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Old 16 July 2009, 19:23   #1
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Alternative kill switch ?

1996 Evinrude 55hp
For no apparent reason the kill switch on the cable and the one fitted to the engine have stopped working.
Traced the wires back to the plug from the cdi and all looks fine, earth is fine as well.
Assumption is there is something wrong in the CDI/powerpack which in this engine is under the flywheel.

The obvious solution is to replace it but we have an event this weekend and we don't have the time to get and fit a new pack.

So the question is, apart from just removing the fuel line or pulling off the HT leads, is there another way of stopping the engine in the short term?

For example could we short the low tension leads to earth?
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Old 16 July 2009, 20:05   #2
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Originally Posted by javelin View Post
1996 Evinrude 55hp
For no apparent reason the kill switch on the cable and the one fitted to the engine have stopped working.
Traced the wires back to the plug from the cdi and all looks fine, earth is fine as well.
Assumption is there is something wrong in the CDI/powerpack which in this engine is under the flywheel.

The obvious solution is to replace it but we have an event this weekend and we don't have the time to get and fit a new pack.

So the question is, apart from just removing the fuel line or pulling off the HT leads, is there another way of stopping the engine in the short term?

For example could we short the low tension leads to earth?
It won't be a CDI or stator fault-the kill switch makes a circuit to stop the engine rather than breaks a circuit. You've got a broken wire or poor contact somewhere. Multimeter time...
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Old 16 July 2009, 20:34   #3
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We traced the yellow/black all the way back to the 5 pin plug that exits from under the flywheel, where I assume the powerpack/cdi lives.

From that plug the yellow/black splits into two, with one feed to the kill on the engine (little red button) and the other with the main loom wires which ends up at the centre console kill switch.

After both kill switches there are two plain black wires that return and are terminated on the engine block.

I will treble check again the connections tomorrow (already done this a number of times) with the only option left to cut the wire where it exits the feed from under the flywheel and before the plug and try shorting that out.
I don't hold up much hope here as all these wires/connections are in very good condition as they live under a plastic cover bolted to the side of the engine.
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Old 17 July 2009, 11:11   #4
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I assume it still turns off on the key?
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Old 17 July 2009, 11:54   #5
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I assume it still turns off on the key?
If it doesn't it sounds a bit like the problem I'm having.
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Old 17 July 2009, 18:18   #6
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sounds like corrosion in the switch itself,contacts gone green ,can you take the switch apart and clean up the contacts ,it needs a good earth to stop.,
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Old 17 July 2009, 18:25   #7
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We found the issue.
Having seen that there were two Black/yellow wires and two black earth wires we assumed each switch worked independently.
However we have now found this assumption is incorrect.

We found a break in the wire that leads to the console kill switch where it entered the conduit that runs along the floor.
We fixed this and lo and behold, both switches now work.

Just goes to show how assumption could cost a lot of money and hassle.
Sorry to have bothered you guys.

However we could do with some guidance on prop selection.
The 55hp Evinrudes were in a twin configuration and now we have one on a 5.4 Searider and the other on a 5.5 Humber.
The props look very chunky and coarse.
Both ribs will be used for sailing support, moving marks about, standing by capsized dinghies and towing them back into the harbour if required.
Therefore speed is not really that important other than to get to the assistance of a dinghy in trouble but in practice this tends to happen in 20+knot of wind a and a fair chop so again speed has to be balanced against the state of the sea.

We think the current props are either 17 or 19's but corrosion/dirt and scratches makes it difficult to identify.

Any suggestions?
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Old 17 July 2009, 18:37   #8
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Sorry to have bothered you guys.
Not at all (i'm sure I can respond to your thanks for other contributors) were all about learning here, and saving a few bob too and youve given me a pointer for someone else ta
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Old 18 July 2009, 03:56   #9
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However we could do with some guidance on prop selection.
The 55hp Evinrudes were in a twin configuration and now we have one on a 5.4 Searider and the other on a 5.5 Humber.
The props look very chunky and coarse...........

We think the current props are either 17 or 19's but corrosion/dirt and scratches makes it difficult to identify.

Any suggestions?
No, but take into consideration that a properly set up "pair" should be carrying a "size up" in pitch, so you might want to consider dropping down one, now that they are "singles", all else being equal.
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