kill circuit

[mjharley]

I have a 1989 Johnson 225 that will only crank with the main harness or the blk/yw wires disconnected . ..The stator was replaced after a meltdown and since then I have had this problem. The stator is a used part. The ignition switch has been replaced.. All troubleshooting I have found points toward the wiring harness. I can not find any problems with. Does anyone have any ideas..Motor runs good.Thx for any help..I have run out of ideas.

 

[Faztbullet]

Once it cranks if you reconnect harness does it kill it????

 

[mjharley]

Yes it does..

 

[F_R]

Obviously, there is a fault in the forward harness or remote control. There is a leakage from the black/yellow wire to ground somewhere. By design, grounding that wire is how you stop the engine.

 

[mjharley]

I agree.. I have checked the circuit at all three disconnects at the motor for the kill circuit, all open and close with the key switch..that's what I don't understand..it still want crank untill the main harness is disconnected..

 

[hondam]

Try taking up the power pack and make sure all the wires are in good condition under there. Also disconnect the yellow/red wire from the power pack and see if the problem still remains.

 

[mjharley]

Will do..thanks

 

[igotit]

Check out nuetral start switch for correct operation.....and the remote kill switch/lanyard....that tied into the kill/ground circuit aswell.
Any of those with ground the kill.
Maybe the nuetral switch came outta place telling the motor its in gear....its a possibility.

 

[mjharley]

Your right but these are both bypassed and not in the circuit.

 

[F_R]

So basically you are saying there is nothing left in the circuit but the key switch? Try removing the kill wire from it and see what happens.

 

[Faztbullet]

If it kills when reconnected that eliminates the wiring on the engine. It going to be in the control box either the key or lanyard switch or I have seen the wires crimped where it enters the cowling. Forget the neutral switch as its not tied into kill circuit. I would disconnect the blk/yell from key and see if it has spark,if so there is something wrong with that switch. You stated that the lanyard is bypassed if the wires are tied together that's your problem as it should be isolated....

 

[mjharley]

My last resort was disconnecting the ylw/ blk at the key switch thinking this would eliminate the wire in case it was grounding somewhere..nothing..still no spark..in all this process connecting/disconnecting I will sometime have some spark but not all cylinders and will never crank..soon as I unplug the the harness it cranks..I disconnected the shift interrupt switch thinking that may be a problem still nothing..

 

[mjharley]

To add, I'm at the point where I'm going to pull the boatside harness and examine the wiring..another problem I encountered is I no longer have current from the choke circuit after it leaves the key switch..do you think I'm on the right track?

 

[F_R]

I would say that at this point, it is the only track. Trouble is the fault may not be visible.

 

[mjharley]

The latest, all wiring connected, turned the key motor started ran for about 10 seconds.Tried about 5 or 6 more times with some sputtering. Unhooked the main red plug and tried with my remote starter at the motor started immediately. ran perfect. after engine warmed connected main red plug and motor continued to run. Motor will not stop with key so choked to stop. tried again with key motor starts and runs perfect. not sure what causes this sporadic behavior. thanks for any suggestions.

 

[oldboat1]

may have been covered, but might be a bad key switch (may need replacement).

[ed. Indeed. Covered in your opening post... Was it a new switch, and correct for your model? Replacement stator was used; perhaps the keyswitch as well.]

 

[mjharley]

may have been covered, but might be a bad key switch (may need replacement).

[ed. Indeed. Covered in your opening post... Was it a new switch, and correct for your model? Replacement stator was used; perhaps the keyswitch as well.]

Key switch is new..and I've tested each terminal..it works properly.

 

[jakedaawg]

It can be really frustrating to find faults in harnesses. Is there any where you could borrow a separate set of controls and harness to plug in and see how it does? It seems clear that the issue is in the vessel side; swapping in a different set would confirm. Many times, once confirmed, I just replace the harness as it is cheaper to replace than find and repair the fault.

Have you checked for short to ground on the vessel side? To do this you would disconnect the harness plug at the motor, place key in the run position and then check for resistance between blk/yel terminal in plug and ground. There is a pic somewhere in these forums that shows which pin is which in the red plug.

 

[mjharley]

Unfortunately I don't have access to another harness but I'm beginning to think it may be my only and best option..tough to trace down the fault..haven't checked the yw/blk to ground..will see if I can..thx

 

[jakedaawg]

Replacement harness can get a little spendy so it is best to absolutely confirm before replacing. Maybe a small independent shop would let you "rent" one. I know that I personally have loaned out many similiar things to DIY guys, I think its good business and many times I have gotten work from the same people I helped for free. It certainly doesn't hurt to ask, especially if you have a place where you are a known customer.