RE: [omc-boats] Starter Assist Solenoid follow-up

I just did most of mine. It is much easier to remove the exhaust manifold
to access the started and wire harness. I had mine off anyway but it only
takes 15 min or so to get it out of the way. Just a suggestion.

Ryan

   _____

From: owner-omc-boats@... [mailto:owner-omc-boats@...] On
Behalf Of Gregory B. Fell
Sent: Monday, April 30, 2007 10:27 AM
To: omc-boats@...
Subject: RE: [omc-boats] Starter Assist Solenoid follow-up

Thanks for the replies. I think I’ll give it a try.

Gregory B. Fell

The Fell Law Firm

3300 Oak Lawn Avenue, Suite 700

Dallas, Texas 75219

PHN : 972-488-8177

FAX : 214-219-4218

HYPERLINK "mailto:GFELL@..."GFELL@...

   _____

From: owner-omc-boats@... [mailto:owner-omc-boats@...] On
Behalf Of lib1@...
Sent: Monday, April 30, 2007 9:18 AM
To: omc-boats@...
Subject: Re: [omc-boats] Starter Assist Solenoid follow-up

Hi Gregory,

>>Here are my questions:

1. Is there a wiring bundle/harness available or am I looking at
individual wire replacement? I looks like a bundle is in there right know
because it is clearly machine wrapped.

2. Three of the four wires that connect the Starter Assist relay are
INDIVIDUAL replacements, and are NOT part of any other wiring harness or
bundle, other than having tape wrapped around them.

3. They are:

4. 1) RED - (heavy) 14 gauge to 12 o'clock position (BATTERY) on Main
Starter Solenoid

5. 2) WHITE/RED STRIPE ((heavy) 14 gauge to 3 o'clock position on Main
Starter Solenoid

6. 3) BLACK(?) 16 or 18 gauge (smaller) to ground next to Starter
Assist Solenoid
-----------------------------------------------------

7. 4) Only the WHITE 16 gauge (smaller) routes back through control
harness connector. The same connector that carries the shifter and tilt
wires. If you boat is one of the later models with the two round (Yellow &
Black) engine connectors the white wire comes out of the YELLOW connector.

8.

9. >>Is this a DIY project? I’m pretty capable; but, I don’t have the
desire or skill to remove major engine components in order to get to
connections.

10.

11. I did this job myself last winter and I would say it EASILY falls into
the DIY category. It's a job that will take you a couple of hours, but You
don't need to remove any major parts. You do need decent lighting and easy
physical access to the starboard side of the engine. Here's a brief
description of how I did mine.

12.

13. WARNING: ALWAYS START by COMPLETELY REMOVING THE BATTERY!!!

14.

15.

16. a) Remove the Starter Assist Solenoid. Draw a diagram of how all the
wires connect. Just remember the large wires go on the relay's heavy
terminals and the small wires go on the relay's small terminals (HYPERLINK
"http://hhscott.com/evinrude/wiring.htm"Reference Diagrams are available on
my website.)

17. b) Remove the tape that bundles the three wires coming from the stern
(or from the Main Starter solenoid)

18. c) Remove the large RED and WHITE/RED wires from the MAIN STARTER
SOLENOID (again noting their terminal location).

19. d) Check the overall condition of the small white wire that
eventually routes back to the CONTROL connector, if you are lucky this wire
will be fine (mine was). If you haven't been living right and you do find
this needs repair, then you'll need to splice in upstream (toward the stern)
a new section. It is highly unlikely the existing wire is rotten very far.
Again, this is the wire that runs back to the helm to the key-starter
switch. If you have the later (1969) model it also has to run thru the
neutral-safety switch in your shifter.

20. e) With the three remaining wires, you now simply need to duplicate
them now on the workbench. If you don;t have the crimping tools or don't
feel comfortable building new replacement cables, take them into any
automotive electrical shop and they'll duplicate them for you. Heat and oil
take their toll, not to mention potential corrosive effects, so I'd grab
Ancor Marine grade wire and decent self-sealing crimp-connectors but that's
probably overkill (and the originals lasted almost 40 years).

21. f) Re-assemble correctly. You can retape and use split-loom to help
protect your new wires.

22.

23. Wiring is pretty straight-forward and is well documented on these boats
(most boat builders never document their wiring). It also tends to get
neglected and often over-looked in diagnosing problems. It seems daunting,
try to break it down into the individual circuits or subsystems and tackle
them one at a time.

24.

25. Good luck and let us know how you are progressing.

26.

27. Lee Shuster

28. Salt Lake City

29.

30.

31. ----- Original Message -----

From: HYPERLINK "mailto:gfell@..."Gregory B. Fell

To: HYPERLINK "mailto:omc-boats@..."omc-boats@...

Sent: Monday, April 30, 2007 7:18 AM

Subject: [omc-boats] Starter Assist Solenoid follow-up

I had previously written that I had diagnosed by starting problem to the
starter assist solenoid. I purchased a new one (only $13.00) and attempted
to install in this weekend. I started off being a very simple remove and
replace procedure. However, it didn’t turn out that way. My wiring is so
brittle that any stress on it causes it to break apart. The wire on the
blind side (stern) of the solenoid had broken. I don’t know if I did it
during the removal or whether that was the problem in the first place.
Bottom line, I need to replace all the wiring. I’m hoping to do some
patching to get me through the summer then do a complete replace over the
winter.

Here are my questions:

32. Is there a wiring bundle/harness available or am I looking
at individual wire replacement? I looks like a bundle is in there right
know because it is clearly machine wrapped.

33. Is this a DIY project? I’m pretty capable; but, I don’t
have the desire or skill to remove major engine components in order to get
to connections.

Gregory B. Fell

The Fell Law Firm

3300 Oak Lawn Avenue, Suite 700

Dallas, Texas 75219

PHN : 972-488-8177

FAX : 214-219-4218

HYPERLINK "mailto:GFELL@..."GFELL@...

No virus found in this outgoing message.
Checked by AVG Free Edition.
Version: 7.5.467 / Virus Database: 269.6.2/781 - Release Date: 4/30/2007
9:14 AM

No virus found in this incoming message.
Checked by AVG Free Edition.
Version: 7.5.467 / Virus Database: 269.6.2/781 - Release Date: 4/30/2007
9:14 AM

No virus found in this outgoing message.
Checked by AVG Free Edition.
Version: 7.5.467 / Virus Database: 269.6.2/781 - Release Date: 4/30/2007
9:14 AM

No virus found in this incoming message.
Checked by AVG Free Edition.
Version: 7.5.467 / Virus Database: 269.6.2/781 - Release Date: 4/30/2007
9:14 AM

No virus found in this outgoing message.
Checked by AVG Free Edition.
Version: 7.5.467 / Virus Database: 269.6.2/781 - Release Date: 4/30/2007
9:14 AM
 
    

-----
To get off this list send mail to omc-boats-unsubscribe@...