28hp evinrude only runs with black/yellow wire removed

[Mthirsch14]

After replacing stator, coil packs, and power pack I realized my no spark problem is in the kill switch (black/yellow wire going to the coil pack). I removed the wire and it runs greats but won’t shut off, I have to put my hand over the carb. The problem is this boat never had a kill switch. It only has a knob under the key that turns with some force but doesn’t unscrew or do anything. How can I fix this problem and turn the engine off? Do I need to open up the console and check inside for clues? Thanks for the help this group has helped me tremendously so far

 

[urbanredneck]

Open up the gear selector box In the photo. If I'm thinking of the proper thing, what you need is to ground it out.
Had exact same issue with one of mine. Killswitch would randomly engage and keep engine from starting. I took apart the shift box and grounded that switch to the body. Problem Solved.

This is just a suggestion. You didn't include any model or year number for your motor so it could be a bit different. But again, the symptom sound identical and since you've already cut the wires, it's worth a shot. If you're super concerned or paranoid about it, put a fusible Link in between the wiring before grounded. Let me know how it goes

 

[Mthirsch14]

It’s a 1996 evinrude 28spl e28esledr. I opened up the box. Do you mean you grounded the key switch to the body? I’m not seeing the black/yellow kill switch wire here either

 

[Mthirsch14]

I see the yellow black wire now. Ground that one?

 

[GA_Boater]

If you ground the Y/B wire the motor won't start. Look at the drawing below and with the key off the two Ms should have continuity. One M is connected to ground. You may have a bad key switch or a broken wire between the switch and through the harness to the motor.

 

[urbanredneck]

I don't recall the wiring with one I fixed. But, if it never was equipped with an " deadmans switch", like a little cord and clip one would attach to themselves on a jetkski in the event they fall off, cord disengages and kills the motor. It would be on the outside of your gear selector box, a black button looking thing. That would be the kill switch. If yours isn't equipped with that, I'm hesitant on giving you improper info. Let me know if you see that black plug on the side of the box

 

[Mthirsch14]

I see the yellow black wire now. Ground that one?

 

[Mthirsch14]

I have continuity between the two Ms with the key off. Does this mean the switch is good and there is a ground somewhere in the harness?

 

[GA_Boater]

Look at that diagram. The ground is supplied inside the box. Find the screw with the black wires on it and make sure one goes to the kill switch and one to the M terminal on the key switch. The ground is supplied from the battery through the harness.

BTW - Knob under the key is for throttle tension.

 

[Mthirsch14]

I’ve looked at the diagram and there is no kill switch and no screw with black wires. The black/white and black/yellow wires come in the front with the rest, underneath that plastic piece and go straight to the Ms In the ignition switch.

 

[Mthirsch14]

Is this picture on the side of the box referring to a kill switch?

 

[Fed]

Do you have continuity between the two Ms when the key is in the on position?

The black yellow is grounded to stop the motor, these are not like a car ignition.

 

[F_R]

Yes, that is referring to a kill switch----the one that shuts the motor off if you get tossed overboard. Motor will not run if lanyard is yanked off (and black/yellow wire intact)

 

[Fed]

FWIW the kill switch is just a clip that goes on the keyswitch, it physically turns the key to off when it's pulled.

 

[Mthirsch14]

Yes there is continuity between the two Ms when the key is off and no continuity when the key is on. Does this sound correct? It’s confusing because it worked fine, I would turn the key on to start it and turn the key off to stop it and never had an actual kill switch or lanyard and then one day I had no spark until I pulled the BY wire from the power pack.

 

[Mthirsch14]

Cause the key switch itself be bad?

 

[racerone]

There is a short to ground somewhere in the wiring I would say.-----Can be easy to find or it can be difficult to find.

 

[Fed]

Yes there is continuity between the two Ms when the key is off and no continuity when the key is on. Does this sound correct?

That is correct & your keyswitch is OK.

As racerone said above you have a short to ground on the black yellow somewhere between the powerpack and the keyswitch.
I'm assuming you disconnected the black yellow at the powerpack to get spark?

It shouldn't be hard to find with a meter, disconnect the big plug to see if it's on the motor side or the controller side.
It could also be in the big plug itself I suppose.
More likely to be at a connection point rather than in the looms but look for chaffing at any obvious places.

 

[Joe Reeves]

In case you haven't solved the problem as of yet.........

In your very first post (#1), you state, among other things:

1 - I realized my no spark problem is in the kill switch (black/yellow wire).
2 - I removed the wire and it runs greats but won’t shut off.
3 - The problem is this boat never had a kill switch.
4 - It only has a knob under the key that turns with some force

1 - I assume that your engine had NO spark with the "black/yellow" wire connected to the kill switch.

2 - You removed the "black/yellow" wire from where... the Kill Switch, the ignition switch, the engine at the p/pack? If initially at the kill switch or ignition switch... and that had spark returned... then nothing is wrong with that "black/yellow wire from that point back to the p/pack.

3 - Never had a kill switch? You installed a new control box, installed a kill switch in your present box, what?

4 - That knob is a friction knob that applies pressure to the throttle handle yoke so that you can set the needed pressure to keep the handle from moving due to vibration, but still allow you to move the throttle freely.

 

[Mthirsch14]

The black yellow wire I removed is from the connector going to the power pack, and I have spark but the engine won’t shut off. The black yellow wire going into the shift box just goes straight to the key ignition, it does not go to a kill switch like the diagrams show. There is no kill switch or screw with black wires inside the box. Like you guys said I think there is a short somewhere in the cluster of extra harness wires and plugs that have been zipped tied together since I bought the boat. I’m going to go through it soon and get let you know what I find