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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.

INSTALLATION INSTRUCTIONSOUTBOARD JET PUMP – SECONDARY SHIFT CABLE

APPLICATIONThis instruction sheet is intended to supplement the aftermarket jet pump manufacturer’s installationinstructions. Evinrude® E-TEC™ outboards require a secondary shift cable and hardware to actuate thepowerhead shift linkage when outboard jet pump kit is installed.

SAFETY INFORMATIONFor safety reasons, this part 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 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 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.

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JET PUMP MOUNTINGMODIFICATION

Remove jet pump housing exhaust tube retainerassembly and exhaust tube.

Drill the threaded mounting hole at rear of jetpump housing to 0.386 in. (25/64 in.)

Refer to appropriate service manual for waterpump installation and gearcase mounting screwtorques. Install jet pump housing on outboard.

Use the 2 in. x 3/8 in. screw in the rear mountinghole of jet pump.

Reinstall exhaust tube in jet pump housing.

SECONDARY SHIFT CABLEINSTALLATION

Assemble secondary shift cable components asfollows.

Secure secondary cable (5 ft.) to jet pump cablebracket with mounting hardware. Install lockingnut and cable end provided. Secure cable endwith locking nut with approximately 1/4 in. ofthreads exposed.

WARNING

To prevent accidental starting while servic-ing, disconnect the battery cables at thebattery. Twist and remove all spark plugleads.

1. Exhaust tube

1. Retainer assembly

1. Rear mounting hole

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Cutaway view

CAUTION

Failure to install and adjust the secondaryshift cable will affect outboard operation.Neutral idle run quality may be adverselyaffected and outboard will not acceleratein gear.

1. Cable2. Bracket

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Secure cable bracket to jet pump housing andcable end to shift cam. Position shift cam inNEUTRAL position as shown.

Secure cable trunnion with retainer in endposition as shown. Install locking nut and cableend provided.

Position trunnion in bracket on powerhead.

Adjust cable end (or ends) to position shiftlinkage in NEUTRAL position. Neutral detentmust be centered in shift lever detent and neutralswitch must be centered on cam of detent.Tighten locking nut.

Secure cable on shift lever pin with flat washerand retainer clip.

1. Mounting hardware2. Locking nut3. Cable end

1. Cable bracket

1. Cable trunnion w/retainer2. Locking nut3. Cable end

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1/4 in

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1. Bracket

1. Shift lever detent2. Neutral switch/cam

1. Flat washer and retainer clip

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Verify shift linkage is adjusted properly.

SHIFT GATE ADJUSTMENT

Move remote control handle to NEUTRALdetent.

Hold reverse gate up and check for properclearance between reverse gate and water flowpassage:

• 15/32 in. (11.9 mm)

If adjustment is required:• Loosen shift cam screw• Rotate cam eccentric nut while holding

reverse gate up, until proper clearance isachieved. Tighten cam screw and recheckadjustment.

Move remote control handle to FORWARDdetent.

When roller is in FORWARD position, apply handpressure to move the reverse gate up, towardNEUTRAL. If properly adjusted, reverse gateshould not move toward NEUTRAL.

If gate can be moved toward NEUTRAL, readjusteccentric to hold reverse gate in FORWARDposition.

SHIFT CABLE ADJUSTMENT

Pull up on shift cam until cam roller is at the farend of the FORWARD detent range.

Shift remote control to FORWARD position.Temporarily push cable guide onto shift camstud. Pull firmly on cable casing to remove free

1. Neutral switch depressed with shift actuator in NEUTRAL position

1. CLEARANCE 2. Eccentric nut3. Reverse gate4. Screw

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1. FORWARD position

WARNING

The shift cable must be adjusted correctlyor water pressure from forward boat travelcould move the gate into REVERSE, caus-ing the boat to stop abruptly. Occupantscould be thrown about or ejected.

1. Shift cam2. FORWARD detent range

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play. Adjust cable trunnion to align with trunnionbracket. Pull cable off the stud.

Insert cable trunnion in anchor bracket and turn90° to lock the trunnion in place.

Push cable guide onto stud. Install washer andhand tighten the locknut.

Shift remote control to NEUTRAL. The cam rollershould snap into NEUTRAL detent when you pullup on the reverse gate with moderate pressure.

If you cannot achieve NEUTRAL detent,lengthen cable slightly and recheck youradjustment.

IMPORTANT: The reverse gate must remainlocked in the FORWARD detent range when re-mote control is in FORWARD. When properly ad-justed, the reverse gate cannot be pulled out ofthe FORWARD detent range by hand.

Do not restrict movement of shift cables. Routecables carefully and secure with tie straps.

Refer to the appropriate service manual and theremote control installation instructions foradditional installation information.

Connect battery cables, positive cable first andthen negative cable. Connect spark plug wires tospark plugs.

Test outboard operation before returning ordelivering to customer.

1. Cable guide2. Stud3. Trunnion anchor bracket

1. NEUTRAL detent

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WARNING

The shift cables and linkage must be cor-rectly installed and adjusted. Failure tocorrectly install the outboard could resultin property damage, serious injury ordeath.