BRP 5006181 User manual

DSS04098I 1 of 24
Printed in the Japan.
© 2005 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
PREWIRED SURFACE MOUNT REMOTE CONTROL
INSTALLATION INSTRUCTIONS
APPLICATION
This surface mount remote control assembly is
designed for use on Evinrude ®and Johnson ®
outboards.
SAFETY INFORMATION
For safety reasons, this kit should be installed by
an authorized Evinrude ®/ Johnson ®dealer. This
instruction sheet is not a substitute for work experi-
ence. 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.
IMPORTANT: Identifies information that will
help prevent damage to machinery and appears
next 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. If
you have not had training related to common
shop 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 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 in-
structions and checked the pictures relating to the
repairs.
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, 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 be-
comes weak. Definite resistance to turning must be
felt when reusing a locking fastener. If replacement
is specified or required because the locking fasten-
er 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 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 your
owner’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 in
death or serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, CAN result in severe
injury or death.
CAUTION
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.

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CONTENTS OF KIT
004865
Ref P/N Name of Part Qt
y
*5006180 REMOTE CONTROL w/ TRIM SW
*5006181 REMOTE CONTROL
1 NA *REMOTE CONTROL AY 1
2 176360 *HORN 1
3 175974 *SWITCH
,
KEY & LANYARD 1
4 176288 **LANYARD Ass
y
.1
5 514696 *CONNECTOR
,
3-Pin 1
6 514697 *LOCK WEDGE
,
3-Pin connector 1
75006550 *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)
9
7
6
1
7
1
2
3
4
5
8
3
6
1. Trim and tilt switch
2. Remote control lever
3. Fast idle lever
4. Emergency stop / key switch
5. Clip and lanyard assembly
6. Adjusting screw, remote control lever friction
7. Neutral lock lever
8. Shift position label
9. Handle, shift and throttle
004849
Nautical Orientation 004861

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REMOTE CONTROL OPERATION
Read and familiarize yourself with the complete
operation of the remote control before attempting
to 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 for
specific instructions related to outboard.
Emergency Stop Feature of Key Switch
Push clip of emergency stop lanyard onto key
switch as shown.
Lanyard MUST be securely attached to operator.
If operator is thrown from helm, lanyard will pull
clip from key switch to stop outboard.
IMPORTANT: In an emergency, a passenger
can put control handle in NEUTRAL and restart
outboard without lanyard.
Fast Idle Lever
Use of the fast idle lever is not required on all
models. Refer to operator’s guide for outboard.
The fast idle lever can be used to open throttle
without shifting into gear. With control handle in
NEUTRAL, lift fast idle lever to open throttle for
starting and warm-up. The control is locked in
NEUTRAL when fast idle lever is raised to
prevent shifting into gear at higher than IDLE
RPM. The control handle is unlocked when fast
idle lever is all the way down.
Key Switch
Turn key switch from OFF to ON position. The
warning horn should sound momentarily to
indicate it is working. Turn key to START
position. To use PRIME feature, push and hold
key IN and turn switch to START position.
Release key as soon as motor starts. DO NOT
turn key to START while outboard is running.
Push key IN momentarily (in ON position) for
additional enrichment (PRIME) to keep outboard
running. Not used on all models.
DO NOT run a cold outboard any faster than
necessary to keep it from stalling. DO NOT
exceed 2500 RPM in NEUTRAL. If raised for
starting, push fast idle lever part way down as
soon as outboard starts. For outboards with
Quikstart™, wait until engine slows to IDLE RPM
before shifting into gear. Refer to operator’s guide
for specific instructions related to outboard.
1. Emergency stop clip 004848
1. Key switch
2. Lanyard
004850
WARNING
Lanyard MUST be securely attached to
operator, and clip MUST be installed on
key switch. DO NOT operate outboard with
clip removed from switch, except in an
emergency.
1
21
1. Fast idle lever 004851
004852
1

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Control Handle
IMPORTANT: Outboard must be OFF. If remote
control cables are connected to outboard, turn
propeller shaft while shifting remote control.
With control handle in NEUTRAL and fast idle
lever DOWN, lift the neutral lock lever, and move
control handle to FORWARD gear or REVERSE
gear position. Release neutral lock lever and
continue movement of control handle in same
direction to open (advance) throttle.
Refer to Remote Control Configuration for
remote control handle set-up.
Control Lever Friction Adjustment
Move the control lever to FORWARD throttle
range. Control lever should move freely. Adjust
control lever friction adjustment to prevent
vibration from changing throttle setting.
Use a flat head screwdriver to adjust control
lever friction adjustment screw. This adjustment
is used to increase or reduce the force required
to move the control lever.
Turn adjustment screw clockwise to increase the
friction or counterclockwise to reduce the friction.
Warning Horn
The warning horn sounds to alert operator when
certain engine problems occur. A 1/2-second
self-test beep should sound when the key switch
is turned ON.
IMPORTANT: The warning horn must connect
to wiring harness with a SystemCheck™ gauge
or an audible horn driver module to be functional.
Refer to Operator’s Guide and instrumentation
instructions for additional information related to
the outboard’s warning system.
Trim/Tilt Switch
Push top of switch to trim out and tilt up, or push
bottom of switch to trim in and tilt down.
1. NEUTRAL
2. Fast idle lever
3. Neutral lock lever
004853
Remote Control Handle Positions 004854
WARNING
DO NOT adjust control lever friction
adjustment screw with outboard running.
3
1
2
1. Adjustment screw, throttle friction 004856
1. Warning horn
2. 2 in. SystemCheck gauge
3. 3 in. Tachometer / SystemCheck gauge
004857
1. Trim/Tilt switch
2. Top – Trim out / tilt up
3. Bottom – Trim in / tilt down
004853
004860
1
32
1
3
2
1

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INSTALLATION INSTRUCTIONS
Read and familiarize yourself with the complete
installation instructions of the remote control
before attempting to install the remote control.
Always test operation of remote control once
installed.
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 the
starboard side of the boat, or port side of center
console. In the “starboard side mount” position,
the starboard side of the control is next to the
boat mounting surface.
The control can be mounted on the port side of
the boat, or starboard side of center console if
the control handle is relocated to the opposite
side on control. In the “port side mount”
position, the port side of the control is next to the
boat 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 surface
and must be strong enough to provide a rigid
support. Strengthen mounting surface as neces-
sary.
Place remote control at proposed location and
check clearance around remote control handle at
full throttle in FORWARD and then at full throttle
in REVERSE. There must be at least 4 in. (10
cm) of clearance between the handle and any
part of the boat throughout the control handle
travel.
There must be at least 12 in. (30.5 cm) of clear
space behind the remote control for cable
routing. Control cables must be straight as they
exit the remote control. Allow at least 6 in. (15.2
cm) to the beginning of the first bend of control
cables.
WARNING
Failure to properly install and test remote
control may result in remote control mal-
function and loss of control of boat.
1. Starboard side mount
2. Port side mount
004855
21
12
1. Remote control
2. 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 Length
Measure from center of control handle with
remote control in mounting position, along
intended cable route to engine centerline at
transom height as illustrated by dotted lines in
diagram. 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 increments
from 5 ft. to 20 ft. lengths and two-foot incre-
ments from 20 ft. to 50 ft. lengths. Use cables
that are equal to your calculated length, or are
the next longer available length.
IMPORTANT: Route cables with fewest number
of bends. Bends must never be less than 6 in.
(15 cm) radius.
Remote Control Configuration
The remote control lever can be positioned on
either side of remote control, and the trim/tilt
switch can be oriented to face the port or
starboard side of remote control.
IMPORTANT: Determine the required control
handle 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 Mount
1. Port side trim/tilt switch
2. Starboard side trim/tilt switch
004863
21
21

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Remote Control Configuration Diagrams
IMPORTANT: 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 prevent
trim/tilt switch wire damage.
Starboard Mount w/Port Side Trim/Tilt Switch
(Standard/Original Configuration)
21
3
1. Port side view of remote control
2. Forward view of remote control
3. Shield
004882
Shield 004916
004919
004918

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Starboard Mount w/Starboard Side Trim/Tilt Switch
12
3
1. Port side view of remote control
2. Forward view of remote control
3. Shield
004883
Shield 004921
004919
004918

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Port Mount w/Starboard Side Trim/Tilt Switch
21
3
1. Starboard side view of remote control
2. Forward view of remote control
3. Shield
004892
004922 Shield 004925
004269

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Port Mount w/Port Side Trim/Tilt Switch
21
3
1. Starboard side view of remote control
2. Forward view of remote control
3. Shield
004893
004927 Shield 004928
004929

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Control Lever Removal
IMPORTANT: Refer to Trim/Tilt Switch Wire
Routing. Route trim/tilt wiring carefully when re-
mote control lever and trim/tilt switch wiring are
repositioned.
Refer to Remote Control Configuration
Diagrams before performing the following steps.
Remove back control cover. Compress tabs of
trim wire cover to remove cover. Remove cover
(standard configuration) and trim wire and
retainer from remote control.
Loosen control lever retaining screw (12 mm)
three to four rotations counterclockwise.
Support the remote control housings. Strike the
screw head with a center punch and hammer to
unseat control lever.
Remove the screw and washer. Detach remote
control lever and joint from remote control. Place
flat tip screwdriver in notch of joint to pry from
control.
Loosen and remove two screws and neutral lock
plate from remote control housing.
Position neutral lock plate on appropriate side of
remote control housing. Install two screws with
lock washers through plate and torque screws to
35 in. lbs. (4 N·m).
1. Trim/tilt wire cover
2. Retainer
004868
1. Lever retaining screw 004875
004874
1
2
1
1. Lever
2. Joint
3. Notch
004878
004911
004876
004877
2
1
3

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Trim/Tilt Switch Wire Routing
Refer to Remote Control Configuration
Diagrams. 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 specific
control lever configuration. The standard config-
uration is shown below (starboard side mount
with port side trim/tilt switch).
Route trim/tilt switch wires based on diagram for
your specific control lever configuration. Use the
trim/tilt wire retainer in all configurations. Route
wire through the correct cutout of control housing
cover. Refer to Remote Control Configuration
Diagrams.
IMPORTANT: Remote control cables must be
installed to check routing of tilt/trim wiring. Refer
to Install Remote Control Cables.
Torque screws to 36 in. lbs. (4 N·m). Install
remote control lever joint. Wire shield must be in
position as shown. Solid side of shield must be
down.
CAUTION
To prevent trim tilt switch wiring from
being damaged, route wires carefully and
provide adequate slack in wiring. Refer to
Remote Control Configuration Diagrams.
1. Cover
2. Wire routing
3. Shield
004879
Starboard Mount Wire Routing
1. Retainer, trim/tilt wire
004918
2
3
1
1
1. Cover, trim/tilt wire 004920
1. Wire cutout, control housing cover
2. Joint, control lever
004929
004919
1. Screws (2)
2. Shield
004928
1
12
2
1
1

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Position lever on remote control joint. Align
splines of lever with splines of joint. Neutral lock
lever must align with neutral lock plate. Secure
lever with screw and washer. Torque screw to 7
ft. lbs. (10 N·m).
Align wire and shield to prevent rubbing before
installing control lever cover.
IMPORTANT: Trim/tilt wire must be routed as
shown in diagrams. Refer to Remote Control
Configuration Diagrams.
Install Remote Control Cables
Remove two screws and back cover from remote
control housing.
Use Triple-Guard ®grease to lubricate all moving
mechanisms, trunnion pockets, and remote
control cables.
Install shift cable and flat washer on to shift pin
and secure with new cotter pin. Bend cotter pin
as shown.
004887
1. Shield, solid side down 0049306
1
004867
004910
WARNING
Always use new cotter pins and bend both
sides of cotter pin as shown to prevent
interference with remote control housing
or possible dislodging of cotter pin from
mounitng pin.
1. Shift cable 004885, 004889
1

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IMPORTANT: Use Evinrude/Johnson Genuine
Parts or parts with equivalent characteristics, in-
cluding type, strength, and material.
Install throttle cable and flat washer on to throttle
pin and secure with new cotter pin. Bend cotter
pin as shown.
IMPORTANT: Refer to Trim/Tilt Switch Wire
Routing before installing the remote control
housing’s rear cover.
Make sure shift and throttle cables are in the
trunnion pockets, and trim and tilt wire is properly
installed and does not rub or interfere with
movements of control box components.
Align throttle cable trunnion and wiring grommet
with 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 drive
assembly and install remote control lever.
Align splines and position lever on joint. Neutral
lock lever must align with neutral lock plate.
Make sure trim/tilt wire shield is in position.
Secure lever with screw and washer. Torque
screw to 7 ft. lbs. (10 N·m). Align wire and install
cover.
Check operation and movement of control
levers. Make sure control locks in NEUTRAL
position and shift and throttle functions operate
smoothly. Refer to REMOTE CONTROL
OPERATION TEST.
1. Throttle cable 004885, 004890
Port Mounting Configuration
1. Trunnion pockets
004922
Starboard Mounting Configuration (Standard)
1. Trunnion pockets
004918
1
1
1
1. Shield 004887
004899
1

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Install Remote Control in Boat
Hold remote control(s) in selected position. Re-
fer to specific outboard installation instruc-
tions for information related to connecting
remote controls to outboard. Mark three
mounting hole locations on mounting surface.
Refer to profile drawing and use drill template if
needed.
Drill three 1/4 in. (6 mm) holes.
Fasten control box in position with mounting
hardware provided. Install using three each of
screws, spacers, washers, lock washers, and
nuts. Tighten mounting screws to 7 ft. lbs. (10
N·m).
IMPORTANT: After remote control is installed,
check that at least three threads of the mounting
screws are extended beyond the nut. Be sure re-
mote control assembly is secure and does not
move during operation.
Electrical Connections
Install trim and tilt wiring into electrical connector.
Position wiring terminals in connector housing as
indicated:
• 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 positioned
in connector.
IMPORTANT: Apply a light coat of Electrical
Grease™ onto the electrical connector seals.
Push connectors together until latched.
Fasten warning horn bracket to mounting stud of
gauge, or tie strap it to wiring harness. Carefully
route wiring and connect two-pin position horn
connector to two-socket horn connector of
ignition harness. Connect six-pin key switch
harness connector to six-socket connector of
ignition harness.
1. Mounting holes, standard configuration 004900
004897
1
1
1. Electrical connector
2. Lock, wedge
004901
1. Lock, wedge 004903
1. Horn connector
2. Key switch harness connector
004902
1
2
1
21

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REMOTE CONTROL OPERATION TEST
IMPORTANT: Disconnect all spark plug wires
and/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 propeller
shaft while shifting remote control.
Depress neutral lock lever and shift control lever
into FORWARD and advance throttle to FULL
THROTTLE. Next, move lever back to IDLE po-
sition and then back into NEUTRAL. Notice shift
detent function of lever and make sure control le-
ver locks at NEUTRAL position. Repeat process
moving control lever into REVERSE.
Remote control must shift smoothly and accu-
rately into FORWARD, NEUTRAL, and RE-
VERSE and throttle must move smoothly
through the entire throttle range from IDLE to
FULL THROTTLE (WOT). Check throttle opera-
tion in both FORWARD and REVERSE.
NEUTRAL START TEST
Remote control is designed to crank outboard in
NEUTRAL only.
Use this “non running” test to make certain the
starter motor will NOT operate when control lever
is in FORWARD or REVERSE.
The lanyard clip may be attached to key switch or
removed for the following test.
IMPORTANT: Disconnect all spark plug wires
and/or disconnect crankshaft position sensor
(CPS) connector to prevent outboard from start-
ing during test procedure.
With control lever in NEUTRAL position, turn key
switch to START. The starter should operate.
With the key switch in START position and the
starter cranking the engine, lift the neutral lock
lever and move control lever to FORWARD. The
starter should stop as lever leaves NEUTRAL.
Release key and move control lever to
NEUTRAL. Turn key to START. The starter
should operate.
With key switch in START position and starter
cranking engine, lift neutral lock lever and move
control lever to REVERSE. The starter should
stop as lever leaves NEUTRAL.
1. Neutral lock lever 004896
004904
1
WARNING
Make certain starter will not operate when
the outboard is in gear. The start-in-gear
prevention feature is required by the
United States Coast Guard to help prevent
injuries.

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OPERATOR TESTS AND ADJUSTMENTS
IMPORTANT: Test operation of emergency
stop switch at each outing. Refer to EMERGEN-
CY STOP SWITCH TEST. If outboard does not
stop, return control to dealer for repair.
Check throttle friction. When properly adjusted,
control lever should have low friction to allow
easy 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. Attach
lanyard to key switch. Place control lever in
NEUTRAL position. If needed, use fast idle lever.
Turn key ON. Warning horn should sound
momentarily as self-test. Turn key to START.
Release key as soon as outboard starts. Push in
on key for enrichment function if outboard is
equipped. Do not turn key to START while
outboard is running. Refer to outboard’s
operator’s guide.
IMPORTANT: Do not exceed 2500 RPM in
NEUTRAL during warm-up.
With fast idle lever all the way down, check shift
operation. Check that motor shifts to FORWARD
when control is shifted to FORWARD, and shifts
to REVERSE when control is shifted to
REVERSE.
Check that remote control operates freely and
equal friction is felt in FORWARD and REVERSE
throttle range of control lever.
EMERGENCY STOP SWITCH TEST
Check emergency stop function. Install lanyard
clip on key switch and start outboard.
With outboard running, remove emergency stop
lanyard. Outboard must STOP. If outboard does
not stop, check key switch and wiring. Repair as
needed.
WARNING
Always use the safety lanyard when oper-
ating boat to help prevent a runaway boat
and reduce the risk of personal injury or
death. Check emergency stop function
often.
004848

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MAINTENANCE
Check mounting of remote control. Tighten
screws or secure as needed.
While turning propeller, check for smooth and
correct operation of remote control. Observe
linkages at outboard and be sure shift and
throttle linkages move accurately and completely
for each remote control setting.
If an abnormal condition is found, repair as
needed. Replace all damaged parts. Recheck
operation of remote control after servicing.
Remote control must shift smoothly and
accurately into FORWARD, NEUTRAL, and
REVERSE, and throttle must move smoothly
through the entire throttle range from IDLE to
FULL THROTTLE (WOT). Check throttle
operation in both FORWARD and REVERSE.
Check remote control for looseness, damage,
and corrosion. Clean and replace parts as
needed.
Use Triple-Guard grease to lubricate all moving
mechanisms and remote control cables.
Reassemble all components disassembled for
inspection and servicing. Check operation of
remote control.
Start outboard and check shift and throttle
operation.
With outboard running, remove emergency stop
lanyard. Outboard must STOP. If outboard does
not stop. Check key switch and wiring. Repair as
needed.
CAUTION
Inspection and maintenance must be per-
formed with outboard stopped. Disconnect
emergency stop lanyard, disconnect bat-
tery cables, and remove spark plug wires
from spark plugs to prevent accidental
starting of outboard.
Port Mounting Configuration
1. Screws (3)
004912
1
1
004914
004915

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