possible ignition problems

[sprouticus]

Well Iboats experts...........it's almost boating season for me again, so once again I find myself back here with more questions.

Last year I put a bigger motor on my boat, from a 70hp to a 90 hp. the new motor was 80lbs heavier, and it left my back end a little low in the water while gowing slow. To compensate for this, recently I have moved the weight around in my boat. I extended the gas lines and put the gas tanks in the bow. Yesterday I bought 18 feet of 2 gauge wire and crimped it on to the 4 gauge wire that used to come off the batery. I pulled the wire through the sides of the boat, which allowed me to move the battery to the bow as well. This is when things got weird.

I rehooked up the battery, and turned the key to see if the engine would turn over (did not use choke as I did not want it to actually start yet..just checking to see if it would work) enigine turned over fine. I pulled the wires a little tighter, so I could get the battery farther forward into the bow, and hooked up the hose and the muffs to the engine. turned the key, expecting the engine to start.............nothing. stood there for a sec wondering what happened, then eventually I decided to see if I could by-pass the solenoid by useing the 2 screw driver trick the engine turned over.....so I thought I found my problem. With all stores being closed for the evening, I started to pack up my tools. when I was ready to go in for the night, I decided to try the key one last time for kicks. The solenoid engaged, and the engine turned over. I turned off the key and tried again......this time nothing. I never touched any wires......never changed anything. So I tried by-passing the solenoid again, and the engine turned over again. I have never heard of a solenoid working intermittedly........but decided this must be my problem.

So today I bought a new solenoid and installed it. (to be honest the marina was closed by the time I got off work..so I went to an automotive place to find a 4 pole solenoid that I could mount on the engine.) I ended up with one made for ford, later model trucks........and also bought a 1000 CCA marine starting battery for my boat, as the 650 CCA that was on there is nearing the end of it's life..and I figured the extra amps could not hurt. I hooked up the new solenoid, expecting all my problems to dissapear. Nope. Once again the only way to turn the engine over was by connecting the battery lead on the solenoid...to the starter lead using 2 old screwdrivers. Now I started to think perhaps the problem was in the extension I made to the battery leads. There were 2, 12 gauge wires hooked up to the battery posts that I thought maybe were not getting a good connection......but I am pretty sure those are for dash instruments. I did not want to take my splice apart to see...I was pretty proud of my crimping and shrink wrap job.............plus I don't see how this could be the problem. Then I thought that maybe the problem was with the ignition.....that would explain why the key wouldn't work, then did, then didn't again. So I took apart my controls...and got a look at the wires. There was a blue wire that wasn't connected to anything, but to be honest...if it was supposed to be and broke off...it was a clean break.........cause it doesn't look like it was ever hooked up to anything. It was starting to get dark so I went in for a flashlight to get a better look.......and of course got a phone call that tied me up till it was pitch black outside. While on the phone I thought maybe while I was pulling the battery leads through the side of the boat I may have disrupted the ignition wires somehow. Then I noticed that the ignition wires look like they had been spliced at some point by a previous owner. I unwrapped the tape to find 5 wires inside. The black and white wires were intact, but there were 3 wires, a green, and I think blue and a red wire that had been taped up. I was going to take the tape off and do the repair properly, but then I thought that the problem might be in the ignition again. I flip flopped a few times, before decideing to come in here and post my findings, hoping someone could help me, I was kinda hoping to get out this weekend.........but it's not looking like it is going to happen. I'm sure it is only a small fix......the issue is finding where the problem is.


BTW.................I have a 90 hp evinrude......and I think it's a 1990. I am still using the controls that came with the boat............the old engine was a 1977 70hp.

sorry for the long read.I didn't want to leave anything out.

thanx for reading and any input you can give me

 

[steelespike]

Re: possible ignition problems

Just some generic thoughts.It appears you did a good job on your splice though the best way would be one piece wire with no splice.If it cranks at the starter then it isn't the splice.First place I would look is the neutral safety switch( usually at the control box).Next the key switch and any wires identified with the secondary starter circuit.If you go to broke boats.com they have color codes keyswitch terminal connections and many other help tips.

 

[sprouticus]

Re: possible ignition problems

thats kinda what I was thinking about my splice.............but I am still assuming that the extra wires that were hooked up directly to the old battery posts were for dash instruments............I never actually traced them.

Sorry for sounding stupid, I know what a nuetral safty switch does obviously................but I have no idea what it would look like................where it would be located, (I assume the controls, not the engine, but am not sure) and don't know what to look for even if I find it. How do I tel if it is non functioning?

I still have the controls that came with my 90hp. I did not hook them up as I do not like where the trim control switch is on them. Also comestically, my old controls are in beter shape. However, I can "borrow" parts from these new controls, like the actualy ignition. I am assuning that one way to completly rule out both solenoids being a problem would be to do a current check on the ignition leads on the solenoid. If I get power to the leads, obviously my wires and ignition are fine. I'll see if I can get my buddy to come over today after work to turn the key for me.

I am still wondering about this blue wire tha wasn't connected to anything inside my contols..............any guesses on where thats supposed to go?

thanx again for reading

 

[red boat]

Re: possible ignition problems

the green blue and red wires are probably for the trim and tilt switch. If you have one that is red is hot blue is up and green is down. The neutral safety switch is inside the control box and will have two wires going to it, one comes from the main wire harness and the other from the ignition switch they should be orange or orange with black stripe. You probably need to clean all the ground wire connections and all the hot wire connections. while turning the switch to the start position try jiggeling the shift lever. I you get it to begin turning over that will give you an indication if the problem is with the neutral start switch

 

[sprouticus]

Re: possible ignition problems

ok.got off a little early today, and I got my buddy to come help me. first thing we did was to hook the voltmeter up to the ignition leads on the solenoid. I turned the key...and it read almost 13 volts (which means I do not have a voltage drop on my splice for sure I guess). so then we did a continuity test on the new solenoid between the ignition leads...........and there was nothing. I remember to grab my old solenoid out of my work truck today, so we did a continuity test on that........it was good. So we hooked up the old solenoid, and sure enough the engine turned over with the key. I have no idea what the problem was, but my engine is starting better than ever now. (I assume the new 1000 CCA battery is really helping) So it looks like I will get on the lake tommorrow........thankyou all for your help. I realize I still have a potential problem here with a wire shorting out............so I am bring my kicker motor with me, and a cell phone........just in case. I will take a closer look at the ignition when I get a chance. But I'm stupid like that...lol. All I know is.I get to go out...............and I am once again reminded of how friendly and helpfull everyone is on this site. thanx guys......and happy boating.