'83 Johnson 35 hp Runs fine but will not shut off when key turned off?

[tallcar]

1983 Johnson 35 hp runs fine but will not shut off when key turned off? I have replaced the key switch, that still does allow it to shut down. I have checked for continuity from the key switch back to power pack on the black/yellow stripe wire, it checks fine ans so does the black wire from the key switch to the ground at the coil.

I normally deal with much older motors, from the 1914 Evinrude to my 1955 Evinrude. So much easier to deal with as none of this routing one function thru 15 parts all intertwined so you spend days on a simple project.

On to other trouble shooting. Diagnostics say for me to "Disconnect the stop wire from the power pack, connect a jumper to stop wire to ground. If it, ( the power pack ) stops sparking the stop circuit is at fault. Check the key switch, harness and shift switch, If this does not stop the pack from sparking replace the power pack."

That is taken from an online source here:

http://issuu.com/cdielectronics/doc...231&noteText=&noteX=&noteY=&viewMode=magazine


Now I have the wiring diagram for this motor, but for the life of me I can't seem to gather which wire is the stop wire?

Any thoughts?

Thanks

Richard

 

[DJ]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

That issue is usually caused by a poor connection in the BIG RED PLUG which is in the upper left corner of your diagram.

 

[tallcar]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

Ok great, so now if I bypass the black wire around the big red plug, and do that to the black/yellow, that should allow it to shut down correct?

And the plug is cruddy looking...

 

[DJ]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

Ok great, so now if I bypass the black wire around the big red plug, and do that to the black/yellow, that should allow it to shut down correct?

And the plug is cruddy looking...

No. Fix the plug.

 

[tallcar]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

suggestions on fixin it would be greatly appreciated

 

[DJ]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

Without knowing how bad it is, you can usually clean them up.

You can always wire around it, circuit by circuit but I wouldn't recommend it. It always seems that as soon as you do that, you need to take the engine off.:facepalm:

Anyone one of these places will sell you one. Pretty cheap.

sea-way.com
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salvagemarine.com
marinepartsoutlet.com
Superior Marine (800-338-9281)
trixieslanding.com Trixie?s Landing, Bayville, NJ 732-269-5838
americanoutboard.com
piratemarinesalvage.com/
Don's marine Salvage, 5601 126th Avenue North Clearwater, FL 33760 - (727) 576-8577
timsoutboard.com

 

[tallcar]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

Thanks

I had already bypassed the plug with the black wire as it did not have continuity thru the plug, and I checked the black w/ yellow stripe thru the plug and it was good, at this point I checked the continuity at the key switch and when the key is off, the key switch shows continuity, but when turned it shows correct or nothing. SO in a nutshell, why wont it shut off? and back to my original question, which wire and where the heck is it that they refer to as being the "stop wire at that power pack"

Thanks again, lol


Richard

 

[boobie]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

You could have a bad power pack where the black/yellow wire has lost its continueity. You can check this with the diode test on your volt/ohmmeter.

 

[tallcar]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

could you be so kind as to instruct me as to how to check this?

 

[wingnutz]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

i had the same problem with my 81 35hp....turned out to be a ground wire in the back right corner broke completely

 

[Daviet]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

Just some thoughts.
The ign system on your engine shuts down when you ground out the power pack.
The key switch connects the black and black/yellow togeather to kill the engine.
If the black wire has a good ground at the engine, and the black/yellow is a complete circut from the key to the pack the engine should shut down.
Remove the 3 pin connector with the black/yellow wire and connect an ohm meter to the harness end of the black/yellow wire.
Disconnect the black wire where it grounds to the block. With the key off you should get an ohm reading showing a complete circut between the two, if so you have just checked out the complete shorting system.
Now connect the ohm meter to the power pack side of the three pin connector on the black/yellow wire and the ground wire coming out of the power pack, should show a circut.
If you can't get a complete circut through the power pack, I would think the power pack has an open circut and not grounding out. I guess it is possiable to have a broken wire in the harness between the 3 pin connector and the power pack, pull on the black/yellow wire and see if it pulls out of the harness.

 

[SuperDave81]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

Where did you get the wiring diagram? I'd like to find one for my motor. I'm having the same problem.

 

[tallcar]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

Just some thoughts.
The ign system on your engine shuts down when you ground out the power pack.
The key switch connects the black and black/yellow togeather to kill the engine.
If the black wire has a good ground at the engine, and the black/yellow is a complete circut from the key to the pack the engine should shut down.It passes this test


Remove the 3 pin connector with the black/yellow wire and connect an ohm meter to the harness end of the black/yellow wire.
Disconnect the black wire where it grounds to the block. With the key off you should get an ohm reading showing a complete circut between the two, if so you have just checked out the complete shorting system.It passes here as well


Now connect the ohm meter to the power pack side of the three pin connector on the black/yellow wire and the ground wire coming out of the power pack, should show a circut.It fails here
If you can't get a complete circut through the power pack, I would think the power pack has an open circut and not grounding out. I guess it is possiable to have a broken wire in the harness between the 3 pin connector and the power pack, pull on the black/yellow wire and see if it pulls out of the harness.

At this point I am confident about what has failed just scratching my head at the Engineers that decided to incorporate the kill circuit thru to power pack. Can it be wired some other way?

This makes no sense, but I do not fully understand the power packs benefit over say the older coils in the 50's era motors. ground the points and the engine dies, PERIOD. Not today... and they dare call this progress?

I guess the jury is still out on that one, LOL

Many thanks for your help guys

Regards

Richard

 

[tallcar]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

I do not remember, probably from an older AOMCI member Garry, he is from Tampa and very knowledgeable on these things. You are more than welcome to copy that and print it for your records.

 

[Fed]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

Did you connect the stop wire (black/yellow) at the powerpack to ground yet?

 

[tallcar]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

As stated in my previous post, see above and what I entered in red text, yes I did. Am I missing something? I see ppl stating to connect the black/yellow wire to ground, but that wire can't be disconnected anywhere in this harness that I know, so I made a jumper wire and tested as instructed to by Daviet.

As I had stated earlier I know a bit about this, but I know a heck of a lot more about the older ones. I hate all this electronic stuff... just silly in my mind.

If you wish, and I may have misunderstood you, copy my wiring diagram, edit it to show which wires to connect to where, and I will test it that way.

Thanks

Richard

 

[Fed]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

The key switch connects the black and black/yellow togeather to kill the engine.
If the black wire has a good ground at the engine, and the black/yellow is a complete circut from the key to the pack the engine should shut down.It passes this test

What about the black wire from the controller to the engine where is connects at the coil?
I also see no mention of shorting the black/yellow to the black at the power pack.

Remove the 3 pin connector with the black/yellow wire and connect an ohm meter to the harness end of the black/yellow wire.
Disconnect the black wire where it grounds to the block. With the key off you should get an ohm reading showing a complete circut between the two, if so you have just checked out the complete shorting system.It passes here as well

Again, which black wire, the one at the coil or the one at the power pack?
I also see no mention of shorting the black/yellow to the black at the power pack.

Now connect the ohm meter to the power pack side of the three pin connector on the black/yellow wire and the ground wire coming out of the power pack, should show a circut.It fails here
If you can't get a complete circut through the power pack, I would think the power pack has an open circut and not grounding out. I guess it is possiable to have a broken wire in the harness between the 3 pin connector and the power pack, pull on the black/yellow wire and see if it pulls out of the harness.

Although you say it fails to my way of thinking there shouldn't be a circuit between the black/yellow and the black at the power pack, if there was the motor would never start let alone run. To me it looks as if failing that test in your mind is really passing the test.
I also see no mention of shorting the black/yellow to the black at the power pack.

The instructions & responses need to be precise leaving no room for confusion.
You could be 100% correct in thinking the power pack is at fault but when I read it to me it's full of holes so I was trying to get it cleared up before you spend the money only to find out the problem was somewhere else. You may also change the power pack and inadvertently fix a bad connection & get success, I see that all the time with starter motor problems.

I'd be double checking the black grounds at the coil & power pack first then nicking the black/yellow and the black at the power pack with a sharp blade & shorting them together.
Then I guess a bit of liquid tape to repair the insulation if the power pack turns out to be ok.

 

[tallcar]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

Your first question was the black wire from the "controller" to the engine where it connects to the coil. I think you are referring to the black wire that starts at the key switch, and goes to the coil? in the diagram I provided it is the black wire, if this is what you are meaning, it has continuity. I recall having the key off and checking continuity from the black/yellow and the black on the key switch with all wires connected and I had a circuit there.

and I may have jumped ahead of myself but I get a bit off when I try to trouble shoot electronics, so I nicked the black yellow wire at the power pack and used a spare piece of wire and tried to ground that to the block, and many other locations, this thing should have died and did not.

To clear up any confusion and if you feel like it, copy the diagram and paint up the connections you are referring to with an arrow and a #1 for the first test and a #2 for the second and so on. This information will clarify exactly which connection you are referring to.

Thanks

Richard

 

[Fed]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

If the black wire from the power pack to the block is a solid connection (clean, shiny & tight) then I think it's time for a new power pack.

One last thought tallcar, could the power pack be working properly but the engine is just 'running on' without ignition, I guess you could connect a spark tester to find out.

 

[gras]

Re: '83 Johnson 35 hp Runs fine but will not shut off when key turned off?

My friend has an '83 235hp evinrude, same means of killing the engine plus one emergency kill switch paralled with the OFF contacts in the ignition switch. Both the ignition switch OFF and the kill switch work as they should We had no coninuity for the gounded black wire from the red plug to the ignition switch, so I ran a wire to the negative terminal on the battery. Now it kills "sometimes". What was weird next was when trying to turn it off with the kill switch caused the motor to idle a little slower then a quick rev and back to normal idle when we opened the kill switch, almost like it was partially grounding the blk/yell. I did not test this out with the ignition switch.

We half-heartedly cleaned the red plug and it turns off more frequently. So, I am not sure if there may be a loss of continuity in both power packs or where the two blk/yell wires from the two power packs come together before the red plug and then head off to the ignition switch, but we are going to order one red plug and try changing it out. Time consuming, but less costly then other troubleshooting by replacement procedures.