Nissan NS40D Control box/neutral switch/dead starter question

Tim Frank

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This a follow-on from my thread from Aug.24/2023 titled "Nissan 40 HP boat turtled". I am going to update that thread with the final piece.
End result was another brain f#rt but it ended up with a trip to a pro and it now has a fully green light and after launching it yesterday it ran beautifully.... until I got back to the dock. Idle was too low and it stalled. Then the starter would not engage.

1) Fully charged battery.
2) all instruments and PTT function fine.
3) jumped the solenoid and starter engaged.

My conclusion is neutral-safety switch either out of adjustment or toast.
This is at a lake house. I may need parts before I go back. I ran out of time after this problem and did not have time to trouble-shoot there.
Manual (the OEM Tohatsu book) is also at lake house. it lives there as I used to move it around and it always ended up in the wrong place.
I had a quick look in the OEM manual before I left and could not find any info in the book re: the control box .... I am sure that is where the neutral safety switch is located.

Added background .... ever since this motor was installed the shifter on control box has seemed much stiffer that it should be. I always attributed this to the cables which are far longer than needed ... like about 4-5 feet longer and they do get in the way a bit. The $%#@@$ dealer said these were the shortest available. Should have researched and called him on it at the time. The really good service tech I deal with now told me yesterday that he can get whatever length I need. I will be measuring and ordering them on Monday.

So, I have to dismantle the control box to see if there is anything obvious that is binding the mechanism, whether the N/S switch is toast, and install the new cables when I get them.

The questions:

a) Does anyone know if there are diagrams and info on the NS40D controls in the OEM manual? I looked but it was a rush.
b) If there is, I will find it ... but if not, I have looked on line and found nothing. Would I be crazy to open the box with no diagram if I am really cautious, methodical, and take lots of pictures as I go?
c) any other suggestions?

That is all. Thanks for reading and any advice you can offer; it is always sound and well laid out.
 

Tim Frank

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Thanks Paul. Got it.
My problem is that I have never opened one of the control boxes before and my factory manual is very limited on details on opening it up.

My question is is I am reasonably competent at repairs, and am careful, is this fairly straight forward.

I am replacing two control cables so have to open it up anyway.

My big fear is if it has springs and lots of small parts that might go "sprrroingg" never to be seen again. :)
 

pvanv

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Apr 20, 2008
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The throttle and shift cables are in the lower compartment. The electrics are in the upper. But I would test first before just throwing parts at it.
 

Tim Frank

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So I opened the electric portion and found the Neutral switch.
The manual says to disconnect the wires to the switch in order to test the switch.
The contacts on the switch appear to be spade terminals so I was expecting them to pull off. They don't and I may have damaged the switch.

The wires attached to the switch only run about 2-3 inches before there is another bullet type connector. Could the wires at the switch be soldered? That would make the second connection the disconnect point.

Questions:
1) Is there a trick to separating those connectors?
2) If I can isolate that switch and test it as per the manual, if it fails, would a new switch come with the short wires attached to the switch?
 

Tim Frank

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5,346
Thanks Paul! Have the new switch and will install today ... God willing and the creeks don't rise.
 
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