trouble with the wiring diagrams

[kjprag01]

Dear everyone, I have read and researched every topic i could find on the matter, studied the diagrams, found the installation instructions for the cdi Electronics, and something just seems odd to me about the mess i have created under this cowl. . . especially when it comes to the unused wires and some oddities in the instructions i have found. Attached is a diagram of what madness i have unleashed and trying to undo burnt wires and really bad splicing and crimp joints. I have omitted the tilt controls and most of the grounds for clarity in the diagram. the red, red/white, light blue from the switch box? the reds coming off the voltage regulator? The purple wire off the plug. the 4th pole on the starter solenoid. Can anyone please shed light on this birds nest for me. I can only make out a partial serial and she has two cylinders. Thank you in advance for checking my work.

 

[jerryjerry05]

Year?

 

[kjprag01]

Honesty I couldn't tell you with any degree of certainty. I can only read a partial serial number which is 0e02 but I believe it's a 1992-1994 40hp.

 

[jerryjerry05]

http://www.ebay.com/itm/1992-1994-FO...dZVtsN&vxp=mtr
Here's a linc to a factory manual

About 35$ but well worth that.
​A factory manual is invaluable and an aftermarket is good if you have an outside toilet

 

[kjprag01]

I have the force shop manual, i bought that and read it before i started the iboat account. The diagram in the manual shows the red, red/white, blue/white all going into the stator, however, the current stator does not have that many wires, because i believe it to be an upgraded model, stator part number 174-2075k2. Switchbox part number 114-4952, Voltage regulator 194-5279, trigger 134-9527-2, and a stator adapter.

 

[roscoe]

Since you have the stator with the adaptor, the red wire on the switchbox is not used at all, just tape it off.

The original stator was connected to the switchbox via the blu/wht and red/wht wires. I believe these are no longer used as well.

The unused terminal on the solenoid should be connected to ground.

Your rectifier has 2 reds, because it is an aftermarket unit from CDI.
This is from the CDI installation guide:

1. To replace a regulator having only one Red wire, tape off the unused Red wire on the new regulator/rectifier.
2. The old regulator?s Black wire is no longer needed. The new regulator/rectifier?s case is Engine Ground.

I would use the heavier gauge red wire, tape off the other.


I think thats it.

Let us know if it works, it will help others in the future.

 

[kjprag01]

thank you Roscoe,
Alright, so i am taping off the blue white, red white, red, and black on the switch box. and attaching the thicker gauge red wire to the solenoid (with fuse) from the voltage regulator and taping off the thinner gauge that is also coming off of the voltage regulator. The coils on this engine are dead and they should be here Friday. Im going to get her all sorted out then and will make a much more professional looking diagram and re-post it, if it works. Like you said Roscoe, for the future. But i do sense, i have a world of other problems with this motor coming in the future. Which im ok with. I built the boat, so why not rebuild the engine? now that the hard part, electrical, is hopefully over. Thank you again

 

[kjprag01]

It works!!!! Update: Crimp off the thinner red wire coming off of the Voltage Regulator. Crimp off the Red, Red/White, and Blue/White coming off of the SWITCH box. Thank you iboat users for sharing you knowledge and experience. The above diagram works like a charm, just terminate the above wires for a force 40 2 stroke, I assume this will work for all 92-94 force 2strokes. This diagram is for after market CDI electronics, where the factory manual is futile and confusing. with the help of everyone the above diagram will guide you and assure you that those wires are not used.

 

[roscoe]

Congrats.

happy boating.