BINNACLE MOUNT REMOTE CONTROLINSTALLATION AND USER’S GUIDE

APPLICATIONUse for “Evinrude® E-TEC®“binnacle mount re-mote control assemblies designed for 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 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.

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

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

CAUTIONIndicates 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.

DSS06215I 1 of 20

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 – BINNACLE MOUNT REMOTE CONTROL

Single Lever Binnacle (with keyswitch) PN 5006186 005476 Single Lever Binnacle, PN 5006182 005478

Dual Lever Binnacle, PN 5006184 005483

2 of 20

BINNACLE MOUNT REMOTE CONTROL FEATURES

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

cables (1979 and newer type)

1

5

3

4

1

2

4

5

1

DUAL LEVER SINGLE LEVER

1. Trim and tilt switch2. Handle, shift and throttle3. Key switch (includes clip and lanyard assembly)4. Adjustment screw, remote control lever friction5. Fast idle button

005497

Nautical Orientation 004861

3 of 20

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 controllever 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 005498

1. Key switch2. Lanyard

005499

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) 005500

005501

1

OFF

ON

STARTKEY

4 of 20

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.

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.

Remote Control Handle Positions 005502

WARNING

DO NOT adjust control lever frictionadjustment screw with outboard running.

1. Adjustment screw, throttle friction 005475

58°

35°

53°

NEUTRAL

FORWARDREVERSE

REVERSE

35°FORWARD

1

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

005474004860

32

1

3

2

1

5 of 20

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.

Refer to “SINGLE LEVER BINNACLE MOUNTREMOTE CONTROL PROFILE DIMENSIONS”on page 15 and “DUAL LEVER BINNACLEMOUNT REMOTE CONTROL PROFILEDIMENSIONS” on page 16.

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 2.5 in.(64 mm) of clearance between the handle andany part of the boat throughout the controlhandle travel.

There must be at least 17 in. (430 mm) of clearspace below the remote control for cable routing.Control cables must be straight as they exit theremote control. Allow at least 6 in. (152 mm) tothe beginning of the first bend of control cables.

WARNING

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

1. Side console (Port side)2. Center console (Port Side)

005471

1 2

1. 2.5 in (64 mm) clearance line 005473

005472

1

17 in

. / 4

30m

m

6 of 20

Cut Mounting HolesRefer to profile drawings and use appropriatedrill template to cut mounting holes.

IMPORTANT: Make sure the mounting locationhas all the required clearances before drilling orcutting. Disconnect battery to prevent accidentalshock from electrical wiring.

Position template. Use center punch and markthe centers of drill locations.

Drill four (4) 3/8 in. (9.5 mm) holes at the fourcorners of the area to be cut out. Cut along thelines of shaded area. Use reciprocating saw orappropriate cutting tools.

Drill four 9/64 in (3.5 mm) holes at mounting holelocations.

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.

Template, single lever remote control 005495

Template, single lever remote control1. Corner of shaded area

005481

1. Mounting hole locations (4) 005504

1

1

1

005450

7 of 20

Install Remote Control CablesRemove friction cover. Remove cover retainingscrew(s) and remote control cover.

Single Lever Remote Control – Remove flangeretainer screws and flange.

Dual Lever Remote Control – Remove three (3)screws and separate port and starboard remotecontrol housings.

Remove screws and side cover from remotecontrol housing.

Single Lever Remote Control1. Screw

005479

Dual Lever Remote Control1. Screws (2)

005489

Single Lever Remote COntrol1. Remote control cover2. Flange

005482

1

1

2

1

Dual Lever Remote Control1. Screws

005492

Dual Lever Remote Control 005491

Single Lever Remote Control (with key switch)1. Side cover

005477

1

1

8 of 20

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.

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

Dual Lever Remote Control1. Side covers (2)

005490

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

Single Lever Remote Control(Dual Lever Remote Control - starboard side)1. Shift cable

005485

Dual Lever Remote Control - port side1. Shift cable

005493

Single Lever Remote Control(Dual Lever Remote Control - starboard side)1. Throttle cable

005486

1

1

1

9 of 20

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

Single Lever Remote Control – Install cover andscrews. Apply Triple-Guard grease to assemblyscrews. Tighten screws securely

Check operation and movement of controllevers. Make sure remote control shift andthrottle functions operate smoothly. Refer toREMOTE CONTROL OPERATION TEST.

Dual Lever Remote Control – Install covers andscrews. Apply Triple-Guard grease to screws.Tighten screws securely

Dual

Dual

Dual

Dual Lever Remote Control - port side1. Throttle cable

005494

1. Trunnion pockets 005488

Single Lever Remote Control1. Screws

005487

1

1

11

Dual Lever Remote Control1. Screws

005491

Dual Lever Remote Control 005492

Dual Lever Remote Control 005496

1

10 of 20

Fasten Remote Control to BoatFasten control box in position with mountingscrews provided. Install gasket and four screws.Tighten mounting screws.

IMPORTANT: Make sure remote control as-sembly is secure and does not move during op-eration.Refer to specific outboard installation in-structions for information related to connect-ing 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.

Connect trim and tilt switch wiring. Connect keyswitch wiring (if equipped).

005503

005505

005506

11 of 20

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.

005507

005502

1

58°

35°

53°

NEUTRAL

FORWARDREVERSE

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.

12 of 20

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 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.

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.

005508

13 of 20

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.

1. Screws (4) 005503

1

1

005509

14 of 20

15 of 20

SINGLE LEVER BINNACLE MOUNT REMOTE CONTROL PROFILE DIMENSIONS

93°

88°

NE

UTR

AL

FOR

WA

RD

210.4m

m / 8.3in

.210.5

/ 8.3in.

122.7mm

/ 4.8in.

86.2mm

/ 3.4in.

430mm / 16.9in.

RE

VE

RS

E

194mm / 7.6in.

141mm / 5.6in.252.6mm / 9.9in.

16 of 20

DUAL LEVER BINNACLE MOUNT REMOTE CONTROL PROFILE DIMENSIONS

213m

m /

8.4i

n.

141.

5mm

/ 5.

6in.

196mm / 7.7in.

114.4mm / 4.5in.252.6mm / 9.9in.

93°

88°

NE

UTR

AL

FOR

WA

RD

210.

4mm

/ 8

.3in

.21

0.5

/ 8

.3in

. 430mm / 16.9in.

RE

VE

RS

E

17 of 20

57mm / 2.24 In.

150

mm

/ 5.

91 In

.

170

mm

/ 6.

69 In

.

4-R3

DRILL TEMPLATESingle Lever Binnacle Mount Remote Control

Note: For mounting surface less than 25mm thick use bolts and nuts. Dril l 4-6mm dia. through-holes. For mounting surface more than 25mm thick use selftapping screws. Dril l 4-3.5mm dia. through-holes.

58 mm / 2.28 In.

BOW

Remove shaded area

005455

18 of 20

19 of 20

113 mm / 4.45 In.

111.6 mm / 4.39 In.

4-R3

DRILL TEMPLATEDual Lever Binnacle Mount Remote Control

BOW

Note: For mounting surface less than 25mm thick use bolts and nuts. Dril l 4-6mm dia. through-holes. For mounting surface more than 25mm thick use selftapping screws. Dril l 4-3.5mm dia. through-holes.

Remove shaded area

150

mm

/ 5.

91 In

.

170

mm

/ 6.

69 In

.

005456

20 of 20