Just replaced ESA and now having diff. problem.

I have a 89 Bayliner with a 5.8L OMC. The ESA wasn't working so I just replaced it. Now when activated it does stumble the engine, but won't stop stumbling it in forward. I shift it all the way forward and it goes into gear, but the gray cog? that the ESA arm rides in jumps around like crazy and motor stumbles! If I move the shifter around a little I can get it to quit stumbling and stay in gear about half the time. It only does this in reverse. I did check the overstroke switch with an Ohmmeter and it seems to be switching properly. This is in the driveway BTW, not in the water. Ideas please??

Jason

Re: Just replaced ESA and now having diff. problem.

I will be worse in the water... Unfortunately, if the ESA mechanism is moving around like that, more than likely there is a problem with the lower shift cable.. it is binding somewhere, or is severely maladjusted - don't run it on the water until you get this problem located... it can cause severe gear wear or failure

Re: Just replaced ESA and now having diff. problem.

jtfisher63 said:

I have a 89 Bayliner with a 5.8L OMC. The ESA wasn't working so I just replaced it. Now when activated it does stumble the engine, but won't stop stumbling it in forward. I shift it all the way forward and it goes into gear, but the gray cog? that the ESA arm rides in jumps around like crazy and motor stumbles! If I move the shifter around a little I can get it to quit stumbling and stay in gear about half the time. It only does this in reverse. I did check the overstroke switch with an Ohmmeter and it seems to be switching properly. This is in the driveway BTW, not in the water. Ideas please??

Jason

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Are you sure your not talking about the overstroke switch ?

Re: Just replaced ESA and now having diff. problem.

Black as said:

Are you sure your not talking about the overstroke switch ?

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The overthrow is the switch that does not have an arm right? I am talking about the switch that has an arm that rides in a groove on the gray cog. It has two peaks and two valleys. It works great going into reverse, I only have a prob going into forward. The gray cog bounces up and down violently which in turn throws the swith for the ESA and makes the engine throw fits!

Re: Just replaced ESA and now having diff. problem.

jtfisher63 said:

The overthrow is the switch that does not have an arm right? I am talking about the switch that has an arm that rides in a groove on the gray cog. It has two peaks and two valleys. It works great going into reverse, I only have a prob going into forward. The gray cog bounces up and down violently which in turn throws the swith for the ESA and makes the engine throw fits!

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That's your overstroke switch mechanism not the E.S.A. you need to read this. http://www.hastings.org/~stuart/cobra/index.html

Re: Just replaced ESA and now having diff. problem.

Actually, it is the interrupter switch, the one without the arm is the overstroke... The interrupter activates the ESA module ( which is not a switch at all) the overstroke switch, cancels the ESA - so when people talk about the switch with the arm, they call it the ESA (but actually it only activates the ESA) The main confusion with this is the entire switch set is labeled as the overstroke in the some parts diagrams, so people are not sure what switch is what. Matter of fact, the OMC parts manuals call this switch several things over the years, Interrupter, Cut Out, etc etc..

One again... if the shift interrupter housing ( the gray "W" looking thing) is jumping around and activating the interrupt switch (ESA) when you put it in gear, there is too much tension on the lower shift cable, it needs to be looked at immediately.. it has failed, is binding or obstructed.. and it can ruin your gear set in your drive..

Re: Just replaced ESA and now having diff. problem.

Reinell-BRXL-191 said:

One again... if the shift interrupter housing ( the gray "W" looking thing) is jumping around and activating the interrupt switch (ESA) when you put it in gear, there is too much tension on the lower shift cable, it needs to be looked at immediately.. it has failed, is binding or obstructed.. and it can ruin your gear set in your drive..

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This x1000000!

If your lower shift cable is causing that lever to jump around like that there is a mechanical problem, not electrical. Sounds to me like it is frayed or otherwise out of tolerance and the gears are kicking the shift rod up and down when in forward.

I wouldn't put the boat back in the water until this is checked. Do you notice a lot of resistance when shifting, or difficulty with the control lever positioning back into neutral?

Re: Just replaced ESA and now having diff. problem.

Projo198, is yours still shifting okay with the bypass? I get mine on the water the 8th of next month for the first time. It shifts awesome on the muffs with the bypass, but have to shift faster the what I'm use to, but well worth it.

Re: Just replaced ESA and now having diff. problem.

Boats-A-lots said:

Projo198, is yours still shifting okay with the bypass? I get mine on the water the 8th of next month for the first time. It shifts awesome on the muffs with the bypass, but have to shift faster the what I'm use to, but well worth it.

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Yep, so far so good! I did have a snafu last time on the water that I thought was related to the new set-up, but it ended up just being a sticking interruptor switch.

It looks a little worn and if I tighten the mounting screw too tight the switch sticks in the on position. I just added Loctite and snugged it down lightly. So for 20 minutes or so I was the guy at the ramp cranking away on a boat that wouldn't start lol! 5 minutes of troubleshooting in the parking lot figured it out though.

Re: Just replaced ESA and now having diff. problem.

projo198 said:

Yep, so far so good! I did have a snafu last time on the water that I thought was related to the new set-up, but it ended up just being a sticking interruptor switch.

It looks a little worn and if I tighten the mounting screw too tight the switch sticks in the on position. I just added Loctite and snugged it down lightly. So for 20 minutes or so I was the guy at the ramp cranking away on a boat that wouldn't start lol! 5 minutes of troubleshooting in the parking lot figured it out though.

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OH NO. I make fun of people like you.. (laughing of course) I always shake my head and say to my wife "why don't they make sure it starts and runs before bringing it to the launch ramp".. Happy you got it figured out.. those can be a nightmare tracing out.

Re: Just replaced ESA and now having diff. problem.

Boats-A-lots said:

OH NO. I make fun of people like you.. (laughing of course) I always shake my head and say to my wife "why don't they make sure it starts and runs before bringing it to the launch ramp".. Happy you got it figured out.. those can be a nightmare tracing out.

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Ha ha yeah, it pretty much sucked. I even told the lady in the boat next to me who was waiting on her husband to park their trailer that I never thought I would end up being "that guy".

At least I had the decency to give up and pull my boat out before anyone else came to the ramp!