How do I remove kill switch from Mercury Commander 4000 control

[iammarcuse]

I have a 2004 Ranger with a Commander 4000 shifter. Everything on these boats is enclosed. Just want to remove the kill switch to test it as i suspect it is faulty. I cannot seem to figure out how to get the control off. 3 bolts have nuts on them which i cannot access and 3 bolts screw into the backing plate. But because there is no way to reach behind i am going to end up loosing the nuts. Or can i leave these 3. At a bit of a loss. Anyone know?

 

[iammarcuse]

Maybe the kill switch just pops out with a screw driver? I just don'e want to break it

Here is the diagram
https://ww2-secure.justanswer.com/uploads/HavasuBoatman/2012-05-26_171959_scan0110.jpg

 

[GA_Boater]

Don't try to pry the switch or it will break.

Item #12 is the kill switch retainer. May a little messy with the 3 screws, nuts and washers.

 

[iammarcuse]

Thanks for pointing that out. I will need to figure out how to get into that enclosed gunwale.

 

[GA_Boater]

What is the kill switch doing......or not doing?

The switch is tied into the ignition wiring using two bullet connectors and they live somewhere behind the side panel, probably next to the three nuts. Bullet connectors can loosen and can corrode.

 

[iammarcuse]

It is an 2004 225 Optimax on the Ranger. The motor will cut out completely while underway.. Sometimes 10 times a day, sometimes not at all. It literally dies dies completely like you turned off the key or hit the kill switch. It has been to the dealer 5 or 6 times. They replaced the entire computer for $5000 and nothing changed. They have done new lift pumps, fuels lines and filters and screwed around endlessly at $120/hour. They say that there is nothing wrong with it, but they are not the ones driving it in the middle of the lake when it quits.

Because of the way it shuts down instantly I doubt it is fuel. Because the power is still live to the helm gauges i doubt it is the key switch. Often it will take a few seconds to get it to fire up again. You turn the key and nothing happens. After a few seconds it fires up.

If you hit the kill switch while underway you can replicate the problem exactly. That is why I am looking into this. There are no bullet connectors. I traced the wires from the kills switch (2 black) and they go forward to the helm and then into the harness which eventually leads to the computer on the motor.

If you have some ideas i am all ears.

 

[iammarcuse]

I realize there must be bullet connectors somewhere but the Ranger has a fiberglass innerliner and all the wiring is run in behind. After I got the control off, the hole was only 4" and I was not able to reach any bullets.

My understanding is that the kill switch closes a ground circuit killing the motor. I wouldn't think a bad connector would be able to do that.

 

[harringtondav]

I'd try removing one screw and see if the nut is retained. If so remove the rest and pull the control. If not look again at the construction. Hard to believe the builder assembled the cables and wiring in the top mold. Last ditch, let the nuts drop and use SS wood or sheet metal screws to assemble.

 

[harringtondav]

PS. My 3000 dead man kill switch grounds/opens the run circuit, but will allow crank and run as long as the key is held in start. Since you mentioned no crank, I suspect your key switch may be faulty, especially if your key chain is heavy. Your neutral switch opens the crank circuit, don't know about the run circuit.