stop circuit test interpretation of manual.......

[bob johnson]

hello guys...beyond my starter motor issues I have a stop circuit issue of sorts

The last time I used the motor..it was hard to start, but i got it running and used it for half a day restaring at least 4 or 5 times....then while running the motor died...that happens often until i am running a long while because of the length of my gas line...I have to pump the bulb to keep the gas pressure up...if I ran for 5 minutes i would be good once I got a solid colum of gas the whole system( 12 feet or more)...so i didnt think much when the motor died.

it usually started right back up!!

but this day it wasnt...but finally it did.

then it died..then a long time no start..then I got it going....all in about a 1/2 mile then it finally died, never to be restarted...

at the time I didnt know if it was fuel issues getting worse..or my starter issue from the battery going weak from being used so much.

today I did some tests

found there was no spark to the wires!!

(all tests are per manual for V4 models)

I did the stop circuit test per the manual....and when i pulled the packard connector off the power pack the motor got spark!!

ok so it says to go onto the ohmeter test-key switch

luckily I have the adapter PN 437270 the book says to use!!!

I went through the steps all the way to step 5

5 says: If step 4 key ON reading is a low one( it was) disconnect harness black/yellow leads from key switch "M" terminal


ok "leads" was spelled with an "S" on the end..as if there are more than one???

I only see one wire that is black/yellow on my switch

so I remove that wire from the key switch

book says:
* if meter shows a high reading test key switch. Refer to electrical section
* if meter shows a low reading, go to step 6

my test showed a low reading
step 6 reads:

Seperate the emergency stop switch lead from the harness black/yellow lead at the key switch:


me again: isnt that exactly what i just did in step 5????????????????????

what is the black/yellow wire going into the key switch if it isnt partt of the HARNESS???

I cant see how step 5 and 6 are any different!!!!


what is the emergency stop switch lead that is connected to the black/yellow lead at the key switch??

is there a connection that JUMPS into that SINGLE BLACK/YELLOW WIRE AFTER IT LEAVES THE KEY SWITCH????

TOTALLY LOST HERE

when they talk about disconecting a lead at the "M: terminal...thats the KEY SWITCH!! right??

how many things have an M terminal


actually there are two "M" terminals on my key switch but only ONE has a black/yellow wire.



next how do I test the emergency stop switch???

Thought thats what i was doing anyway

I do have an extra key switch from a back up control, i could use

by the way both controls i have ar POST 1996

I have an adapter inline to connect to my pre 96 motor


hope to hear from someone

BOB

 

[metriccrescentwrench]

Re: stop circuit test interpretation of manual.......

I've got a 1990 engine, so if my answer doesn't apply to your post '96 control my apologies. I THINK this part will be the same though. Yellow/black enables the ignition, as I take you've figured out. It goes to one of the "M" terminals on the key switch, and then on to the emergency kill switch. The other "M" terminal on the key switch (there are two) is connected to ground, and in the off position the two "M" terminals are connected, shorting the yellow/black wire to ground. The safety kill switch will also short the yellow/black wire to ground when the lanyard is pulled, stopping the engine.

Hope this helped.

 

[bob johnson]

Re: stop circuit test interpretation of manual.......

is the safety kill switch the same as the books "emergency stop switch"?

I went ahead and read up on testing the key switch..using the spare. and it tests good...so my back up may be to just replace the switch and hope that was it....

but Id like to be able to follow the book as i wont always have spares around...

the killer is this manual doesnt address controls...with OMC factory manuals.. you have to go buy a manual just for the controls


and i am thinking some of these tests maybe be directing me to tests that are spelled out in those manuals


bob

 

[metriccrescentwrench]

Re: stop circuit test interpretation of manual.......

is the safety kill switch the same as the books "emergency stop switch"?

Yes


If you think there's an issue with that particular wire just check to make sure that yellow/black is NOT grounded when in the run position, and IS grounded in the off position.

 

[bob johnson]

Re: stop circuit test interpretation of manual.......

OK I tested both of my key switches per the manual and they both test good


but I still get no spark to the plug wires, when the packard connector with the stopo circuit wiring is plugged into the power pack. If i disconnect that plug, I DO GET SPARK to the plugs!!

the bokk seems to be guiding me to a bad wiring harness...

in that thought I checked continuity from the black/yellow wire at the key switch to the black /yellow wire at the power pack..i have continuity...so that wire isnt broke

I am trying to figure how i check the rest of the harness...probably somehow there is a short maybe??

once before I had a broken wire in the harness, but it wouldnt let the starter turn

so my guess is that the black/yellow is shorted to ground somewhere....

wondering how i check for that...the harness has an adapter rolled up under the floor....it might have got pretty wet this winter with water in the boat...salt water


Id hate to rip the floor and side benches up, if i cant test as is....

any help..its saturday and i am out there now..

thanks bob

 

[bob johnson]

Re: stop circuit test interpretation of manual.......

update:

bypassed the black/yellow in the harness....cut the wire close to the switch and close to the power pack spliced in a clean line direct over the floor and the motor started fine!!!!

so there is a short in that black/yellow wire in the harness somewhere


so now i got to drops the cowling and pull up the floor and check where it is..

this rig has an adapter in between the motor harness and th control harness...thats 20 feet long!!! and its all coiled up under the floor in the rear. the day the problem started, the boat took on a ton of water...salt water..so i probably shorted that day...like i said earlier it was intermitten ,for a while then permanent!!

bob