Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft?

[henfjel]

Hello!
i have an Evinrude 9.9hp from 1987. its probably the best motor i've ever tried, and it runs amazingly well! but i have one problem. the dead man switch/stop button does not work. i've checked both places on the block, where the ground wires go + anywhere i could reach the wires. so, my question is: is the wire broken somewhere in the steering arm or can it be the switch? its driving me mad..

how big a task would it be for me to convert the long shaft to short shaft? is all i need a shorter driveshaft and a shorter gear shift rod?

thanks, henfjel

 

[oldcatamount]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

It's hard to tell if it's the wire or the switch itself. My suggestion would be to change them both. No, it's not difficult to change from a long shaft to a short shaft. Shorter drive shaft, same shift rod (just shorter connector piece) and shorter water tube (you can cut the long one down 5 inches) Finding a short drive shaft will be the hardest part.

 

[henfjel]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

ok, thanks for the quick answer! i'll replace the wires and switch then.
i don't think it'll be a problem. ill just order one from crowley marine or find one on ebay. the shift rod connection piece, is that the one located in the gearcase?
you know what? my local dealer said that it couldn't be done. bastard..

 

[rolmops]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

Some of these 9.9 engines do not have the 5 inch extension piece that makes it a long shaft.Instead they have a longer gear case.If you have the extension piece and usually 1987s do you should not have a problem.
Make sure that your outboard is not set up with the extra long shaft(for sail boats),that makes things a bit different

 

[henfjel]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

it has the 5 inch extension.

 

[henfjel]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

when i am to remove the gearcase and extension, should i loosen the bolt on the extension or the bolts on the gearcase to access the shift rod link?

 

[watergecko]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

The whole extension needs to come out anyways so all the bolts will have to be removed anyway, id say start with ext and if its not there u know where it is. Im at work or id check the diagram for you. Somebody here will be able to answer though.

Also the driveshaft is a bugger to locate, i looked into that on my 15 and was over 200 from brp, there were no used ones at the time that i could find. I decided to spend 75 more and get an entire motor for parts.

 

[Joe Reeves]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

Kill circuit: Black wire from powerhead to powerpack, black/yellow wire from powerpack to push button, black wire from push button to poserhead ground.

 

[henfjel]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

Kill circuit: Black wire from powerhead to powerpack, black/yellow wire from powerpack to push button, black wire from push button to poserhead ground.

yeah, that circuit i see too, but its not working so there is a fault one place along the circuit. can it be in the power pack? even though the engine goes well, it looks like the circuit board is light burned some places.

 

[jrs_diesel]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

Info on converting shaft lengths:

http://www.sschapterpsa.com/ramblings/OMC-Converting_shafts.htm

 

[Joe Reeves]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

I described the kill circuit so that you could check out the wiring continuity with an ohm meter. If there are no breaks in the circuit wiring and the button shows to be good ohm wise, then the only thing left is the circuitry within the powerpack.

Check the continuity first and the open/close action of the push (kill) button.

 

[henfjel]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

I described the kill circuit so that you could check out the wiring continuity with an ohm meter. If there are no breaks in the circuit wiring and the button shows to be good ohm wise, then the only thing left is the circuitry within the powerpack.

Check the continuity first and the open/close action of the push (kill) button.

doh, of course.
i'll check it when i get access to the engine. its at our summer house, 860 miles from where i live... i think next time will be in april. does anyone know where i can get spray paint similar to the original? same color as that one: http://waterski.tv/db4/00340/waterski.tv/_uimages/evin2.jpg i think metallic blue, but i've heard some people call it gray

and another question:
9.9 and 15 hp carbs! i'm not going to start a discussion here about bumping the motor up to 15 hp, but IF i put a 15 hp carb on it, will that alone give it more power and speed? i've read that to make it a real 15 hp, you have to replace the reed valves, exhaust tubes e.t.c. but what will the carb ONLY give me? thanks

 

[Joe Reeves]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

Carburetor 9.9 to 15hp? Not worth the effort on that model. Too many other non-compatible components within that model.

 

[henfjel]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

that's not what i asked, but ok..
i'm going to change most gaskets, the water pump, fuel filter and i'm going to get a carb kit. i don't think those has been changed ever. i guess thatat least will make it run better? anything else i should change or take a look at for maintenance (except for changing plugs)?
and i have water coming out of the exhaust when i go full throttle. bad gasket somewhere or is it normal?

 

[HighTrim]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

You didnt mention the gear oil. Be sure to change the drain and vent screw gaskets when reinstalling screws.

If you ground the black/yellow wire does it kill the motor?

 

[henfjel]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

of course, gear oil. how could i forget? :facepalm:

actually when i think back, i think that my father and I tested that last summer. i think the wire is faulty somewhere

 

[Joe Reeves]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

Carburetor 9.9 to 15hp?

Okay, sort of misread your question (blame it on age, failing eyesight, late hours etc)

When I was working years back, I tried that just for the heck of it (slow day) on a late model 9.9. I didn't see any difference in power.

 

[raczekp1]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

i had some problem with stop switch in ny jo 83'. the problem was the powerpack.something broke down inside the powerpack, becouse overhiting accident.

to check if the problem is in powerack is to cut 2 wires( one is going from powerpack to kill switch and the second one is wire going from kill switch to one of bolts of powerhead) and conect them for permament.this will couse that powerpack should be grounded all the time.and motor wil have nos spark and wil not start.
i did this in my motor and was sure the powerpack is not working well.

 

[henfjel]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

Carburetor 9.9 to 15hp?

Okay, sort of misread your question (blame it on age, failing eyesight, late hours etc)

When I was working years back, I tried that just for the heck of it (slow day) on a late model 9.9. I didn't see any difference in power.

hehe, no problem
ok, then i know that.

i had some problem with stop switch in ny jo 83'. the problem was the powerpack.something broke down inside the powerpack, becouse overhiting accident.

to check if the problem is in powerack is to cut 2 wires( one is going from powerpack to kill switch and the second one is wire going from kill switch to one of bolts of powerhead) and conect them for permament.this will couse that powerpack should be grounded all the time.and motor wil have nos spark and wil not start.
i did this in my motor and was sure the powerpack is not working well.

ok, thanks! maybe a overheat is to blame then.. last year, i started the engine after it had sat for a year, and after a five minute trip it was so hot i couldn't touch it. a lot of smoke under the cowling. maybe it broke the powerpack. and it has the original powerpack from '87 so its probably time to change it anyways

 

[raczekp1]

Re: Evinrude 1987 9.9HP Dead-man/stop switch not working + converting to short shaft

first cut the wires and conect them to avoid stop swich.
maybe in your case the problem is just the switch.
i cut the cabels and make quick conectors(malen and female conectors)