1976 Evinrude 40 Wiring

[BamaGunner]

Hello all. 1st post, as I havent had to post yet. Generally find what I am looking for through a search, but I did a search for my problem, and couldnt find anything. I will try to keep it short, but will give a little background to see if its something simple I am missing...

Working on trying to get a new keyswitch installed on a 76 MonArk, with a 76 Rude 40 Elec. Start. Keyswitch is a new 6 pole Seadog-Line switch. I think I have some wires wrong, or backward, so I wanted to see where I had to go with it. I had the motor running on a test stand, as it sat for quite some time, (Close to 8 years), and the points and everything were corroded up. I pulled the flywheel (easier than most say it is) and cleaned everything up, reset the points (.020), etc etc. I hooked in a spare control box that I have, that the throttle controls dont work, but the key switch does. Fired the girl up on the stand, and ran like a top, other than some 2 cycle smoking, but for being parked for 8 years, I was impressed. While hooked to that box, I couldnt get the thing to shut off with the key, so I would just choke it out, and kill it. I assumed it was something on how the box is wired, for a different engine. No biggie, will get it working on the boat. Installed it on the boat, and the keyswitch that was there, we didnt have a key for, so I bought a new switch (stated above). It is a 6 pole switch, but I only have 5 wires coming off the harness coming from the engine. Bear with me here, but I believe it was Lt. Blue, Lt.Blue/White, Red/Purple, Yellow, and Blue/Green (???) From what I have found, the 2 blues are the kill for the magneto, and hook to the 2 "M" posts on the key switch. The Blue/Green (???) Hooks to the "C" Post, and does operate the choke correctly. (Pushing switch in/key on) The red/purple from what I can tell is the 12V+ wire, and I have it hooked to the "B" post on the switch. After that, I get lost. I have this yellow wire left, and 2 posts for it to go on. The wiring diagram that came with the switch doesnt match the switch too well, if at all. Its more of a suggestion. I believe the 2 places on the switch I have left are "A" and "I". I can get this thing to turn over all day long, but I cant seem to get the fire to keep it running, and working alone, I cant see if its sparking, but from the looks of the plug I pulled, its not. (wet plug). I was playing around moving wires around, and I ended up blowing the mini fuse, so I stuck a regular 20A back in there so I could at least test things. I have a spare, but dont want to blow it as well, while swapping things around. So I have 5 wires, and a 6 pole switch. I put the yellow wire on one of the 2 (cant remember which at this moment), and the moment I turn the switch on, it starts turning the motor over, in the ON position. On the other post, the switch works correctly, but it wont fire up. I have been looking for a wiring diagram picture online, but havent found one yet. I know a manual is a good thing, and I had one, but I gave it to someone that needed it worse than I did, and I would hope someone could save me the 40 bucks on another...

Anyone able to guide me? Sorry for the long post, but I like to give details if they are there, in case I am missing something.

Thanks

[BamaGunner]

Ok, did some research, and I have an "I" and an "S" post left. From what I can tell, the yellow goes to the "S" post? If that is the case, I have another problem somewhere else, as I know I tried it, and it didnt fire. Wonder if when I blew that fuse, I didnt do some damage to the condensors or points or something....

Any guidance? Its probably something simple, and Im just not seeing it....

[BamaGunner]

Update:

I think I found the whole problem tonight... I was playing with things, and checked spark, best I could, and it appeared to have spark, but seemed weak to me. Could have been how bright it was outside still, and the last time I saw the spark, it was indoors. I decided to pull the flywheel again, and double check the points to see if they lost or gained gap. One of them was a little tight, so I opened it up to where it looks good. In the process, I just so happened to look where the flywheel key goes, and noticed it looked like it was flat, and had been ran over a few times...DOH! I sheered the key apparently. I plan on getting a new one tomorrow. Hopefully, that was my problem. I will post tomorrow, after I reinstall the flywheel and give er a whirl... Some things you cant see until you tear down a little bit.

[samo_ott]

A busted key is not good. You probably did not torque it down right. Make sure the surfaces are clean and torque it to 105 lbs I believe (at least that's what the earlier 40's were). Make sure you get it that tight.

[BamaGunner]

Post is way past due on a dead topic, but I wanted to let everyone know that may see this post in the future. I did shear the key. The key was in bad shape the first time I tore the flywheel off, but I figured it might hold. It didnt. I bought a new key (like $2.50) at the local marine shop, installed it, and works great now! We have had it out 3 times since then, ran probably 4 tanks of gas through it, working all the bugs out of it. Seems to work flawlessly for sitting in a shed, on its side for close to 8 years. Over the winter, I plan on puttin a new impeller in it, as just because of the age, it should be replaced. It is circulating currently though, and we dont take it out that much right now, as we are busy. I need to work on the oil mix though, I think. First tank through, bout mid way through, all the 2 cycle smoking stopped, or went to about an absolute minimum. Now that we have had to guess a few times on the level of gas in the tank, when we top it off, I might have it just a hair rich now. It smokes a bit at idle, but dont notice it too much going full throttle. Oh well, better to be a little too much oil than not enough! Happy boating all. Onto the next boat, my pontoon.

[gene andrusco]

Hi:

Just saw your post going back to June - - I have the same motor as you - - would you know where I can get a wiring diagram for that motor ?

Thanks !

Gene.

[mstahl1171]

You can order a complete service manual and wiring diagrams from the following: http://www.outboardbooks.com/

For parts try here on iboats or http://www.**********/parts/search/BR...976/parts.html

Mark