92 Four Winns 5.0L OMC

[mbrown0772]

I just bought a 92 Four Winns with 5.0 liter OMC. We took it out on the water for the 1st time and I have a few problems.


1.The boat will not shift into neutral after I get it into forward or reverse. I worked fine on the muffs. Could it be something as simple as a cable adjustment or something more serious?

2. The engine start up and runs fine. I eased out of the dock and got into open water and opened her up and she ran great and planed out and than about 30 seconds later she started missing and died. It only does this after I get her opened up and about 30 seconds to 1 minute later she misses, if i back off quick enough she stays running. Could this be a bad fuel issue. The fuel in the boat was older but the owner was not sure if it was from last year or if it was from this season. The tank was full. If it dies it fires back up and runs smoothly at idle and runs fine in gear just wont stay running at top end. I am thinking this is not a fuel issue or it would be all the time.

Any advice would be greatly appreciated.

 

[mcleaves]

Re: 92 Four Winns 5.0L OMC

Is this carbed or injected?

 

[HT32BSX115]

Re: 92 Four Winns 5.0L OMC

Howdy,

Welcome Aboard!

More info might help......like the model number for example: 502APLAMH 1992
You can find parts info at http://epc.brp.com

In 1992 OMC offered 2 styles of vertical drive. Cone clutch and Dog-Clutch......it does appear that they ONLY offered the Dog-clutch behind the 5.0L engine........ (it also appears that none of them were injected.......they either had a 2v or a 4v carb)

So if it's a Dog-clutch drive, it sounds a lot like a problem with either the ESA, shift actuator, associated switches, lower shift cable or wiring.

You might also do a little reading to help you understand how your drive works. http://www.hastings.org/~stuart/cobra/

If you want to be able to fix it yourself, you NEED to read the above article and get your hands on an OMC (OEM) service manual. You can usually find them on EBAY. It needs to be the correct one for your model engine and drive.

Regards,


Rick

 

[mbrown0772]

Re: 92 Four Winns 5.0L OMC

Thanks Rick. Great article. Wish cI would have read that before I purchased this boat. But as it is, I now have it and will probably frequent this forum often while I am figuring this thing out.

Any other advice would be greatly appreciated.

 

[mbrown0772]

Re: 92 Four Winns 5.0L OMC

Any ideas about it stalling after I get to cruising speed?

 

[a70eliminator]

Re: 92 Four Winns 5.0L OMC

Stalling out during higher speed operation is usually related to fuel delivery.

 

[mbrown0772]

Re: 92 Four Winns 5.0L OMC

Upon further investigation of the shifting mechanism I found a disconnected wire that goes to a switch. I have reconnected it and attaching a picture. Could this be the real problem with my shifting? The blue wire harness on the switch is what was disconnected.

Sorry for the lack of technical terms. I am pretty good at most repairs and am mechanically inclined but the marine engine terminology is still foreign to me. Might even get a few doodads and thingamajiggy's out of me til I get the terminology down. :facepalm:

One other item. Half of my gauges dont work. The trim, fuel, RPM, and MPH are not working. I checked trim and fuel gauges and they are receiving power. Do they just need to be replaced or could it be something more?

Thanks for all your help. I have already learned a lot in this forum.

 

[HT32BSX115]

Re: 92 Four Winns 5.0L OMC

Upon further investigation of the shifting mechanism I found a disconnected wire that goes to a switch. I have reconnected it and attaching a picture. Could this be the real problem with my shifting? The blue wire harness on the switch is what was disconnected.

It could be the problem.

One other item. Half of my gauges dont work. The trim, fuel, RPM, and MPH are not working. I checked trim and fuel gauges and they are receiving power. Do they just need to be replaced or could it be something more?

The gages don't necessarily need to be replaced.

A LOT of times boat electrical problems are simply a poor/corroded/loose ground connection either at the block, battery, or up at the instrument panel.



Also, If you look at the point where the lower shift cable (red) connects to the shift actuator, you'll notice that the shift actuator will move one way or the other (depending on which gear, FWD/REV, you're shifting out of)

It will also move a little when you shift INTO gear but because it takes (or should take) far less force going into gear, the actuator shouldn't move much (certainly not enough to actuate the switch)


When running in gear (in idle.....IN THE WATER), it will take a LOT more force to shift out of gear due to the torque on the prop turning and because of the under-cut shift dogs. (like Hastings indicates in his article)

When the shift actuator moves far enough, and activates the ESA (electronic shift assist module), the engine "stumbles" briefly reducing the torque on the dogs enough for the out-of-gear pressure you're holding and they separate placing the drive in neutral.

If the ESA is not activating, you will not easily get it out of gear and probably not at all.

It could be the switch, the module itself, or adjustment of the assoc cables etc....

 

[mbrown0772]

Re: 92 Four Winns 5.0L OMC

Thanks, I will look into replacing the ESA. Hate to get back out on the water and continue having the same problem. Anything special I need to know about switching out that assembly?

 

[HT32BSX115]

Re: 92 Four Winns 5.0L OMC

Thanks, I will look into replacing the ESA. Hate to get back out on the water and continue having the same problem. Anything special I need to know about switching out that assembly?

The ESA module is an epoxy potted electronic device. you just unplug the old one and plug in the "new" one. Problems with them are not always a failed ESA module though.

Knowing how the system works helps a LOT when troubleshooting it. You really need an OMC service manual (not an aftermarket manual) if you're going to do it yourself.

 

[mbrown0772]

Re: 92 Four Winns 5.0L OMC

Going to order a OMC Service Manual off EBay. I am starting to see why I got such a good deal on this boat. Everything needs repaired. LOL

 

[HT32BSX115]

Re: 92 Four Winns 5.0L OMC

Going to order a OMC Service Manual off EBay. I am starting to see why I got such a good deal on this boat. Everything needs repaired. LOL

Welcome to the "club"

 

[mcleaves]

Re: 92 Four Winns 5.0L OMC

Going to order a OMC Service Manual off EBay. I am starting to see why I got such a good deal on this boat. Everything needs repaired. LOL

All boats cost the same. You either pay up front or over time

 

[mbrown0772]

Re: 92 Four Winns 5.0L OMC

Alright I am back to square 1 here. I talked to a boat mechanic about the problem I am having with the boat not going into Neutral once I have it in the water. I was under the impression the ESA was probably bad. I was going to buy a new one but the mechanic told me to start the boat up on the muffs and than trip the little switch that sends the signal to the ESA. He said if I trip that manually and the motor does not stall than that would tell me my problem. I did that and nothing happened, the motor just ran normal with out even a hesistation. I did not think you could trouble shoot the problem I am having without the boat being in the water with prop load. Is this the case? I am just getting more confused and aggravated that I cant get my boat out on the water and have some fun. Please help.

 

[HT32BSX115]

Re: 92 Four Winns 5.0L OMC

The ESA could be bad. You can test it by simply moving the shift actuator. That could tell you that the ESA is defective or it could indicate the wiring or switch is "bad".

The water test is a "whole" system test. It tells you if the cable is adjusted right and is not binding etc. You can test the esa anytime the engine is running by pushing the microswitch.

 

[mbrown0772]

Re: 92 Four Winns 5.0L OMC

The ESA could be bad. You can test it by simply moving the shift actuator. That could tell you that the ESA is defective or it could indicate the wiring or switch is "bad".

Please give me some more information. I am a NOOB when it comes to boat motor and drive terminology. What is the shift actuator? What will it do when I move it if it is bad. I am starting to see that the more I think I figure out about this D*mn boat the less I really do know. All the vehicle engine and transmission knowledge is worthless when you start talking about this boat crap. Sorry starting to get peeved. LOL

 

[bruceb58]

Re: 92 Four Winns 5.0L OMC

If you tripped the switch and the engine didn't stumble, either:

1) The ESA is bad.
2) The switch is bad
3) The output of the ESA is not connected to the negative side of the coil
4) The ESA is not getting power.

 

[mbrown0772]

Re: 92 Four Winns 5.0L OMC

If you tripped the switch and the engine didn't stumble, either:

1) The ESA is bad.
2) The switch is bad
3) The output of the ESA is not connected to the negative side of the coil
4) The ESA is not getting power.

Thanks. I can trouble shoot these items. Let you know what I find out.

 

[HT32BSX115]

Re: 92 Four Winns 5.0L OMC

Thanks. I can trouble shoot these items. Let you know what I find out.

having a service manual will give you the color coding of which wires go where.

if the ESA is really "bad", you should be able to find one online ( I think you can even buy one right here on boats)


Your other electrical problems might indicate a loose or corroded connection someplace or in several places (hot or ground)

 

[PatBurke]

Re: 92 Four Winns 5.0L OMC

Check your anti-syphon valve right above the gas tank. My 93 FW sundowner OMC 5.0 Cobra had the same symptoms at speed. Was an easy fix for me.