Evinrude 90 v4 - help with relay box wiring

[KafuePhil]

HI all,

Wondering if anybody would be so kind as to help me with some advice re: wiring up the above engine to the t/t relay box...

Inherited the above engine and all wiring disconnected/cut, so have bought new components and rebuilt the t/t relay box as per the wiring diagram inside the lid of the old box, which was mounted somewhere in the boat from what I can see. Where I am unsure however is on the +/- leads from the relay box, I can't determine if they are to be connected to the battery or if +ve to the solenoid and -ve to earth on the motor? The old leads coming out of the relay box were 16mm and what look like welding cable...

Any help much appreciated

Best regards

Phil

 

[boobie]

Re: Evinrude 90 v4 - help with relay box wiring

Got a model # ???

 

[KafuePhil]

Re: Evinrude 90 v4 - help with relay box wiring

Not to hand unfortunately, will be with the engine tomorrow, but i do know its a mid to late 80's model... if that helps!

 

[KafuePhil]

Re: Evinrude 90 v4 - help with relay box wiring

The Model # is E90TLCTE & Serial # J0272951; grateful for any advice!

 

[yorab]

Re: Evinrude 90 v4 - help with relay box wiring

Take a look at the sticky thread at the top called "Top Secret File UPDATED 8/1/2012". It has links to wiring diagrams. Study the diagram for your motor while waiting for a reply. I don't know your motor so I can't give a better answer.

 

[KafuePhil]

Re: Evinrude 90 v4 - help with relay box wiring

Thanks, I think the wiring diagram has put me on the right track...!

 

[emdsapmgr]

Re: Evinrude 90 v4 - help with relay box wiring

The serial number of that engine indicates a 1983. By that time, the trim box was mounted on the exhaust cover of the engine (under the cowling) and it had two relays inside the box to control the up or down movement. The trim motor on that engine was a 2-wire motor. From your description of your box, it would seem that you may have an older box, from a 79 or 80 model. Those mounted under the boat's rear splashwell and were wired direct to the battery-using pretty heavy cables. That box fed the older style 3-wire trim motor. It had a wiring diagram glued to the inside the cover of the box. These two systems were incompatible, so you may want to recheck/compare the box you are working on with the appropriate wiring diagrams appropriate to your 83 engine.

 

[KafuePhil]

Re: Evinrude 90 v4 - help with relay box wiring

Hi! Thanks for your reply; ok, that sounds as though I may be on the wrong track here... attached photos show the old relay box wired with new relays/fuse/wires as per the diagram in the second photo (reverse of relay box lid). The third photo is the wiring diagram that I found with the useful links on this forum, followed by a photo of replacement +/- leads of the same gauge (16mm) that I found in the boat that were connected to the relay box. They are now connected from the relay box to the solenoid and earthing point on the block as per the last photograph. With my limited knowledge (a little bit of knowledge is a dangerous thing, as they say...!) I would now assume that I can connect the battery to the main +/-ve cables from the solenoid/starter setup and earth point respectively, and it should work...?

 

[emdsapmgr]

Re: Evinrude 90 v4 - help with relay box wiring

Looks like you are working on the correct box. It has the two relays, which is proper for that year engine. Also, the wiring diagram looks correct. There is one thing. In the upper left corner of the #2 picture, there is a fuse holder. I don't see that holder wired into the box in the #1 picture. That should be wired into your system and have the required amperage fuse, similar to the one in the main engine harness. I wouldn't consider the system "ready" till that's in place.

 

[KafuePhil]

Re: Evinrude 90 v4 - help with relay box wiring

Looks like you are working on the correct box. It has the two relays, which is proper for that year engine. Also, the wiring diagram looks correct. There is one thing. In the upper left corner of the #2 picture, there is a fuse holder. I don't see that holder wired into the box in the #1 picture. That should be wired into your system and have the required amperage fuse, similar to the one in the main engine harness. I wouldn't consider the system "ready" till that's in place.

Hi! Thank you for your response. The fuse holder is there, just out of shot, between the two red wires that go left out of the picture- I have used a 30 Amp fuse? Would you be able to confirm if the positive and negative leads that come out of the relay box (as per the diagram on the reverse of the lid) connect to the solenoid and earth respectively?

Many thanks for your advice, much appreciated

Phil

 

[KafuePhil]

Re: Evinrude 90 v4 - help with relay box wiring

Also, in photograph 5, where would I make the short circuit in order to test the starter as ignition key is not working? I understand that I would have to disconnect the big red plug and if the engine starts, to stop I must disconnect fuel supply?

Thanks again!

 

[emdsapmgr]

Re: Evinrude 90 v4 - help with relay box wiring

Glad to hear you have the fuse in the trim box.. You can test the starter by jumping it with automotive jumper cables and a known good battery. Black to the engine block, red to the side terminal of the starter. It will/should crank the starter vigorously. Not sure what you mean by the ignition key is not working. Do you mean the key switch is not working? When the key switch is in the "off" position, it creates a dead short to the power pack, killing spark. If you try to jump start it with the key switch in the off position, it will crank, but will not fire/start. If the key switch is known to be defective and you want it out of the wiring altogether, then you'd disconnect the red plug. Then when you jump start it-the plugs will be able to fire and if fed fuel, it could start. Usually, a brief starter jump-for test purposes is not enough to actually get the engine to fire and run. (you'd need to choke it to get it to run.)

 

[KafuePhil]

Re: Evinrude 90 v4 - help with relay box wiring

Many thanks for all your help- engine running smoothly, although a couple of minor problems to work through... engine sparks when jump started, but not from ignition switch; it turns over but no spark?! Trying to find the cause. Seal gone on bleed for the tilt/trim, so hopefully will replace from somewhere, and choke lever on control box broken... but getting there! Amazed how smooth the engine sounds- has been in storage for ten years+... but was put to sleep with great care! Thanks again.