnion, P/N 126034 DCS1085DSC1086

1. Throttle cable 006376

1

1

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Make sure shift and throttle cables are intrunnion pocket(s), and safety switch wiring doesnot rub or interfere with movements of remotecontrol components.

Apply Triple-Guard grease to assembly screws.Install cover and screws. Tighten screwssecurely

Check operation and movement of control lever.Make sure remote control’s shift and throttlefunctions operate smoothly. Refer to REMOTECONTROL OPERATION TEST.

Fasten Remote Control to BoatPosition remote control behind mountingsurface. Align mounting plate with remotecontrol. Install four washers and screws andtighten screws to 35 in./lbs.(4 N·m)

Align mounting plate with holes and secure tomounting surface. Use bolts and nuts if surfacethickness is less than 0.8 in. (20mm) thick andscrews for surface thicknesses between 0.8(20mm) and 1.2 in. (30mm) thick. Tighten screwsor bolts and nuts to 53-71 in./lbs.(6-8 N·m).

IMPORTANT: Make sure remote control as-sembly is secure and does not move during op-eration.

Align handle friction adjustment screw with open-ing in trim ring and install trim ring.

1. Trunnion pockets 006377

006372

1

006340

006341

1. Trim ring 006348

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Position lock ring in mounting plate. Orient notchfor neutral lock lever UP as shown.

Route trim/tilt switch wiring. Make two (2) loopsof trim wire around lever as shown

Position remote control lever on splines of re-mote control. Install retaining washer and screwsand washers to secure lever to output shaft of re-mote control.

Insert neutral release button into center of shaftand install cover.

Refer to specific outboard installationinstructions for information related toconnecting remote controls to outboard.

Electrical ConnectionsConnect neutral safety switch wiring.

IMPORTANT: Apply a light coat of ElectricalGrease™ onto the electrical connector seals.Push connectors together until latched.Assemble trim and tilt wiring in connector. Alignwiring colors in connector to match engine har-ness wiring.

Connect trim and tilt switch wiring.

1. Notch, lock ring 006374

006349

006351

1

UP

006371006352

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005506

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REMOTE CONTROL OPERATION TEST

IMPORTANT: If remote control cables are con-nected to outboard, turn propeller shaft whileshifting remote control.

Shift control handle into FORWARD and ad-vance throttle to FULL THROTTLE. Next, movehandle back to IDLE position and then back intoNEUTRAL. Notice detent function of remote con-trol handle. Repeat process moving control han-dle 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 handle in NEUTRAL position, turnkey switch to START. The starter shouldoperate.

With the key switch in START position and thestarter cranking the engine move control handleto FORWARD. The starter should stop as handleleaves NEUTRAL.

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

With key switch in START position and thestarter cranking the engine move control handleto REVERSE. The starter should stop as handleleaves NEUTRAL.

CAUTION

Operation Tests must be performed withoutboard stopped. Disconnect emergencystop lanyard, disconnect battery cables,and remove spark plug wires from sparkplugs and/or disconnect crankshaft posi-tion sensor (CPS) connector to preventaccidental starting of outboard.

006353

006158

53°

35°

53°

NEUTRAL

FORWARD REVERSE

REVERSE

35°FORWARD

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, repair as needed.

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 Handle Friction Adjustment.

ON-WATER TEST

Secure boat to dock to prevent motion. Attachlanyard to key switch. Place control handle inNEUTRAL position. If needed use fast idlefeature. Turn key ON. (Warning horn shouldsound momentarily as self-test on SystemCheckequipped installations.) 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.

Check shift operation. Check that outboard shiftsto FORWARD when control is shifted toFORWARD, and shifts to REVERSE whencontrol is shifted to REVERSE.

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

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.

006352

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.

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Port Side MountingRemove back cover.

Remove dwell plate retainer.

Remove circlip and dwell plate.

Remove circlip from shaft assembly. Removewasher and throttle arm assembly. Remove thebrake disc and bushing from throttle shaft.

Turn throttle lever friction adjusting screw coun-terclockwise and remove from brake shoe. Re-move brake shoe from shaft assemble.

006356

1. Retainer 006357

006358

1

006359

006360

006361

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Loosen the two bolts and remove shaft assembly.

Loosen bolt and remove shift arm assembly.

Install shift arm assembly in inverted (opposite)position. Secure with bolt. Tighten to 4-6 in. lbs.(5-8 N·m).

Move shaft assembly from upper to lower (oppo-site) position. Secure with bolts. Tighten to 4-6 in.lbs. (5-8 N·m).

Install brake disc and busing on throttle shaft.

Install Turn adjusting screw clockwise to attach tobrake shoe. Refer to Control Handle FrictionAdjustment.

006364

006365

006366

006367

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Install throttle arm assembly on shaft assembly.Install washer and circlip.

Align cam groove in dwell plate on roller of throt-tle lever assembly. Install dwell plate on pin ofthrottle arm assembly and install circlip.

Position neutral switch wire in opposite positionof remote control housing.

Install dwell plate retainer and screws.

See “Install Remote Control Cables” onpage 8.

006344

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006345

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006347

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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 and/or disconnect crank-shaft position sensor (CPS) connector toprevent accidental starting of outboard.

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PROFILE DIMENSIONS - CONCEALED SIDE MOUNT REMOTE CONTROL

30m

m /

1.2

in. M

AX

53.3

mm

/ 2

.1in

.

123.4mm / 4.9in.

88°

88°

NE

UTR

AL

FOR

WA

RD

201.

1mm

/ 7

.9in

.20

1.2

/ 7

.9in

.

RE

VE

RS

E

122.

3mm

/ 4

.8in

.

58m

m /

2.3

in.

226m

m /

8.9

in.

88m

m /

3.5

in.

61m

m /

2.4

in.

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0061

56 D

rill (

3) 1

/8 in

. (3

mm

) hol

es to

use

scr

ews

DRILL TEMPLATE - CONCEALED SIDE MOUNT REMOTE CONTROL

(32.

8 m

m)

(32.

8 m

m)

1.3

in1.

3 in

0.5

in (1

2 m

m)

0.5 in

(12 m

m)

3.9

in (9

9 m

m)

M

ount

ing

plat

e fa

sten

er h

oles

- Q

ty 3

M

easu

re m

ount

ing

surfa

ce th

ickn

ess

- Les

s th

an 0

.8 in

(20

mm

) thi

ck,

Dril

l (3)

9/3

2 in

. (7

mm

) hol

es to

use

bol

ts- 0

.8 in

- 1.

2 in

. (20

to 3

0 m

m) t

hick

,

Dri

ll fo

r PO

RT M

ou

nt

ON

LYD

rill

for S

TARB

OA

RD M

ou

nt

ON

LY 4.8

in(1

23m

m)

2.9

in(7

3mm

)

0.3

in (8

mm

)

1.65

in(4

2mm

)

0.6

in (1

5 m

m)

TOP

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