1996 90HP Evinrude blowing fuse and ignition

[OBW414]

I just purchased this boat with a 1996 Evinrude 90HP. The motor has great compression started going over the motor and noticed a blown fuse. Replaced fuse then replaced ignition. Started motor up ran for a bit everything working well. Ran a few more times through the week all good. Wanted to run one last time before taking out all worked well shut off turned back on shut off. Went to start at ramp turned over then nothing smelled electrical smell. Took home fuse was melted up replaced and nothing. Brand new ignition is fried again. So looks this may be an ongoing issue. Before I replace with another new ignition and risk blowing it is there anything you can recommend that may be wrong or could it have been just a faulty new ignition I put in and undersized fuse.

 

[emdsapmgr]

Re: 1996 90HP Evinrude blowing fuse and ignition

OMC made two distinctly different 90 hp engines in 1996. A looper version and a crossflow version. Pls identify which type you have or post the model number. They both take the same fuse. What amp fuse did you install?

 

[OBW414]

Re: 1996 90HP Evinrude blowing fuse and ignition

OMC made two distinctly different 90 hp engines in 1996. A looper version and a crossflow version. Pls identify which type you have or post the model number. They both take the same fuse. What amp fuse did you install?

How do I tell what one it is? I will look for model number also. I had a 20AMP fuse and was pissed it fried the new ignition.

 

[boobie]

Re: 1996 90HP Evinrude blowing fuse and ignition

You may want to figure out what mtr you have and then look at the wiring diagrams in the top secrect files at the beginning of this forum and then trace down what this fuse feeds.

 

[emdsapmgr]

Re: 1996 90HP Evinrude blowing fuse and ignition

The model number will identify the engine. It's on a sticky label, usually located on the swivel bracket of the engine. It should be in plain sight. You also can compare the engine parts to the original factory parts lists on the Bombardier website: epc.brp.com. Those parts diagrams are segmented by that model number. The wire harness on that engine is a 20 amp fuse. Normally that fuse will blow-long before there is any damage to the wire harness. What part of the wiring harness is damaged? The ignition side or the chaging side? Was the combination regulator/rectifier damaged? Most of the wiring damage I've experienced relates to a damaged/shorted rectfier regulator. Many of these fail (smoke/catch on fire) if the engine leads to the battery terminals are loose (or not making proper contact) and the charging current has no place to go.

 

[OBW414]

Re: 1996 90HP Evinrude blowing fuse and ignition

The model number will identify the engine. It's on a sticky label, usually located on the swivel bracket of the engine. It should be in plain sight. You also can compare the engine parts to the original factory parts lists on the Bombardier website: epc.brp.com. Those parts diagrams are segmented by that model number. The wire harness on that engine is a 20 amp fuse. Normally that fuse will blow-long before there is any damage to the wire harness. What part of the wiring harness is damaged? The ignition side or the chaging side? Was the combination regulator/rectifier damaged? Most of the wiring damage I've experienced relates to a damaged/shorted rectfier regulator. Many of these fail (smoke/catch on fire) if the engine leads to the battery terminals are loose (or not making proper contact) and the charging current has no place to go.

I haven't seen any burned wires. The actual ignition switch just stopped working. the fuse and switch were bad when got the boat. I replaced both then worked fine for a bit. The fuse smoked and then the new switch bad cant see any melted wires or anything. The choke for switch engages but turn key and get nothing. Hooked in another switch and starts up again. Don't want to fry another new switch and not sure what would cause this. If could find out somethings that may cause this will start chasing them down. I asked a basic outboard mechanic around here and he said probably just got a faulty ignition but I'm not so sure of that. Any ideas much appreciated boat is at shop so don't have access till tomorrow.

 

[emdsapmgr]

Re: 1996 90HP Evinrude blowing fuse and ignition

On offbeat comment. Maybe the key switch is accumulating water and shorting out. All OMC key switches have an up and a down orientation. They must be mounted correctly-insuring the moisture drain hole in the switch is mounted down. That's why they have that shaved side on the barrel of the key switch. To insure it gets mounted correctly. If yours is mounted upside down, rainwater can accumlate in the bottom of the switch, and can cause currrent shorts, wiring issues.

 

[OBW414]

Re: 1996 90HP Evinrude blowing fuse and ignition

On offbeat comment. Maybe the key switch is accumulating water and shorting out. All OMC key switches have an up and a down orientation. They must be mounted correctly-insuring the moisture drain hole in the switch is mounted down. That's why they have that shaved side on the barrel of the key switch. To insure it gets mounted correctly. If yours is mounted upside down, rainwater can accumlate in the bottom of the switch, and can cause currrent shorts, wiring issues.

I do know about this and they were both mounted correctly. The old one anything could have happened as it was old. The new one was mounted correctly and only 2 days old. This is what leads me to think it has happened before. 2 fried fuses and 2 bad ignitions.

 

[emdsapmgr]

Re: 1996 90HP Evinrude blowing fuse and ignition

An odd problem for sure... I'd be inclined to do some wiring checking. There are two distinct halves to the wiring harness on that engine, even though they all seem intertwined. The starting/charging side and the ignition side. Most of the coils under the flywheel make power to run the ignition system. The two remaining coils make current to charge the battery/run the trim system. The ignition side generates extremely high voltages, the charging side generates high current (9 amps at WOT.) Would be interesting to take a colored factory wiring diagram and check for any melted wires, or apparent burn marks at any connection points or grounds. You might be able to determine which system is the problem from the wiring colors that appear distressed. You may need to pull the flywheel to check the stator and visually inspect the combination rectifier/regulator.

 

[OBW414]

Re: 1996 90HP Evinrude blowing fuse and ignition

An odd problem for sure... I'd be inclined to do some wiring checking. There are two distinct halves to the wiring harness on that engine, even though they all seem intertwined. The starting/charging side and the ignition side. Most of the coils under the flywheel make power to run the ignition system. The two remaining coils make current to charge the battery/run the trim system. The ignition side generates extremely high voltages, the charging side generates high current (9 amps at WOT.) Would be interesting to take a colored factory wiring diagram and check for any melted wires, or apparent burn marks at any connection points or grounds. You might be able to determine which system is the problem from the wiring colors that appear distressed. You may need to pull the flywheel to check the stator and visually inspect the combination rectifier/regulator.

Thanks for this I will start digging through the wires and connections to see what I can come up with.

 

[OBW414]

Re: 1996 90HP Evinrude blowing fuse and ignition

The model number will identify the engine. It's on a sticky label, usually located on the swivel bracket of the engine. It should be in plain sight. You also can compare the engine parts to the original factory parts lists on the Bombardier website: epc.brp.com. Those parts diagrams are segmented by that model number. The wire harness on that engine is a 20 amp fuse. Normally that fuse will blow-long before there is any damage to the wire harness. What part of the wiring harness is damaged? The ignition side or the chaging side? Was the combination regulator/rectifier damaged? Most of the wiring damage I've experienced relates to a damaged/shorted rectfier regulator. Many of these fail (smoke/catch on fire) if the engine leads to the battery terminals are loose (or not making proper contact) and the charging current has no place to go.

model # is E90TLEDA 1996
any help appreciated

 

[emdsapmgr]

Re: 1996 90HP Evinrude blowing fuse and ignition

It's a crossflow.