BRP EVINRUDE Johnson 5007118 - User Manual

DSS05166I REV 1 (12/05) 1 of 14
Printed in the United States.
© 2005 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
TILLER HANDLE KIT, P/N 5007118
INSTALLATION INSTRUCTIONS
APPLICATION
Use this instruction sheet when installing the above tiller handle kit on 2004 (SR) and newer
Evinrude
®
E-TEC™ outboards, 40 – 60 HP. DO NOT install on any other models.
SAFETY INFORMATION
For safety reasons, this kit should be installed by
an authorized Evinrude
®
/Johnson
®
dealer. This in-
struction 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 assembly and op-
eration 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 protect your-
self, 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 and the op-
erating instructions to the owner. Advise the owner
of any special operation or maintenance informa-
tion 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 en-
gine.
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.

Summary

Application

Safety Information

Safety Signal Words

Explains safety signal words like DANGER, WARNING, CAUTION, and IMPORTANT for hazard identification.

General Safety Practices

Emphasizes following common shop safety practices and using genuine parts for safe operation.

Inspection

Installation

Angle Adjustment Plate Placement

Guides on placing the angle adjustment plate in the steering arm bracket for desired tiller positioning.

Control Cable Installation

Cable Routing and Attachment

Steps for installing shift and throttle cables, including routing, securing, and adjusting.

Securing Control Cables

Retainer Clip Installation

Instructions for correctly installing retainer clips on shift and throttle linkage pins for secure attachment.

Electrical Connections

Wiring Harness Routing

Instructions for routing wiring harnesses from the tiller handle through the flywheel cover to the engine.

EMM Reprogramming Requirement

Crucial step requiring dealer to reprogram EMM for start-in-gear protection to prevent injury.

Steering Friction Adjustment

Final Installation Checks

System Operation Verification

Lists essential systems like stop circuit, throttle, and shift controls to verify before customer return.

Operating Instructions

Engine Starting Safety

Covers essential steps for starting the engine, including water supply and emergency stop switch usage.

Key Switch and Start Procedure

Throttle and Gear Shifting

Details on setting throttle to idle, shifting to neutral, and starting the engine.

Engine Stopping

Shifting and Speed Control

Speed Control Adjustment

Explains how to adjust speed using the throttle grip and friction adjustment knob.

Trim Control

Tiller Height Adjustment

Storage and Winterization

Winterizing In Water

Step-by-step guide for winterizing the outboard when it remains in the water.

Winterizing On Trailer

Step-by-step guide for winterizing the outboard when it is on a trailer.

Optional Accessories

BRP EVINRUDE Johnson 5007118 Specifications

General

Brand	BRP
Model	EVINRUDE Johnson 5007118
Category	Offroad Vehicle
Language	English