77 Evinrude 25hp- Stalled won't start

[lenny94]

I recently purchased this engine, it kept stalling so I rebuilt the carb. I then took it for a test drive and the engine ran strong all the way to the middle of the lake where I turned the key off and the engine continued to run. I immediately realized that I must have made a mistake in wiring up the ignition switch, so I attempted to make it back to the dock. Halfway there, the engine stalled out and would not restart, no turning over, no click, nothing. I checked the fuse and it was fine. The only way I can now start the engine is by directly jumping the starter. I am not sure if I fried the ignition switch or solenoid or something worse, was wondering what I should check or replace first. I have 5 wires- red, black(2), yellow, and purple. I have a 6 terminal igniton switch wired as follows: red-B, black-M, black-M, yellow-A, purple-C. I don't have anything going to the "I" terminal. Any help would be greatly appreciated.

 

[Lion hunter]

Re: 77 Evinrude 25hp- Stalled won't start

Ok, we jumped from rebuilt carbs to ignition switch. Was there a problem with the ignition to begin with and you had to rewire? Did the kill wire get unhooked when you were rebuilding the carbs?

 

[lenny94]

Re: 77 Evinrude 25hp- Stalled won't start

It is a brand new switch, engine always started right up but would then stall because of dirty carb, so wasn't until after I cleaned carb that I realized I had a problem because engine would not turn off. Don't know which one is kill wire- someone told me black w/ yellow tracer but I only have two solid black wires.

 

[Lion hunter]

Re: 77 Evinrude 25hp- Stalled won't start

you may have to trace the wires into the harness and see if the yellow stripe just hasn't wore off. Is there a black yellow wire coming out of the power pack plug on the motor? Are you sure you have the right switch? I have a wiring diagram, it only shows a 5 position switch. If you pm me your e-mail I'll send the diagram. The file is to large for the forum.

 

[lenny94]

Re: 77 Evinrude 25hp- Stalled won't start

Not positive I have the right switch. I bought engine w/o switch, went to marina and they had 5 position switch without push-to-choke and a 6 position switch with push-to-choke. I was able to trace purple wire to push-to-choke so guy at marina told me to go with 6 position. I don't know what power pack plug is-sorry novice when it comes to outboards-thanks.

 

[tashasdaddy]

Re: 77 Evinrude 25hp- Stalled won't start

Ignition wiring.

Are you trying to connect the key switch in the control box, or some wires under the cowling? Do you have a Johnson/Evinrude key switch? The color wiring diagram, including a key switch diagram is on a fold-out at the back of the factory manual. Starting from the 12 o'clock terminal, going clockwise:
A: two purple wires
M: black
B: red/purple
M: black/yellow
S: white
C: purple/white.
The black yellow should be ground when the key switch is off and will short out the power pack. Make sure this leak is not grounded somewhere else, causing a "no spark" problem.

 

[lenny94]

Re: 77 Evinrude 25hp- Stalled won't start

In the control box. I bought a six terminal omc switch and have it wired up as described, it used to work, now it doesn't. Just got the service manual in the mail, fold-out is showing a 5 terminal switch with corresponding 5 wires. Should I buy a 5 terminal switch? Something must have fried because now I don't get power to the starter, but don't know where to start.

 

[Lion hunter]

Re: 77 Evinrude 25hp- Stalled won't start

It really shouldn't matter, the 6 position just adds a chocke to the key switch. Do you have a separate choke switch? If not you will need the 6.

Ok for trouble shooting: Use a test light or multimeter at the switch first then at the motor . 1st make sure the wiring is hooked up per diagram. Make sure the motor is in nuetral.
might even disconnect the choke wire to simplify things a bit.

1.Do you have power coming in from the battery red/purple wire. If no there may be a fuse blown.

2. If there is power from the battery is there power to the purple wire with the key on? If no power here and no fuse is blown it may be a bad switch.

3. If there is power to purple with key on, move key to start position and see if there is power to the white wire (s terminal)

4. If all that checks out, go to the solenoid is there power to the white wire when the key is in the start position? If no then something is wrong in the harness.

5. If yes, is there power on the starter side of the solenoid. If no then your solenoid is likely bad.


try that and get back to us.

 

[lenny94]

Re: 77 Evinrude 25hp- Stalled won't start

Thanks for help. I replaced the switch and it starts right up but will not turn off when I turn the key to off position. I turn the key to off position and engine continues to run for about 5 minutes before stalling out on its own and will not restart because the fuse blows everytime. I traced the black/yellow wire and it ends at a wire nut. About 6 inches away is another wire nut on the end of the remaining black/yellow wire. Should these be there or should my black/yellow wire be one continous wire that hooks to something or grounds out somewhere?

 

[Lion hunter]

Re: 77 Evinrude 25hp- Stalled won't start

You will need to find the short that blows the fuse before you go any farther. Does the fuse blow when you turn the key to the off position or is it blowing while it's just running? If I had to take a wild swing I would say the PO unhooked the Black/yellow wire because one of the hot wires shorted on it and blew the power pack.

The 2 black/yellow wires must be connected for the key to shut it off. Before you connect those wires use a multimeter to make sure there is no voltage on the ignition side of the wire. If there is voltage it will fry the power pack. which may explain the theory about the fuse blowing. Usually the key switch shorts and sends voltage through and kills the pack.

 

[lenny94]

Re: 77 Evinrude 25hp- Stalled won't start

Thanks for help. The problem turned out to be a bad choke solenoid. I disconnected it at the ignition switch and now everything works fine. The engine now only stalls due to the bulb not staying firm but at least this is a common problem and should be easy to fix. Since the kill wire is not hooked up, I am just using the manual choke to stop the engine. I do have a multimeter, and when you said to check the kill wire for voltage, is that with the engine running or off and in what switch position?

 

[Lion hunter]

Re: 77 Evinrude 25hp- Stalled won't start

You don't want voltage going through the kill wire at any key position (there may actually be like 0.2 volts). I would test it with the key in the on,start and off position to make sure there is no voltage.

The bulbs usually will not remain firm while running, but if you can pump the bulb and keep it running it is likely the bulb is no good or the fuel pump is bad.