Starting Issue with a '91 Evinrude 140

[jmmd321]

Greetings,
I have a 1991 Evinrude 140 Trim/Tilt,
I am troubleshooting a non starting issue..
I know the starter/battery are good, I can disconnect the wireharness and jump the starter and it starts just fine.
As for the ignition, I have tried disconnecting the kill wire, nogo.
I have bypassed the neutral safety and have it on a constant short and no go.
If I hit the choke on the ignition it engages fine.

Basically everything seems good except it will not engage the starter from the key..
I have read through few threads and the Top Secret File, however I am not quite clear on the trouble shooting steps for the solenoid, if someone could clear it up a bit for me or make any other suggestions I would appreciate it.

Thanks!

 

[ezeke]

Re: Starting Issue with a '91 Evinrude 140

The circuit from the ignition switch just activates the starter solenoid, so if it doesn't work, either the solenoid is bad,or the wiring is.

You can activate the starter solenoid by running a short wire from the incoming large post on the solenoid to the positive small post on the solenoid. If this works, the problem is not the solenoid.

When you jumped the starter, did you jump it through the solenoid, or use jumper cables directly to the starter?

There are two small posts on the starter solenoid: one is the ground and is connected directly to the engine block; the second is the positive and runs to the ignition switch through the main harness. It is connected to the S post on the switch. The thumbnail shows the starter circuit.

 

[jmmd321]

Re: Starting Issue with a '91 Evinrude 140

Greetings,
Thank you for the reply Ezeke.

When I jumped the starter I used a 2 gauge cable to connect figures 6 and 8 on your diagram.

I have not attempted to route 6 to 3, and will do this as soon as I return home.

If this works I am to assume the solenoid is functioning correctly and I should begin troubleshooting the S wire, correct?

I have checked the S wire and it has continuity from the key to the harness.. however I was unsure where it went from there being it was in the harness. This clears that up for me, thank you kindly.

 

[ezeke]

Re: Starting Issue with a '91 Evinrude 140

"If this works I am to assume the solenoid is functioning correctly and I should begin troubleshooting the S wire, correct?"

Yes.

Check the circuit from the big red plug at the engine; click the thumbnail, please.

 

[jmmd321]

Re: Starting Issue with a '91 Evinrude 140

Good day,

I jumped the Main power to the small connection and it turned over, so I am ruling out the solenoid.

I checked the Wire harness to the small connector with an ohm meter and it got nothing, so I am to assume there is a break in the wire continuity from the motor harness connector to the solenoid, I will disassemble the wire harness and check for the break this afternoon.

There is not a fuse or any other intermediate connection between the harness and the solenoid for that particular wire correct?

Thank you again for your help and guidance.

 

[ezeke]

Re: Starting Issue with a '91 Evinrude 140

The only stock fuse in the starter circuit is the one in the diagram.

These ignition switches are not foolproof, so check that you are getting continuity from B to S when the switch is in the start position.

 

[Amelite]

Re: Starting Issue with a '91 Evinrude 140

I literally have the exact motor and had the exact same issue as you last week. I finally figured out that it was the battery cables. Use jumper cables from your current battery and attach them onto the solenoid, so that you're bypassing the cables. If it starts, you know you have the same issue as I did and your solenoid is bad.

 

[ezeke]

Re: Starting Issue with a '91 Evinrude 140

Put your ohmmeter leads on the two control end connections that I marked in the Red Plug diagram. The meter should show open with the switch in anything but the start position, and closed when you turn the switch to Start.

 

[jmmd321]

Re: Starting Issue with a '91 Evinrude 140

Good evening,

Amelite,

Thank you for the input, I have gotten the engine to turn over by bypassing the solenoid and also by engaging it manually with a short to the start post, I have cleaned and checked the battery wires are they are good. I have had that issue previously and initially was hoping that was the extent of it.

Ezeke,

I verified that I could engage the starter by connecting the main power wire to the other side of the solenoid, I also verified that I could turn it over by connecting a wire to the small post on the solenoid and to the main power feed.

I then check the continuity on the S wire from the key switch all the way to the small post on the solenoid and it read 0 resistance. So as far as I can see the wiring from key to solenoid passing through the harness is fine.

I then checked the voltage at the key on the S post while attempting to start and it read 12.8V when the wire was not connected, 9V when the wire was connected, and then at the solenoid when trying to start it reads 6.7V this is puzzling to me.

I also noticed that my Trim/Tilt is not working at the moment, it was working day before yesterday, and this may be a non connected issue, however I figured it would be prudent to mention in case there is something I am unaware of effecting both.

 

[ezeke]

Re: Starting Issue with a '91 Evinrude 140

To loose that much voltage over that short a run would indicate that you either have a very poor connection or a wire that has nearly corroded or broken through.

You can isolate the resistance by using your DC Voltmeter between the several points and cranking. On the same side of the circuit you should get no reading unless there is resistance but you will if there is a resistance problem. For example, connect your voltmeter to points 3 and 4 on the earlier diagram and turn the key to start - you should get no reading, but if you do, you have a problem in that part of the circuit.

 

[jmmd321]

Re: Starting Issue with a '91 Evinrude 140

Good day again to you,

I have resolved the issue,

These additional issue had a bearing on the situation, the wire running from the S terminal on the ignition to the small post on the starter solenoid was getting hot, it was drawing a very large amount of volts and anytime I held the key in the start position for more than a few seconds the main fuse would blow..

Next, in troubleshooting the solenoid, I was able to jump form the main battery connection on the solenoid to the small post with a HEAVY gauge wire and it would spark on contact but engage the starter. On the other hand if I were to attempt this with a smaller gauge wire, equivalent to the standard wire running from the ignition to the solenoid then it would simply spark and not engage.

This led me to believe there was a possible dead short in the solenoid itself, requiring an extremely large amount of amperage to engage, more so than the stock wire could provide.

I got a used solenoid from the local boat shop and low and behold... everything works as it should.

As for the previous issue I mentioned with the trim tilt not working, that was a non related issue stemming it seems from a bit of corrosion on the ground that connects to the back of the trim/tilt relay box.

I am going through all this in hopes that at some point in the future this is beneficial to another and saves them a bit of all the time I spent attempting to come to a resolution.

Thank you Ezeke for the help and time you provided me.

 

[Mobusapollo]

Re: Starting Issue with a '91 Evinrude 140

Im having a similar issue, can start by jumping solenoid or starter easily, correct voltage at the terminals you showed in this diagram, butthe engine wont come on with the key, I have a 1972 evinrude 50 hp do you know where the nuetral safety switch is located for my engine I would like to check it.

 

[ezeke]

Re: Starting Issue with a '91 Evinrude 140

To Mobusapollo:The neutral safety switch is inside of the remote control, activated by moving the control arm. http://www.maxrules.com/graphics/omc_pics/REMCONTBOX.jpg