AHHHH HELP !!! ready to shoot it.....

doc_ff

Cadet
Joined
Apr 24, 2009
Messages
7
----Disclamer--- You are about to read the brain dump of a VERY frustrated man who has dealt with schiesty mechanics, and retards.. so I have come to the people that actually know something. I am not a smart man, but I know what wrong is... Nor am I a mechanic of any sort.

1986 Fabuglas Tempest 16' with a Merc 115 S/N 5922301 ( i think it is an '82)

Ok, here goes. Bought our first boat about 3 weeks ago. $1500, boat, motor, trailer. Rough on the eyes, but was repeatedly assured that everything worked.( alot had to be replaced...) Engine ran in-front of my eyes, sounded like silk, smooth. Get it home, can't get it to start. Charged the battery, just a clicking sound. Ignition system is cracked, so replaced it, one wire at a time almost "color by numbers" matching each letter on old ignition to new one and wires...etc. No dice. Nada. Replaced the starter solenoid after being told by a " certified mechanic " to just use a screwdriver to start it everytime....:mad:... once again took digital pics of everything to remember what went where... and after replacing it.. no click, no juice, nothing on the multi-meter. After checking the ohms on the old solenoid ( 3-3.9 ohms ) the new one has none. had an "s" and an "i" on the smaller poles. Called the local parts guy and he says i have the wrong one... drive an hour to get the new solenoid. hook it up ... 2 red leads on the inside, yellow with red stripe on rear small pole, big yellow lead on outside and black ground wire on the front small pole. It fires up, and runs. I notice that the ignition is smoking, the wiring harness is smoking, so I turn the key to the "off" position and and remove the key. Engine is still running, remove the battery and pull the spark plugs. it dies.
The ground wire is almost completely melted at the solenoid, and it is showing some melting at the controls. Tried to get it to start or run by putting the ground wire on the solenoid mounting screw. No dice. Makes sense to me, since there is no continuity to the circuit.

What would cause the ground wire to get that hot?
Why can't I open the circuit to kill the engine?
What is the proper wiring for the solenoid, and does it matter on a universal model?
and where is the water from "ear muffs" at the hose supposed to come out?

Any and all help will be greatly appreciated, since I am trying to get the boat on the water by tomorrow, or sunday. I have been working on this for almost 3 weeks... The local mechanic is saying $165 an hour for a minimum of 4 hours in order to tell me what is wrong...... Arghhhhhh:confused:
Help?
 

BaileysBoat

Senior Chief Petty Officer
Joined
Sep 29, 2008
Messages
716
Re: AHHHH HELP !!! ready to shoot it.....

So, $1500 invested. Boat is an 86. On a trailer. Project for somebody.

Sell the the whole thing for what you paid, and start over.
 

cannonford57

Petty Officer 1st Class
Joined
Mar 5, 2008
Messages
353
Re: AHHHH HELP !!! ready to shoot it.....

my gosh i'll do it for 150.00 an hr.(even though my shop rate is 65.00)dang did i say that outloud?
 

boatguya1

Chief Petty Officer
Joined
Apr 24, 2009
Messages
444
Re: AHHHH HELP !!! ready to shoot it.....

Not to up on older merc stuff but I'll try. Most outboards of semi recent design do not shut off by opening a circuit. They shut of by connecting a ground circuit to the power pack/ign module/CDI.

Sounds like you have a key on positive 12v hooked to ground somewhere thus letting the magic smoke out of the wires.

The ground/shut off circuit is open not allowing you to shut off motor. If this happens again hit the choke while idling should kill it. Should be black wire with yellow stripe.

If this motor has a distributor none of the above is correct.

James
 

CharlieB

Vice Admiral
Joined
Apr 10, 2007
Messages
5,617
Re: AHHHH HELP !!! ready to shoot it.....

I'm afraid that Sunday is already here, and you don't have a factory service manual (yet).

Oooops! Having Fridays off really throws of my judgement, I tend to forget that Saturday is here!

You really need the factory service manual with the correct wiring diagram for your motor.

The black wire with/Yellow stripe is the 'ground-to-kill' from the ignition module to the ignition switch and lanyard, either SHOULD ground and kill the motor.

Yellow with/red stripe is the starter relay/solenoid trigger from the ignition switch thru the neutral safety switch in the control box, to the solenoid.

Smoking wires is a sign that something is crossed.

The stator has 2 yellow wires that screw into seperate terminals on the rectifier, which has one larger red wire that connects to the battery positive cablel on the starter relay, the other side of the starter relay connects to the starter. A grey wire on the rectifier goes to the tach.

Once running on the hose most of the water should exit thru the prop, a 'P' hose should have a steady stream of water from the Port side of the lower engine cowling to show you that the water pump is working.

DO NOT rev the motor while on the hose, it is VERY EASY to over-rev the motor and cause significant internal damage.
 
Last edited:

doc_ff

Cadet
Joined
Apr 24, 2009
Messages
7
Update

Update

First off,
JB, sorry i did not see your instructions prior to my post. I am formally appologizing to everyone.

Thanks for the ideas... something is still wrong. Wiring was melted all the way to the run/stop switch at the controls. Pulled the entire wiring harness apart to inspect every inch of wiring. Had either a brain fart, or a terrific idea, so I completely replaced and isolated the ground that had been melted. Still gets hot.

Service manual will be here by the end of next week.
Boat is going to mechanic's on monday.
any more ideas? How much should a resonable man expect to pay for this to be repaired? Is it possible it is a simple fix on something I am overlooking?

Thanks again for all your time and help
 

Plainsman

Rear Admiral
Joined
Apr 2, 2006
Messages
4,062
Re: AHHHH HELP !!! ready to shoot it.....

I'd wait for the manual to arrive and see if you can fix it yourself and /or with the help here. It'll save you money and you'll be learning a lot from this experience.
 

doc_ff

Cadet
Joined
Apr 24, 2009
Messages
7
Update

Update

Wrong ignition switch. Just had to order one from South Carolina... thanks for your help everybody.
( you can close this now if ya'll want..)
 
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