INSTRUCTIONS

Outboard Engines

Evinrude® E-TEC® G2 Shift Actuator Kit

P/N 5010335
APPLICATION
Use this kit to service the shift actuator of Evinrude E-TEC G2 outboards.

SAFETY INFORMATION Torque wrench tightening specifications must

The following symbols and/or signal words may
be used in this document:
 DANGER
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
 WARNING
Indicates a hazardous situation which, if not
avoided, could result in death or serious
injury
 CAUTION
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate
personal injury.
NOTICE
Indicates an instruction which, if not fol-
lowed, could severely damage engine compo-
nents or other property.
These safety alert signal words mean:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
For safety reasons, this kit must be installed by an
authorized Evinrude® dealer. This instruction
sheet is not a substitute for work experience.
Additional helpful information may be found in
other service literature.
DO NOT perform any work until you have read
and understood these instructions completely.
strictly be adhered to.
Should removal of any locking fastener (lock tabs,
locknuts, or patch screws) be required, always
replace with a new one.
When replacement parts are required, use Evin-
rude/Johnson® Genuine Parts or parts with equiv-
alent characteristics, including type, strength and
material. Use of substandard parts could result in
injury or product malfunction.
Always wear EYE PROTECTION AND APPRO-
PRIATE GLOVES when using power tools.
Unless otherwise specified, engine must be OFF
(not running) when performing this work.
Always be aware of parts that can move, such as
flywheels, propellers, etc.
Some components may be HOT. Always wait for
engine to cool down before performing work.
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.
This instruction sheet may be translated into other
languages. In the event of any discrepancy, the
English version shall prevail.
TO THE INSTALLER: Give this sheet and the
operating instructions to the owner. Advise the
owner of any special operation or maintenance
information contained in the instructions.
TO THE OWNER: Save these instructions in your
owner’s kit. This sheet contains information
important for the use and maintenance of your
engine.

Printed in the United States.

© 2016 BRP US Inc. All rights reserved.
TM, ® and the BRP logo are registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
*360244*
Revision Original 1 of 10
Kit Contents Lightly tap the shift actuator with a soft mallet to
loosen it. Then slide the shift actuator forward and
lift to remove.
The Shift Actuator Kit includes the components
listed below.

1
1
3 2

1. Slide the shift actuator forward 009318

2. Lift the shift actuator to remove

Remove the shift actuator and seal.

Ref P/N Description QTY

– 5010335 KIT, Shift Actuator 1

1 – SHIFT ACTUATOR ASSEMBLY 1

2 355835 SEAL 1
1
3 358817 SHIFT ROD 1

NS 360244 INSTRUCTION SHEET 1

1. Seal 009319
Gearcase Removal
Clean the mounting surface and be sure to
Remove the gearcase from the outboard. Refer to remove all old gasket sealing compound or
Gearcase Removal in the correct Service Man- grease from the gearcase housing.
ual.

Shift Actuator Removal

Remove the six screws retaining the shift actuator
to the gearcase housing.
1

1 1. Gearcase housing 009320

1. Screws 009317

2 of 10 Revision Original
Shift Actuator Identification Shift Actuator Part Numbers
TYPE 1 P/N 5009566
NOTICE TYPE 2 P/N 5009741 (or higher)
The shift actuator assembly used in this kit is
a TYPE 2 shift actuator and replaces earlier If the shift actuator is removed from the gearcase,
TYPE 1 versions. it can be identified by the physical differences
The installer MUST correctly identify the shift shown below:
actuator which is REMOVED from the gear-
case to determine if the shift rod must be TYPE 1 TYPE 2
changed, and if the engine software must be
updated.
2 2
Review the following information to determine shift
actuator type.

If the gearcase is installed on the outboard, or if

the actuator is installed in the gearcase the shift 3 3
actuator can be identified by part number. Locate
the part number label near the actuator electrical
connector on the powerhead.
1
1

Shift Actuator Differences 010449

TYPE 1 TYPE 2
1. Coupler Attached Integrated
2. Cover profile Tall Short
3. Actuator length 4.762 in. (120.95 mm) 4.30 in. (109.22 mm)

Review the table below to determine if a software

update or shift rod change is required.
1
Shift
Engine Shift Rod Software
Model Actuator Change Update
Design
66° V6 Models 010238
66° V6 AAB
1. Part number label TYPE 1 Yes (1) Yes (1)
and older

66° V6 AAC
TYPE 2 No No
and newer

74° V6 AGD
TYPE 1 Yes (1) Yes (1)
and older

74 ° V6 AGE
TYPE 2 No No
and newer

(1) ONLY if a TYPE 1 shift actuator is removed.

74° V6 Models 010238

1. Part number label

Revision Original 3 of 10
Shift Rod
Shift Rod Replacement
IMPORTANT: The TYPE 2 shift actuator design
uses a short actuator arm and REQUIRES a lon-
ger shift rod than the TYPE 1 shift actuator.
• If installing a TYPE 2 shift actuator into a gear-
case from which a TYPE 1 shift actuator was
removed, the shift rod MUST be changed.
• If installing a TYPE 2 shift actuator into a gear-
case from which a TYPE 2 shift actuator was
removed, the shift rod does NOT need to be
changed.
Use Shift Rod Installer/Remover, P/N 358162, to
remove the shift rod from the gearcase.
1. Shift Rod Installer/Remover, P/N 358162
Use Shift Rod Installer/Remover, P/N 358162, to
install the new shift rod into the gearcase. Tighten
to a torque of 2 to 4 in. lbs. (0.25 to 0.45 N·m). Do
NOT over-tighten.
Shift Rod Adjustment
NOTICE
ALWAYS check shift rod height BEFORE
installing the shift actuator.
Failure to check and set correct shift rod
height may result in serious internal damage
to the gearcase.
Use Shift Rod Installer, P/N 358162, to check shift
rod height.
Install the plate on the gearcase housing with the
two screws provided.
Install the tool onto the shift rod. Make sure the
gearcase is in the NEUTRAL position. If needed,
rotate the propeller shaft and use the tool to push
or pull the shift rod to the NEUTRAL position.
4 of 10 Revision Original
Turn the handle of the tool clockwise to lower, or
counter-clockwise to raise the shift rod height.
Shift rod height is correct when the clip on the tool
contacts the plate. Turn the handle ± 1/2 turn so
the pin is oriented forward/aft. This ensures the
hex of the shift rod is aligned to accept coupler of
the shift actuator.
1
3
2 4
Shifter Rod Adjustment 010450
1. Shift Rod Installer and Adjustment Tool, P/N 358162
2. Plate
3. Clip
4. Pin
Turn the propeller shaft and pull the shift rod up
until the clutch dog fully engages gear. The shift
rod MUST be in the up position to install the shift
actuator.
Remove the tool from the gearcase.
Alternate Adjustment Method
If the Shift Rod Installer, P/N 358162, is not avail-
able, this alternate method may be used.
Make sure the gearcase is in the NEUTRAL posi-
tion. If needed, rotate the propeller shaft and use
a suitable tool to push or pull the shift rod to the
NEUTRAL position.
Turn the shift rod clockwise to lower, or
counter-clockwise to raise the shift rod height.
Shift rod height is correct when dimension from
the top surface of the gearcase housing to the top
of the shift rod is 5.182 in. (131.62 mm).
Turn the shift rod ± 1/4 turn so the hex of the shift
rod is oriented forward/aft. This ensures the hex of
the shift rod is aligned to accept coupler of the 4. Temporarily connect the shift actuator cable to
shift actuator. the engine harness.

5.182 in. 1
(131.62 mm)

66° V6 Model Shown 009818

1. Shift actuator cable temporarily connected to the
engine harness

5. Turn the key switch to the ON position. Do

Shift Rod Adjustment for TYPE 2 Shift Actuator
1. Top surface of gearcase housing
2. Top of shift rod
NOT start the engine.
6. Use the Tests feature of Evinrude Diagnostics
software v 6.3 or higher. Under Actuators,
010451
select the Center button to center the shift
actuator.

Shift Actuator Installation

IMPORTANT: The shift actuator MUST be cen-
tered in the NEUTRAL position. Make SURE:
• a STANDARD rotation gearcase is in FOR-
WARD
• a COUNTER–ROTATION gearcase is in
REVERSE
1. Verify the correct gear position. Rotate the pro-
peller shaft while LIFTING the lower shift rod to
put the gearcase in the correct gear position.
1
2. Make certain the hex on the lower shift rod is
aligned directly forward / backward as shown: 1. Shift actuator “Center” button 010487

After verifying the shift actuator is centered, turn

the key switch to the OFF position. Then discon-
nect the shift actuator cable from the engine har-
ness.

Hex on Lower Shift Rod 009321

3. Verify the shift actuator is centered.

Revision Original 5 of 10
Apply Gasket Sealing Compound to a new shift Rotate the propeller shaft while carefully pushing
actuator seal and install the seal on the actuator. down on the actuator to shift the gearcase into
neutral. Do NOT force the actuator.

1
1. Seal 010490
009323
Lower the shift actuator into the gearcase cavity,
then slide rearward to capture the lower shift rod. Apply Ultra Lock to the shift actuator retaining
screws. Install the six screws and tighten to a
torque of 84 to 106 in. lbs. (9.5 to 12 N·m).

1. Lower the shift actuator into the gearcase cavity 009318

2. Slide shift actuator rearward to capture the lower shift rod

1. Screws 009317

1
2

Cut-Away View 010451

1. Shift actuator
2. Lower shift rod

IMPORTANT: Verify the shift actuator is connect-

ed to the lower shift rod by lifting the shift actuator.

6 of 10 Revision Original
Shift Actuator Leak Test
NOTICE
After completing the leak test, make SURE
the gasket is installed on the plug and the
plug is tightened securely.
Water intrusion into the shift actuator cavity
will damage the shift actuator.
EMM Software Update
Use Evinrude Diagnostic software v 6.3 or higher
to confirm the EMM firmware.
Software MUST be updated if replacing a TYPE 1
shift actuator in an:
• AAB or OLDER 66° (2.7 L) V6
• AGD or OLDER 74° (3.4 L) V6

Remove the plug and seal from the top of the shift Required software should be the version listed in
actuator. the table below or higher.

Software

Engine Model Version Revision

66° V6 2.7 L, AAA & newer

150 HP 3030567 2022620

1
150 H.O. 3030558 2022621

175 HP 3030568 2022623

200 H.P. 3030570 2022624

1. Plug 009317
74° V6 3.4 L, ABA
IMPORTANT: This is an air chamber. Do NOT fill 200 H.O. 3030548 2022652
with oil.
225 HP 3030549 2022653
Install a gearcase pressure tester and pressurize
to 16 to 18 PSI for 5 to 10 minutes. If the shift 225 H.O. 3030550 2022654
actuator does not hold pressure, repair any leaks. 250 HP 3030551 2022655
After confirming there are no leaks, remove the 250 H.O. 3030552 2022656
gearcase pressure tester.
300 HP 3030553 2022658
Reinstall the plug and seal in the top of the shift 74° V6 3.4 L, AFA & newer
actuator. Tighten the plug to a torque of
60 to 84 in. lbs. (7 to 9.5 N·m). 200 H.O. 3030560 2022645

225 HP 3030561 2022646

225 H.O. 3030562 2022647

250 HP 3030563 2022648

250 H.O. 3030564 2022649

300 HP 3030565 2022650

Revision Original 7 of 10
From the Software screen, select the Update select the correct actuator type. If installing the
EMM button. actuator from this kit, select TYPE 2.

1
1. Update EMM button 010453 1. Set Shift Actuator Type button 010488

After completing the installation, go to the Identity

screen, and confirm the software revision informa-
Shift Actuator Calibration
tion. Calibrate the shift actuator:
1. Temporarily connect the shift actuator cable to
the engine harness.

1
1. Shift actuator cable temporarily connected to the 009818
1. Revision information 010453
engine harness

Shift Actuator Selection 2. Turn the key switch to the ON position. Do

Use Evinrude Diagnostic software v 6.3 or higher
to select the shift actuator type.
Open the Shift & Throttle screen. Use the drop
down menu under Gearcase Maintenance, to
NOT start the engine.
3. Use Evinrude Diagnostic software v 6.3 or
higher to calibrate the shift actuator.
• Select the Shift Throttle screen.
• Rotate the propeller shaft until the calibration
procedure is complete.

8 of 10 Revision Original
• Select the Calibrate Shift Actuator button.

1. Calibrate Shift Actuator button 010488

When Evinrude Diagnostics software displays the

“Shift calibration was successfully completed”
message, turn the key switch to the OFF position.

The gearcase must be shifted into FORWARD

gear before it is installed. Review Gearcase
Installation in the correct Service Manual to shift
the gearcase into FORWARD. Then disconnect
the shift actuator cable from the engine harness.
Install the gearcase, refer to the correct Service
Manual.

Revision Original 9 of 10
10 of 10 Revision Original