28hp evinrude only runs with black/yellow wire removed

[Joe Reeves]

If with the black/yellow wire re-connected to the powerpack... and with that same black/yellow wire disconnected from the ignition switch... you find that there is NO spark.............

Then yes, there could possibly be a black/yellow wire conductance type short in the wiring harness between the engine and the control box... BUT... it is normally/usually a short within the main RED electrical plug. In which case, cut the black/yellow wires at the front & back of that RED plug and rig a jumper wire with either "knife" or "plug in" connections to bypass that RED plug.

 

[Mthirsch14]

Correct, no spark when I plug it back into the power pack and unplug from the ignition. I guess in my case it’s a black plug not a red one? It’s about a foot in front of the shift box. And here is a pic of the extra wires where I suspect something isn’t right.

 

[Mthirsch14]

I may have found the problem lol. What would be best to spray in here to clean it out

 

[Mthirsch14]

I cleaned it out good with electronic cleaner but still not luck. Do these wires pull out the plastic black connector the same as the rubber connections? Would like to try and bypass the plug and see if they helps. I’m running out of ideas

 

[Joe Reeves]

I cleaned it out good with electronic cleaner but still not luck. Do these wires pull out the plastic black connector the same as the rubber connections? Would like to try and bypass the plug and see if they helps. I’m running out of ideas

I'm not familiar with the Black Plastic connector... just the large rubber Red one. Unlikely you have a short within that plastic one though.

In what you're faced with, if it were me... In rethinking the possible conductance type short, I'd run a separate wire from that powerpack black/yellow wire connector clear up to the "M" terminal of the ignition switch.

 

[Mthirsch14]

That’s a good idea. It beats unwrapping 4 feet of wires to look for any damage. I will try that tomorrow

 

[Mthirsch14]

IT WORKED! I ran a separate wire from the powerpack to the ignition and everything works fine. Would it be best to run a new wire along the harness and into the ignition or should I unwrap the whole harness and look for damage in the original ?

 

[Fed]

Looking at the brp website those pins, sockets and housings are all listed as different part numbers which I guess means they are completely replaceable, I'd be repairing it back to original.

Needless to say I think the problem is still at the plug/socket, maybe a better clean up is needed.

 

[Joe Reeves]

IT WORKED! I ran a separate wire from the powerpack to the ignition and everything works fine. Would it be best to run a new wire along the harness and into the ignition or should I unwrap the whole harness and look for damage in the original ?

If it were me.... I'd simply run the new wire along the harness (tape/tie straps, whatever). Taking that harness apart is a chore in my opinion. That will need to be your judgement call. I wish you luck.

 

[Mthirsch14]

Thanks for the help everybody! I tried cleaning the plug out again but no luck. I ended up running a new wire nice and neat but for now I just have the wire shoved into the blue connector at the coil pack end. I can’t find that small metal female connector online anywhere. All I see is the male pin. Anyone know where I can get one to connect it the right way?

 

[heypawpaw]

Maybe disconnect the plug and check continuity from pin back to source then female connector to source to it's source to determine which side is bad. Seeing the corrosion on the plug leads me to suspect it's probably the wire/pin connection inside the plug or the socket/wire connection inside the plug. If so and you cant find parts to repair your plug you can just bypass the plug on that wire with separate connector using original wires. I don't know just my thoughts.