1996 evinrude alarm

[38plymouth]

I have a 1996 evinrude 50 horse on a pontoon and I just got it out for the first time this year. In the past when I turned the key to the on position the little horn under the console would beep once. The alarm has worked in the past by warning me about low oil and last year it went off when the intakes plugged with weeds and the engine went into slow mode until I cleaned the weeds off and cooled the motor down. The other day the alarm didn't beep when I turned on the key. I went out onto the lake and after several starts of the motor the alarm started a continuous beep as long as the key was on or the engine was running. I wiggled the alarm under the console and it eventually stopped. I think the alarm is bad because I had plenty of oil and the engine wasn't hot and had a steady stream of water coming out and it ran great all day. I drove the boat a few miles back to the launch without any issues. I read on here about grounding out the sensor on the head to test the alarm. I looked at it last night and I have 2 wires coming out of the sensor. Do I just ground the tan one to test it? I also tried to find the part online and I can't find it on any microfiche. I guess I don't really know what the part is called.

 

[Joe Reeves]

Re: 1996 evinrude alarm

With the key in the ON position (engine NOT running), grounding the TAN wire will complete the warning horn circuit and the horn should beep constantly as long as you hold that ground.

 

[38plymouth]

Re: 1996 evinrude alarm

With the key in the ON position (engine NOT running), grounding the TAN wire will complete the warning horn circuit and the horn should beep constantly as long as you hold that ground.

If it does not beep would that indicate the horn itself is bad? It sounded different than it did in the past, almost like it was struggling to beep and it sounded weak. It almost looks like there are 2 little horns mounted side by side, should there be 2?

 

[Joe Reeves]

Re: 1996 evinrude alarm

Only one warning horn should exist. From what you've said, it sounds like the horn is failing.

Check to see that the TAN wire is connected to the slide on terminal closest to the built in black ground wire with the purple (usually purple) 12v wire on the slide on terminal furtherest away. If reversed, weird things will happen.

Check to see if you have 12v applied to the hot wire at the horn when the key is in the ON position. Ground the TAN wire directly at the horn to eliminate the possibility of a faulty TAN wire leading to the engine.

Unlikely that a faulty connection exists at the horn BUT slide the wires off the slide on terminals and back on one time to make sure corrosion isn't a factor at that point.

If the horn still sounds weak, weird, doesn't function as it did in the past after the above, I would assume it requires replacing.

 

[38plymouth]

Re: 1996 evinrude alarm

Only one warning horn should exist. From what you've said, it sounds like the horn is failing.

Check to see that the TAN wire is connected to the slide on terminal closest to the built in black ground wire with the purple (usually purple) 12v wire on the slide on terminal furtherest away. If reversed, weird things will happen.

Check to see if you have 12v applied to the hot wire at the horn when the key is in the ON position. Ground the TAN wire directly at the horn to eliminate the possibility of a faulty TAN wire leading to the engine.

Unlikely that a faulty connection exists at the horn BUT slide the wires off the slide on terminals and back on one time to make sure corrosion isn't a factor at that point.

If the horn still sounds weak, weird, doesn't function as it did in the past after the above, I would assume it requires replacing.

I was working under the console on some stereo wires. Maybe I did something when I was in there, I'll double check the wiring.

 

[38plymouth]

Re: 1996 evinrude alarm

Well I think I have a more serious problem than just the horn. I do have 2 horns under the console, one has a moulded in black wire and 2 spade connectors on it. The other has 2 moulded in wires only. I grounded the tan wire to the 1st horn and it beeped like it should. While moving the wires around every once in awhile I could hear one of the horns making a sort of faint crackling type noise. I can't find anything wrong with any of the wires or connectors though. I think the horn I tested is the one for the engine overheating because when I unhooked the wires from it grounding it didn't make it beep anymore. I tried tracing the wires for the 2nd horn and I think it's for the low oil alarm. The wires from the oil tank seem to disappear into the engine and I didn't have time to look further because it started to rain. When you turn the key to on and the horn normally beeps once is that the horn for the engine temp. or the oil alarm? That might help me narrow my search for the problem. I'm thinking it must be a bad wire or connector somewhere.

 

[Joe Reeves]

Re: 1996 evinrude alarm

There is only one warning horn which emits various warnings for the different problems one might encounter UNLESS you have dual engines.

I have no idea why you would have a second horn. The horn with the build in black ground wire and two slide on terminals is your warning horn.

(VRO Horn Warnings)
(J. Reeves)

NOTE: I retired around 1991/92. Possibly some of the later V4 engines and others may also incorporate a fuel vacuum switch that would enable a fuel restriction warning to sound as mentioned below, an unknown factor to myself.

1 - A steady constant beep = Overheating - The V/6 engines, possibly some others, have a fuel restriction warning which is also a steady constant beep.

2 - A beep every 20 or 40 seconds = oil level has dropped to 1/4 tank. (Late model engine = Every 40 seconds)

3 - A beep every other second = VRO failure, air leak in oil line, oil restriction, (anything that would result in a lack of oil being supplied to the engine).

NOTE - If the warning horn is the black plastic (overpriced) three wire type horn, the warning horn should beep once when the ignition key is turned to the ON position. If it does not, it is either faulty or someone has disconnected it (a stupid move!). At any rate, if it does not beep which indicates that the horn is non functional, find out why and do not run the engine until the problem is corrected.

 

[38plymouth]

Re: 1996 evinrude alarm

There is only one warning horn which emits various warnings for the different problems one might encounter UNLESS you have dual engines.

I have no idea why you would have a second horn. The horn with the build in black ground wire and two slide on terminals is your warning horn.

(VRO Horn Warnings)
(J. Reeves)

NOTE: I retired around 1991/92. Possibly some of the later V4 engines and others may also incorporate a fuel vacuum switch that would enable a fuel restriction warning to sound as mentioned below, an unknown factor to myself.

1 - A steady constant beep = Overheating - The V/6 engines, possibly some others, have a fuel restriction warning which is also a steady constant beep.

2 - A beep every 20 or 40 seconds = oil level has dropped to 1/4 tank. (Late model engine = Every 40 seconds)

3 - A beep every other second = VRO failure, air leak in oil line, oil restriction, (anything that would result in a lack of oil being supplied to the engine).

NOTE - If the warning horn is the black plastic (overpriced) three wire type horn, the warning horn should beep once when the ignition key is turned to the ON position. If it does not, it is either faulty or someone has disconnected it (a stupid move!). At any rate, if it does not beep which indicates that the horn is non functional, find out why and do not run the engine until the problem is corrected.

The weather is so crappy out that I can't go out to work on it right now. I forgot to mention, after testing the horn and getting the thing to beep I tested it again after looking around at other things and then it didn't beep anymore. I'm also thinking the 2 wire alarm goes to the oil tank. I'm not positive yet but the wires appear to go that direction. I didn't test that one yet because I couldn't finish tracing the wires, they seem to disappear into the engine.

 

[38plymouth]

Re: 1996 evinrude alarm

I was able to remove the horn and test it I think the horn is bad. It will work normal sometimes and make crackling noises sometimes. If I hit it it starts working again. This is the 3 wire horn, I have no idea why there is a 2 wire horn in there as well. I'm waiting for a call back from the dealer to see if they have one, it stinks the closest dealer is almost an hour away.

 

[38plymouth]

Re: 1996 evinrude alarm

The evinrude dealer called me back and he said that they don't have the old style 3 wire horns anymore. He has a 2 wire horn that he said should work but I need to change the wire connectors which should be no big deal. He says th 2 wire will beep once when I turn on the key and work just like the 3 wire. If thats the case why couldn't I go to radio shack and buy a piezo for a couple of dollars and use that? I wouldn't mind saving some cash and not driving an hour each way to the marina.

 

[Joe Reeves]

Re: 1996 evinrude alarm

The evinrude dealer called me back and he said that they don't have the old style 3 wire horns anymore. He has a 2 wire horn that he said should work but I need to change the wire connectors which should be no big deal. He says th 2 wire will beep once when I turn on the key and work just like the 3 wire. If thats the case why couldn't I go to radio shack and buy a piezo for a couple of dollars and use that? I wouldn't mind saving some cash and not driving an hour each way to the marina.

The function that causes the horn to beep once when the key is turned to the ON position is built within the horn (hence that ground wire). I retired some time back so I'm not aware of any improved two (2) wire horn that will do the same "Beep Once When Turned On" function.

Are any of you other members aware of a new improved two (2) wire warning horn that will indeed "Beep" when the key is turned to the "On" posiiton? Part Number?

 

[38plymouth]

Re: 1996 evinrude alarm

The function that causes the horn to beep once when the key is turned to the ON position is built within the horn (hence that ground wire). I retired some time back so I'm not aware of any improved two (2) wire horn that will do the same "Beep Once When Turned On" function.

Are any of you other members aware of a new improved two (2) wire warning horn that will indeed "Beep" when the key is turned to the "On" posiiton? Part Number?

I called a 2nd much larger marina and they think I should only have a single 2 wire horn. They don't know why I would have a 2 wire and a 3 wire. They said they would research it more and call me back. They did say pontoon boat companies do strange things when they build them.

 

[38plymouth]

Re: 1996 evinrude alarm

I looked around at the wiring some more and did research online. I think my boat has the OMC system check on it but without the lights in the tach. The 2 wire horn wires go to the sensor on the head and then those wires go into some kind of control box mounted on the side of the engine. The wires to the 3 wire horn go into the control box. I got lucky and found a part number online that looks like the 3 wire horn. 0176458 is the warning horn and cable and 058992 appears to be just the horn. I can't believe the marinas don't know about the 3 wire horns and why the system has 2 horns.

 

[Joe Reeves]

Re: 1996 evinrude alarm

I got lucky and found a part number online that looks like the 3 wire horn. 0176458 is the warning horn and cable and 0585992 appears to be just the horn. I can't believe the marinas don't know about the 3 wire horns and why the system has 2 horns.

I retired before your engine was manufactured and franky I don't understand the two horn setup either (reasoning for asking other members in), BUT I would think that the marinas, if they are either a Evinrude or Johnson dealership, would have knowledge of it. If not a dealership, then I can understand their lack of knowledge.

On your latest post you listed just the horn as 058992, I changed it to the proper number here 0585992. No big deal, just wanted to keep things straight.

Horn number 0176458 supersedes up to 0176794. It's description states "Kit Horn Driver" and had a list price in 2010 of approximately $150.00.

Horn number 583891 supersedes up to the number you found of 585992. It's description states "Kit Horn Replace" and had a list price in 2010 of aproximately $74.13.

Frankly I feel that both prices are outrageous. Being retired, my price book only goes up to 2010 so I have no idea what those items are selling for at the present time. If it were me.... I'd be choosing the lower price kit.

 

[38plymouth]

Re: 1996 evinrude alarm

I got my issue fixed and just wanted to update this thread in case anyone else runs into the same problem. Joe Reeves was 100% right that I should not have 2 warning horns but for some strange reason I do. I also bought OMC part number 176458brandnew on ebay for $31 shipped (great deal), it's a 3 wire horn with harness. If I bought a 2 wire horn it would not have worked on my boat, this 3 wire horn is specifically made for 1996 and up evinrude engines with system check but WITHOUT the system check lights or tach with lights in it. My system check only uses the horn and this horn has something inside of it that makes it beep when the key is turned on.