TILLER HANDLE KIT, P/N 5005579 and 5005777INSTALLATION INSTRUCTIONS

APPLICATIONThis kit is designed for use on 2004 (SR) and newer Evinrude® E-TEC™ 75 and 90 HP outboards.DO NOT install on any other models.

SAFETY INFORMATIONFor safety reasons, this kit should be installed byan authorized Evinrude®/Johnson® dealer. This in-struction 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 common shopsafety practices, you should do so to protect your-self, 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 and the op-erating instructions to the owner. Advise the ownerof any special operation or maintenance informa-tion 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 en-gine.

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.

DSS04006I REV 1 1 of 15

Printed in the United States.© 2004 BRP US Inc. All rights reserved.TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

TILLER CONVERSION KIT (Evinrude E-TEC – 75/90 HP)

WARNING

Do not install this kit unless you have the ability to communicatewith the engine using Evinrude E-TEC Engine Diagnostic Software.Complete installation of this kit requires reprogramming the EngineManagement Module (EMM) to provide start-in-gear protection.

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TILLER CONVERSION KIT (Evinrude E-TEC – 75/90 HP)

Ref P/N Name of Part Qty Ref P/N Name of Part Qty1 5005777 TILLER CONVERSION KIT - WHITE 1 37 333374 *SHIM, Steering arm extension 11 5005579 TILLER CONVERSION KIT - BLUE 1 38 333499 *CLIP, Emergency stop 12 434930 *STEERING HANDLE Assy. 1 39 909386 *SCREW, Bracket to intake 13 334960 **SPIRAL PIN 1 40 351376 GROMMET, Cable 14 329878 **STEERING HANDLE, Inner 1 41 318941 *WASHER, Steering handle A 15 332089 **RETAINING RING 1 42 342803 *SLEEVE, Throttle cable & lead wire 16 329881 *ROLLER, Helix to cable 2 43 345201 *LEVER, Steering friction 17 329879 *GUIDE 2 44 344709 *WASHER, Steering friction 18 329880 *PIN, Cable to rollers 1 45 345348 *NUT, Steering friction 19 329063 *SEAL, Steering handle 1 46 345202 *GRIP, Lever 110 351565 *SLEEVE, Throttle cable 1 47 313607 *LUBE FITTING 111 5005692 *CABLE, Throttle 1 48 344705 *BRACKET, Steering friction 112 334083 *ANCHOR, Throttle cable 1 49 345476 *WASHER, Steering friction 113 334153 *CONNECTOR, Throttle cable 1 50 327400 *WASHER, Steering friction 314 329160 *SCREW, Anchor to bracket 1 51 344706 *SCREW, Steering friction 115 328739 *WASHER, Anchor to bracket 1 52 328694 *SCREW, Steering friction 416 336481 *SCREW. Emgy. Stop assy 3 53 340532 *HANDLE, Shift 117 351209 *BRACKET, Anchor to intake 1 54 334815 *BUSHING, Shift handle 118 342933 *PLUG, Idle adjustment 1 55 329885 *SCREW, Shift handle mount 119 436216 *TWIST GRIP & SLEEVE 1 56 313022 *NUT, Linkage rod to handle 120 339722 *HELIX, Twist grip 2 57 328703 *WASHER, Linkage rod nut to handle 221 174741 *THROTTLE FRICTION CONTROL 1 58 314125 *BUSHING, Shift handle linkage rod 222 398602 *LANYARD 1 59 351191 *ROD, Shift linkage 123 586830 *EMGY. STOP SWITCH Assy 1 60 334373 *BUSHING, Shift linkage rod snap 124 514679 **PIN, Terminal 2 61 334119 *CONNECTOR, Shift linkage rod 125 514690 *SEAL PLUG 2 62 320107 *TIE STRAP 426 514688 *CONNECTOR, Start & Stop 6 Pin 1 63 586827 *START SWITCH Assy 127 514684 *LOCKWEDGE 1 64 514679 **PIN, Terminal 228 340779 *BRACKET, Steering handle 1 65 327805 *NUT, Start switch 129 350989 *SCREW, Steering handle to bracket 1 66 335298 DECAL, Emergency stop clip (white) 130 325452 *BUSHING, Steering handle to brkt. 2 66 335299 DECAL, Emergency stop clip (blue) 131 307160 *LOCKNUT, Steering handle screw 1 67 330575 DECAL, Start warning (white) 132 310928 *CLAMP, Stop switch leads 1 67 333978 DECAL, Start warning (blue) 133 315077 *NUT, Steering bracket 2 68 330713 DECAL, Gear shift (white) 134 315391 *COVER, Screw 1 68 333979 DECAL, Gear shift (blue) 135 327254 *SCREW, Strg. brkt. to strg. arm 1 69 5000266 DECAL, Friction 136 320397 *WASHER, Steering handle 2

A Use only under screw head if washer P/N 320397 is too thick.

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INSPECTION

Before installation, check boat for obstructionsthat could interfere with free movement of tillerhandle when steering or tilting outboard.

INSTALLATION

Disconnect battery cables from outboard.

Shift outboard to NEUTRAL. Remove anyscrews from steering arm holes.

Remove four (4) screws and tilt limit switch wireretainer from swivel bracket.

Use tie strap to secure tilt limit switch wire to tilttube. Route wire over transom bracket.

Place shim plate on tiller handle, as shown. In-sert steering arm screw with washer through afthole.

WARNING

Improper installation of this kit couldresult in personal injury due to loss of boatcontrol.

A boat designed for remote steering mighthave a lower maximum rated horsepowerfor a tiller-steered outboard than shown onthe certification plate. To avoid overpower-ing a boat designed and rated for remotesteering, contact boat manufacturer fortiller-steered maximum rated horsepower.

To prevent accidental starting while servic-ing, disconnect battery leads from battery.Twist and remove all spark plug leads.

To prevent injury from contact with a rotat-ing propeller, remove propeller before ser-vicing and when running outboard on aflushing device.

Nautical Orientation

CAUTION

To avoid damaging the tiller handle whentilting the outboard up, position the out-board to clear obstacles in the motor welland boat.

1. Steering arm2. Screws (4)3. Tilt limit switch wire retainer

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1. Tie strap2. Tilt limit switch wire

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1. Shim plate2. Steering arm screw3. Washer

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Install tiller handle on steering arm. Threadscrew into center hole of steering arm and installwasher and locknut by hand. Temporarily threadsteering friction screw through forward hole tosteady tiller handle on steering arm.

Tighten screw to torque of 18 to 20 ft. lbs. (25 to27 N·m), then hold screw with a wrench andtighten locknut to same torque. Remove steeringfriction screw from forward hole.

Secure steering friction bracket to swivel bracketwith four (4) screws. Tighten screws to torque of60 to 80 in. lbs. (7 to 9 N·m).

Slide lever grip onto steering friction lever.

Install washer and plastic washer onto steeringfriction screw. Insert screw through steeringfriction bracket and steering friction pad, asshown.

Thread steering friction screw through steeringfriction lever. Thread jam nut onto screw until topof jam nut is flush with end of screw.

Slide steering friction lever under steering arm.Fit notch in steering friction pad around threadsof steering arm screw, as shown.

1. Steering arm2. Steering arm screw3. Washer4. Locknut5. Steering friction screw

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1. Steering friction bracket2. Screws (4)

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1. Lever grip2. Steering friction lever

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1. Washer2. Plastic washer3. Steering friction screw4. Steering friction pad5. Steering friction lever6. Jam nut

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WARNING

If the notch in the steering friction pad isnot installed around the screw threads, thesteering friction control could jam, result-ing in loss of steering control.

1. Steering arm2. Steering friction pad

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IMPORTANT: When installing the steering fric-tion control, the threads of the steering armscrew must engage at least half the thickness ofthe steering friction pad notch. However, thescrew must not contact the steering frictionbracket beneath the friction pad.

If there is not enough screw engagement,remove steering arm screw and replace topwasher, P/N 320397, with alternate thinnerwasher, P/N 318941.

If there is still not enough engagement, removewasher and install steering arm screw without awasher.

Align steering friction screw with forward hole insteering arm. Hold jam nut with open-endwrench. With steering friction pad and lever lyingon top of steering friction bracket, thread screwup until it engages threads of steering arm hole.

IMPORTANT: Lever and friction pad must bekept tight against bracket while installing screw.

Turn steering friction screw until plastic washercontacts bottom of steering friction bracket, asshown.

WARNING

If there is not enough engagementbetween the steering arm screw and thenotch in the steering friction pad, or if thescrew contacts the steering frictionbracket, the steering friction control willnot function properly and could result in aloss of steering control.

Minimum Screw Engagement1. Steering arm screw2. Steering friction pad

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1. Steering arm screw2. Washer

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WARNING

Steering friction device is not intended tohold boat on a set course. DO NOT over-tighten steering friction screw for“hands-off” steering. Reduced control ofthe boat could result in loss of control bythe operator, creating a risk of personalinjury or property damage.

1. Steering friction screw2. Jam nut

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1. Plastic washer2. Steering friction bracket

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Install clamp and locknut on steering frictionscrew. Do not tighten locknut at this time.

Hold steering friction lever at full starboardposition (increased friction). Hold jam nut withwrench and tighten steering friction screw untilplastic washer is seated snug against steeringfriction bracket.

Steer outboard from side to side. Adjust steeringfriction screw upward until steering effort iscomfortably stiff with steering friction lever at fullstarboard position (increased friction).

Move steering friction lever to full port position(decreased friction). Steer outboard from side toside. Outboard must move with only slight drag.

Adjust steering friction screw until range of fric-tion is satisfactory. Hold screw with wrench andtighten jam nut up against steering arm.

Hold steering friction screw with wrench andtighten locknut. Make sure clamp is turned to-ward starboard side, as shown. Continue to holdscrew and clamp in position and tighten locknutto torque of 18 to 20 ft. lbs. (25 to 27 N·m).

IMPORTANT: In some of the following images,the starboard lower engine cover has been re-moved for photographic clarity only.

Remove trunnion retainer.

Install bushing into each side of upper hole inshift handle.

1. Clamp2. Locknut

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1. Steering friction lever2. Jam nut3. Plastic washer

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1. Locknut2. Clamp

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1. Trunnion retainer 002404

1. Bushing (2)2. Shift handle

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Slide trunnion onto shift rod. Thread connectorcompletely onto end of shift rod.

Place washer on bent end of shift rod. Install shiftrod through bushings in shift handle. Secure shiftrod to shift handle with washer and locknut.Tighten locknut to a torque of 60 to 84 in. lbs. (7to 9 N·m).

Move shift handle and shift lever into NEUTRAL.Position trunnion on shift rod in lower bracketpocket. Adjust shift rod connector and slide itonto shift lever. Secure shift rod to shift lever withclip, P/N 333774 (not included in kit).

Snap throttle cable connector onto throttle lever.

Position throttle cable in upper bracket pocket.Install trunnion retainer and anchor bracket oncable bracket by using screw, P/N 909386,supplied with kit. Tighten screw to a torque of 60to 84 in. lbs. (7 to 9 N·m).

Adjust cable anchor so throttle lever is against itsstop when twist grip is at IDLE. Install washer,cable anchor, and cable anchor screw. Tightenscrew securely.

Remove electrical cover to access engine wiringharness.

1. Trunnion2. Shift rod3. Connector

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1. Washer (2)2. Shift rod3. Locknut

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1. Shift lever2. Trunnion3. Shift rod4. Shift rod connector

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WARNING

The shift rod and throttle cable connectorsmust be properly installed. A risk of per-sonal injury or property damage from lossof boat control could occur if the throttleor shift linkage connectors come loose.

1. Throttle cable connector2. Throttle lever3. Throttle cable4. Trunnion retainer5. Anchor bracket6. Cable anchor

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1. Electrical cover 002421

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Route wiring harness from tiller handle throughchannel in flywheel cover. Use tie strap to secureharness to wiring bracket.

Apply Electrical Grease to engine wiring harnessconnector seal, then connect to tiller handle wir-ing harness.

Arrange connectors in flywheel cover, as shown,and install electrical cover. Seal any unused con-nectors.

• 6-pin connector seal, P/N 586076• 3-pin connector seal, P/N 586111

IMPORTANT: Route and secure all wires toavoid contact with moving parts.

Apply soapy water to inside surfaces of grommetand install components in holes as shown.

Grommet can be modified by cutting at dottedlines for other accessories.

Place grommet into position in lower engine cov-er. Make sure fuel hose is not kinked inside thelower engine cover once grommet is in place.

Route throttle cable, emergency stop switchwire, and start button wire through clamp andsqueeze clamp closed. Place screw cover overexposed threads of steering friction screw.

1. Wiring harness2. Flywheel cover3. Wiring bracket

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1. Tiller handle wiring harness2. Engine wiring harness

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1. Trim and tilt harness (Shown with connector seal)2. SystemCheck™ harness (Shown with connector seal)3. Tiller handle harness (Start/Stop switch)

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1. Throttle cable and wiring harness2. Shift rod3. Fuel hose

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1. Clamp2. Screw cover

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Attach lanyard to emergency stop switch.

Throttle friction control is provided to adjust theeffort required to hold a throttle setting. Turnknob clockwise to increase friction or counter-clockwise to decrease friction.

Have dealer use Evinrude E-TEC EngineDiagnostic Software to reprogram EngineManagement Module (EMM) for Tiller Modelstart-in-gear protection.

CHECK INSTALLATIONMake sure the following operate properly beforereturning outboard to customer:

• Engine stop circuit• Emergency stop switch and lanyard• Steering movement and friction control• Throttle control (IDLE to WIDE OPEN)• Shift control and proper gear engagement• Start-in-gear protection• Trim and tilt control

1. Lanyard2. Emergency stop switch3. Throttle friction control

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WARNING

After installation, dealer must useEvinrude E-TEC Engine Diagnostic Soft-ware to reprogram Engine ManagementModule (EMM) to provide start-in-gear pro-tection. Failure to provide start-in-gearprotection could create a risk of personalinjury or property damage.

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WARNING

Only shift outboard with throttle in IDLEposition. If outboard is shifted into gearwith throttle setting above IDLE speed, theboat could accelerate suddenly, injuringboat occupants and bystanders.

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OPERATING INSTRUCTIONSIMPORTANT: Store these instructions onboardthe boat with the operator’s guide.

SAFETY INFORMATION

ENGINE STARTING

Refer to the Routine Inspection Checklist inthe Evinrude E-TEC Operator’s Guide forpre-launch checks before using your outboard.

You MUST supply water to the engine beforeattempting to start it. Engine damage can occurquickly.

Be sure the water intake screens are below thewater surface.

Connect the clip to the emergency stop switch.Snap the lanyard to a secure place on the oper-ator’s clothing or life vest — not where it mighttear away instead of activating the stop switch.

IMPORTANT: The operator should always usethe clip and lanyard anytime the engine is run-ning.

DANGER

DO NOT run the engine indoors or withoutadequate ventilation or permit exhaustfumes to accumulate in confined areas.Engine exhaust contains carbon monoxidewhich, if inhaled, can cause serious braindamage or death.

Contact with a rotating propeller is likely toresult in serious injury or death. Assurethe engine and prop area is clear of peopleand objects before starting engine or oper-ating boat. Do not allow anyone near a pro-peller, even when the engine is off. Bladescan be sharp and the propeller can con-tinue to turn even after the engine is off.Always shut off the engine when near peo-ple in the water.

WARNING

The engine cover is a machinery guard.DO NOT operate your outboard with thecover off unless you are performing main-tenance or emergency starting, and thenbe careful to keep hands, hair, and cloth-ing clear of all moving parts. Contact withmoving parts could cause injury.

Always shut off the outboard when yourboat is near people who are in the water.

Be familiar with the waters you areoperating in. The gearcase of this outboardextends below the water surface and couldpotentially come in contact with underwaterobstructions. Contact with underwaterobstructions may result in loss of controland personal injury.

1. Clip2. Emergency stop switch3. Lanyard

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WARNING

Always use the safety lanyard when oper-ating your boat to help prevent a runawayboat and reduce the risk of personal injuryor death.

Avoid knocking or pulling the clip off thestop switch during normal boating. Theresulting unexpected loss of forwardmotion can throw occupants forward,causing injury.

Your emergency stop switch can be effec-tive only when in good working condition.At each outing, inspect clip and lanyard forcuts, breaks, or wear. Replace worn ordamaged parts.

Keep the lanyard free from obstructionsand entanglements.

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Move the shift lever to NEUTRAL. Refer to Shift-ing and Speed Control.

Twist throttle grip to SHIFT position or slower.Refer to Speed Control.

Electric Start Button ModelsWhile seated, press the start button. Crank theengine no longer than 20 seconds.

IMPORTANT: The starter motor can be dam-aged if operated continuously for more than 20seconds.

Upon start-up, release the start button.

If the engine did not start, release the start buttonmomentarily, then try again.

WARNING

At each outing, test the system’s opera-tion. With the engine running, remove theclip from the switch by pulling the lanyard.If the engine does not stop running, seeyour Dealer.

1. NEUTRAL 002415

WARNING

Always shift to NEUTRAL before startingthe outboard to prevent sudden boatmovement, which can cause injury.

1. SHIFT position 002406

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DO NOT advance the throttle before start-up.Advancing the throttle overrides the electronicidle control system. After the engine starts, theengine management module (EMM) willautomatically increase idle speed slightly. Idlespeed will decrease as the engine warms up.

If the outboard is started at wide open throttle,twist the throttle grip back to SHIFT beforeshifting.

1. Start button2. NEUTRAL

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Key Start ModelsWhile seated, turn the key switch fully clockwiseto the START position. Crank the engine no long-er than 20 seconds.

IMPORTANT: The starter motor can be dam-aged if operated continuously for more than 20seconds.

Upon start-up, release the key.

If the engine did not start, release the keymomentarily, then try again.

All Models

If your outboard does not react normally to one ofthese starting procedures, or if it fails to start,refer to the Troubleshooting chart in theEvinrude E-TEC Operator’s Guide.

After Engine StartsCheck the water pump indicator. A steadystream of water indicates the water pump isworking. If a steady stream of water from the wa-ter pump indicator is not visible, stop the engine.Refer to Engine Overheating in the EvinrudeE-TEC Operator’s Guide.

ENGINE STOPPING

Twist the throttle grip to SHIFT position orslower.

Move shift lever to NEUTRAL.

Press the STOP button until the outboard stopsrunning. If equipped, close the vent screw on thefuel tank’s filler cap.

SHIFTING AND SPEED CONTROLIMPORTANT: Carefully check the function of allcontrol and engine systems before leaving thedock. DO NOT shift the outboard into FOR-WARD or REVERSE while it is shut OFF.

Shifting

With engine running, twist the throttle grip toSHIFT or slower.

Move the shift lever briskly and decisively toFORWARD or REVERSE.

1. NEUTRAL dr4402

Water Pump Indicator drc4952a

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1. STOP button 002413dr3755a

1. Shift lever2. FORWARD3. REVERSE

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IMPORTANT: When shifting from FORWARDto REVERSE or from REVERSE to FORWARD,pause at NEUTRAL until the engine is at idlespeed and the boat has slowed.

Speed ControlWith the outboard running, twist throttle grip:

• Clockwise to decrease speed; or• Counterclockwise to increase speed.

STEERING FRICTION LEVER

AdjustmentA slight drag should be felt when turning the out-board with the steering handle. If adjustment isnecessary, turn the steering friction lever:

• Starboard to increase friction; or• Port to decrease friction.

STORAGE

WINTERIZATION (Tiller Steering Model)

You can winterize your outboard either in thewater or on a trailer. DO NOT start the outboardonce winterization is completed.

In the Water

Prepare your outboard for the off-season byfollowing these steps:

1) Make sure that the throttle is in NEUTRALand the water intake screens are completelysubmerged.

2) Add 2+4® Fuel Conditioner to the fuel tankand fill it with fuel.

3) Advance the throttle to 1/2 throttle positionand start the outboard. The outboard will run atidle speed.

4) After approximately 15 seconds, move thethrottle to IDLE position. Run the outboard atidle for another 15 seconds, then advance thethrottle again to 1/2 throttle position.

5) The outboard will automatically go to fast idleand fog itself. Allow the outboard to run until itshuts itself off (about one minute).

6) Remove the engine cover. Top off the oil res-ervoir and inspect the fuel filter. If there is debrisin the fuel filter, it must be replaced. Reinstall theengine cover.

IMPORTANT: When finished, leave the out-board in a vertical position long enough to com-pletely drain the water from the powerhead. 7) If equipped, disconnect the speedometerpickup at the upper connection and blow allwater out of the hose using air pressure of 25psi (172 kPa) or less. Reconnect the speedome-ter pickup after all of the water has beenremoved.

WARNING

Do not operate the outboard in REVERSEwith the tilt/run lever in TILT. The outboardmay tilt out of the water, resulting in lossof control.

1. Decrease speed2. Increase speed

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1. Increase friction2. Decrease friction

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On a Trailer

Prepare your outboard for the off-season byfollowing these steps:

1) Make sure that the throttle is in NEUTRAL.Remove the propeller.

2) Add 2+4® Fuel Conditioner to the fuel tankand fill it with fuel.

3) Attach a garden hose to the flushing port andturn on the water.

4) Advance the throttle to 1/2 throttle positionand start the outboard. The outboard will run atidle speed.

5) After approximately 15 seconds, move thethrottle to IDLE position. Run the outboard atidle for another 15 seconds, then advance thethrottle again to 1/2 throttle position.

6) The outboard will automatically go to fast idleand fog itself. Allow the outboard to run until itshuts itself off (about one minute).

7) After the outboard shuts itself off, detach gar-den hose.

8) Remove the engine cover. Top off the oil res-ervoir and inspect the fuel filter. If there is debrisin the fuel filter, it must be replaced. Reinstall theengine cover.

9) Apply the recommended lubricant to the pro-peller shaft splines, then install the propeller.

IMPORTANT: When finished, leave the out-board in a vertical position long enough to com-pletely drain the water from the powerhead.10) If equipped, disconnect the speedometerpickup at the upper connection and blow allwater out of the hose using air pressure of 25psi (172 kPa) or less. Reconnect the speedome-ter pickup after all of the water has beenremoved.

When using this winterization procedure, engineoil may appear on the skeg below the gearcasearea. This is normal. Avoid potential oil stainsby placing a shop towel or suitable containerunder the propeller and skeg for the duration ofthe storage.

WARNING

To prevent injury from contact with rotat-ing propeller, temporarily disconnect thebattery cables at the battery and removethe propeller before servicing and whenrunning the outboard with a flushingdevice.

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