Affected Date Codes WARNING. Reading Date Codes. MODELS: All Evinrude/Johnson Remote Control Boxes Bearing the Date Codes Below

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1 Date: October, 003 MODELS: All Evinrude/Johnson Remote Control Boxes Bearing the Date Codes Below SUBJECT: Remote Control Box Repair No (W) AFFECTED MODELS Identify outboards equipped with the affected sidemount remote control boxes listed below before performing any service procedures. IMPORTANT: DO NOT sell, deliver, or use any affected remote control boxes in your parts and boat inventories, until you have performed the inspection or repair as outlined in this bulletin. Affected Date Codes Remote Control P/N P/N 7638 Manufactured and Distributed Jan., 00 to Aug., 003 Reading Date Codes Day 0-3 Month Year Date Codes 0-A-A (or 0-A-A) to 0-H-C A = January, B = February, C = March, D = April, E = May, F = June, G = July, H = August, I = September, J = October, K = November, L = December A (or A) = 00 B (or B) = 00 C = 003 Date Code Example: 5-F-C = 5 June, 003 IMPORTANT: Bombardier does not have responsibility for remote control boxes made and distributed prior to January, 00 and will not pay warranty claims for those units. The part numbers for newly manufactured remote control boxes have been changed to: P/N 778 (with Trim and Tilt) and; P/N 777 (without Trim and Tilt). PROBLEM These units may have loose or improperly assembled fast idle lever components, which could potentially cause the outboard to stick in gear or in neutral or jam the throttle. WARNING A loss of boat control or diminished boat control could cause a risk of personal injury to the operator, passengers, and people who are nearby. IMPORTANT: ONLY authorized service dealers can perform the repair. Printed in the United States 003 Bombardier Motor Corporation of America. All rights reserved. TM, Trademarks and registered trademarks of Bombardier Motor Corporation of America or its affiliates. DSS03076B of 5

2 IDENTIFICATION Check for a white dot on the bottom of the remote control box. A white dot signifies the remote control box has already been inspected and repaired. IMPORTANT: If there is a white dot, no further identification or repair is needed and no warranty repair costs will be paid. REPLACEMENT PROCEDURE WARNING To prevent accidental starting while servicing, disconnect the battery cables at the battery. Disassembly Remove two () mounting bolts. Remove remote control box from boat. Remove three (3) screws and separate both halves of remote control box. Remote Control Box with White Dot If there is no identifying mark, check the date code on the underside of the fast idle lever.. Mounting bolts (). Screws (3) 4556 Lift throttle cable trunnion from pocket. Pull cable back to expose cable pin. Remove pin and cable.. Date code. Fast idle lever SOLUTION IMPORTANT: Remote control boxes with date codes of 0-A-A or 0-A-A to 0-H-C should be repaired as specified in this bulletin. Replace throttle lever half of remote control box with Remote Control Kit, P/N ; or If there is damage to the shift lever cam, replace complete remote control box. Bombardier does not have responsibility for remote control boxes made and distributed prior to January, 00 and will not pay warranty claims for those units.. Throttle cable. Cable pin 3556 of 5

3 Inspection Inspect shift lever cam for damage in area indicated. If there is no damage to the shift lever cam, only the throttle lever half of the remote control box must be replaced. If damage to the shift lever cam is evident, the complete remote control box must be replaced. Apply lubricant to all points indicated. 468 Place new remote control box half flat. With fast idle lever completely down, move throttle lever out from behind plastic separator plate. Do not remove separator plate. If separator plate is missing, cable pins can fall out.. Shift lever cam 4594 Apply Triple-Guard grease to trunnion pocket and cable pin. 3 4 Damaged Shift Lever Cam IMPORTANT: To receive authorization to replace the complete remote control box, you must first contact Evinrude/Johnson Dealer Support Services at Assembly Apply Moly Lube to all points indicated on the remote control box halves.. Fast idle lever. Throttle lever 3. Separator plate 4. Trunnion pocket Place throttle cable eyelet between throttle lever halves. Secure throttle cable to throttle lever with cable pin.. Cable pin. Throttle cable of 5

4 Insert cable trunnion into pocket, then push throttle lever forward against lever stop. Make sure remote control handle and fast idle lever move freely but with equal friction through full ranges of movement. Any binding could cause remote control to jam when cables are attached to outboard. To increase control handle friction to eliminate throttle creep during boat operation, turn throttle friction knob clockwise. To decrease friction, turn knob counterclockwise.. Cable trunnion. Lever stop Before halves of remote control box are reassembled, shift lever must be in NEUTRAL, throttle lever must be against lever stop, and neutral start switch must be in center of neutral start cam. Apply RTV sealant around top and side mating edges of both remote control box halves.. Throttle friction knob Shift lever. Throttle lever 3. Neutral start switch 4089 To assemble remote control halves, place shift lever half flat to keep shift lever pin from falling out. Place new half over shift lever half. Make sure electrical cable grommet is positioned properly into remote control box. Reconnect battery cables. Identification Procedure Every remote control box that has been inspected and had the throttle lever half of the remote control box replaced must be easily identified. Mark the remote control box using permanent WHITE marker or paint. Place a large dot on the bottom of the remote control box to identify this campaign has been completed. Install and tighten three (3) screws to a torque of 40 to 50 in. lbs. (4.5 to 5.5 N m). Secure remote control to boat with two () mounting bolts. Remote Control Box with White Dot Screws (3). Mounting bolts () of 5

5 ADDITIONAL INFORMATION Dealer Responsibility All dealers, as part of a distribution chain, CARRY A RESPONSIBILITY TO NOTIFY THE CUSTOM- ER of any safety related concern and correct the problem properly. Please contact all of your customers who have purchased these remote control boxes and instruct them not to use the outboard until an authorized Evinrude/Johnson Dealer has completed an inspection and/or replacement. In addition, you MUST inspect your parts and boat inventories for affected remote control units. This is a safety issue. Once you receive the customer s product, if replacement is required, proceed with the instructions outlined in this bulletin. A warranty claim form MUST be completed with the customer s name, address, model, and serial number and submitted along with any parts replaced in the repair. You must return the completed claim with any parts replaced in the repair for warranty credit, and to ensure records are kept for reporting program progress to the United States Coast Guard. Using a standard warranty claim form, use the following information: Flat Rate Code RC03 Flat Rate Labor Allowance for inspection and/or parts replacement.0 hour Failing Part Number Labor will be paid in accordance with the established warranty labor rates listed in the current dealer warranty database. Credit for labor and $0 US to cover shipping and handling of returned parts will be issued only when the warranty allowance request form and required parts are returned. The proper return address is as follows: Ordering Parts ONLY authorized Evinrude/Johnson Dealers may order parts. All parts, including entire control box replacements, must be ordered through Bombardier Warranty Department. If only the throttle lever half of the remote control box must be replaced, order the repair kit. Repair Kit P/N QTY Remote Control Box Kit If the complete remote control box must be replaced, order the necessary remote control box. Remote Control Box P/N QTY Models with Trim and Tilt 778 Models without Trim and Tilt 777 Please clearly PRINT or TYPE your order on dealer letterhead or paper to ensure efficient order processing. Fax the order to The order MUST include the following: Date of order Dealer name and dealer code Dealer phone number P/N(s) of repair kit(s) and/or remote control box(es) Note: Multiple orders for repair kits or replacement remote control boxes can be submitted on one fax. Customer s name, address, and serial number for each repair kit or control box needed Parts will be shipped at no charge UPS ground. Bombardier Recreational Products Evinrude/Johnson Dealer Support Services 300 Seahorse Drive/Dock 5 Waukegan, IL Dealers can call for more information. 5 of 5

6 SAFETY RECALL NOTICE 50 Sea Horse Drive Waukegan, IL October 3, 003 RE: Certain Bombardier Side Mount Remote Control Boxes, P/N and 7638 Dear Dealer, Distributor, Boatbuilder, and Parts, Accessories, and Clothing (PAC) Accounts: This notice is sent to you in accordance with the requirements of the Federal Boat Safety Act and other applicable laws and regulations. What is the reason for this notice? Bombardier Motor Corporation of America in the United States and Bombardier, Inc. in Canada (collectively Bombardier ) are conducting a voluntary safety recall of Remote Control Boxes, P/N and 7638, that were manufactured and distributed between the dates of January, 00 and August, 003. What is the problem? These units may have loose or improperly assembled fast idle lever components, which could potentially cause the outboard to stick in gear or in neutral or jam the throttle. A stuck shift lever or jammed throttle lever could cause the operator of the boat to lose control or have diminished control of the vessel, which presents a risk of personal injury to the operator, passengers, and people who are nearby. of

7 What should you do?. DO NOT sell, deliver, or use any affected remote control boxes in your parts and boat inventories, until you have performed the inspection or repair as outlined in Warranty Bulletin (Safety Campaign) (W). Note that boxes bearing a white dot on the bottom as described in the bulletin have already been inspected or repaired.. You are requested to personally contact all owners to whom you have sold an affected remote control box, you must request that he/she immediately cease further use of the remote control box, and inspect their remote control box to determine if the remote control box is covered by the recall as outlined in Warranty Bulletin (Safety Campaign) (W). If the remote control box is covered, then ask the owner to schedule an inspection of the remote control box with an authorized Evinrude/Johnson Dealer to have any necessary repair completed free of charge. 3. Locate, identify, and inspect the affected remote control boxes in your parts and boat inventories as outlined in Warranty Bulletin (Safety Campaign) (W). If necessary, the remote control boxes will be repaired or replaced as specified in the bulletin. 4. Authorized dealers should promptly submit any warranty claim with any defective parts used in the repair for payment. IMPORTANT: If you are a PAC account, you MUST inspect your inventory for affected remote control boxes. Take affected remote control boxes to an authorized Evinrude/Johnson Dealer. In addition, please contact your customers pursuant to paragraph above. Dealers, boatbuilders, and PAC accounts can call for more information. Customers can call Information will also be posted on the DealerPort website ( as it becomes available. What will Bombardier do? As a result, Bombardier is mailing this SAFETY RECALL NOTICE to all known dealers, distributors, boatbuilders, and PAC accounts who have purchased these remote control boxes. In addition, the notice will be posted on the DealerPort website ( Bombardier is cooperating with the United States Coast Guard and Transport Canada in conducting this recall and in advising those persons and companies who purchased the affected remote control boxes from Bombardier. This notice applies to all current owners of the affected remote control boxes. Bombardier prides itself on preserving and enhancing the leadership reputation of its products, providing you with a satisfying relationship and meriting your future business. We apologize for any inconvenience this may cause you or your customers. Bombardier Recreational Products Evinrude/Johnson Dealer Support Services of

8 SAFETY RECALL NOTICE 50 Sea Horse Drive Waukegan, IL October 3, 003 RE: Certain Bombardier Side Mount Remote Control Boxes, (P/N and 7638). Dear Evinrude/Johnson Registered Owner: This notice is sent to you because you recently purchased an Evinrude or Johnson outboard motor and you may have also purchased one or more of the above remote control boxes. What is the reason for this notice? Bombardier Motor Corporation of America in the United States and Bombardier, Inc. in Canada (collectively "Bombardier") are conducting a voluntary safety recall of Remote Control Boxes, P/N and 7638, that were manufactured and distributed between the dates of January, 00 and August, 003. As a registered owner of an Evinrude or Johnson outboard motor purchased between these dates, you may also own the affected control box. This recall does not involve your outboard engine. What is the problem? These remote control boxes may have loose or improperly assembled fast idle lever components, which could potentially cause the outboard to stick in gear or in neutral or jam the throttle. A stuck shift lever or jammed throttle lever could cause the operator of the boat to lose control or have diminished control of the vessel, which presents a risk of personal injury to the operator, passengers, and people who are nearby. of 3

9 What should you do?. If you have a remote control box (throttle and gear levers) on your boat, please locate and examine the remote control box(es). Compare the remote control box to the picture below. If it looks like the picture, and has an OMC or Bombardier name on it, please check the manufacture date code to see if the control box is covered by this recall. The date code is printed on a tag adhered to the underside of the Fast Idle Lever. This recall does not apply to you if: ) You do not have remote controls; or ) The remote control you have is not made by OMC or Bombardier. TYPICAL - Side mount control box with fast idle lever. Remote control box with white dot NOTE: The remote control box may either have an OMC or BOMBARDIER emblem.. If the date code (see tables below) is (0-A-A), or (0-A-A, 0-H-C) or any sequence between (0-A-A and 0-H-C), check the bottom edge of the box for a white dot. If there is a white dot, your remote control box has already been fixed and this recall does not involve your unit. If your remote control box has a date code in this sequence and does not have a white dot, discontinue use of your boat and the affected remote control box. Please contact your authorized Evinrude/Johnson dealer and schedule repairs immediately. Any necessary repairs will be completed free of charge. (Warranty Bulletin (Safety Campaign) (W)). Date Code - Under fast idle lever of 3

10 Affected Date Codes Remote Control P/N P/N 7638 Reading Date Codes Manufactured and Distributed Jan., 00 to Aug., 003 Date Codes 0-A-A (or 0-A-A) to 0-H-C Day 0-3 Month Year Date Code Example: 5-F-C = 5 June, 003 A = January, B = February, C = March, D = April, E = May, F = June, G = July, H = August, I = September, J = October, K = November, L = December A (or A) = 00 B (or B) = 00 C = If you are unable to verify the date code, discontinue use of your boat and the control box and contact your authorized Evinrude/Johnson dealer to schedule the inspection immediately and make any needed repair. Bombardier does not have responsibility for OMC remote control boxes made and distributed prior to January, 00. If you have a concern regarding a remote control box from that time frame, Bombardier strongly encourages you to have your dealer inspect your remote control box, but the unit is not covered under Bombardier s recall. Need assistance locating an authorized dealer? To contact your nearest authorized Evinrude or Johnson dealer, please visit or or you can contact us via phone at This notice applies to all current owners of the affected remote control boxes. Accordingly, if you have sold your remote control box, please notify the purchaser of this recall. We apologize for any inconvenience that this recall may cause you. Bombardier Recreational Products 3 of 3