www.iFourWinns.com

My 1995 150 Evinrude has been having problems shutting down the last few days. It started to turn off a few seconds after I switched the key off, then the time increased by to about 15 seconds after. I checked the wires going to the switch and it worked fine for today's fishing trip, but when we returned, It would not shut down. I pulled the lanyard for the emergency disconnect and that did not shut it down either. The only way I could shut it down was to pull the plug wires until it stalled. After researching I thought the switch might be bad. A friend of mine thinks the ground wire may be loose or corroded. Any idea where the grounding wire is on this engine? Any other ideas? I have the sequence to test the switch and will try that as soon as weather improves. She is moored now in the Long Island sound. Appreciate any thoughts on it.

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Mannix2
Hyde Park, NY

1997 Four Winns 203 Coast Runner-150hp Ocean Pro Evinrude
"BONA 4 TUNA"
1986 19' Bayliner Capri 125 Force

Worked on her again today. Tried tracing the black and yellow ground wires to the engine. Found two that had a connector with a metal clip holding them together. Cleaned the connections and tested. I successfully started it and shut it down 10 times. Took it out for 15 minutes, a few at WOT, ran great. Pulled up to the mooring and turn it off, she keeps running for about a minute then stops. I started it up again, turned the switch off and she ran for 10 minutes while I snapped the covers on. I disconnected the 2 M wires from the switch and touched them together and still kept running. I. Finally shut her down by pulling three plug wires off. It seems to only be a problem when engine is warm. I'll test it again when it's cold and pull the lanyard to eliminate the key switch. Am I missing something obvious here. Buddy thinks it's the power pack. That's an expensive mistake if it's not. Does the ground share the ground with the batteries?

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Mannix2
Hyde Park, NY

1997 Four Winns 203 Coast Runner-150hp Ocean Pro Evinrude
"BONA 4 TUNA"
1986 19' Bayliner Capri 125 Force

I'd suggest getting on iboats and posting in the Evinrude/Johnson section. Someone there should be able to help. It is an abnormal issue but, I'll bet with some guidance from the crew at iboats you can get it figured out.

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Current Operational Boats:
'04-Four Winns 180 Freedom 150 HP Evinrude
'72-Chris Craft Commander 31 Sedan Twin-350Qs

Thanks for the advice, I posted there too.

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Mannix2
Hyde Park, NY

1997 Four Winns 203 Coast Runner-150hp Ocean Pro Evinrude
"BONA 4 TUNA"
1986 19' Bayliner Capri 125 Force

I know its not the fix but in the meantime will it die if you disconnect the battery. They make cheap battery disconnect switchs just need wired into the battery.

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2001 Four Winns Vista 248 by rick2752, on Flickr

I have a battery switch but thought I would wreck the charging system if I shut off the batteries while it was running. I would love a temporary fix so I can enjoy the rest of our vacation. I still think the ground wire is compromised or loose, just can find where it bolts to the block.

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Mannix2
Hyde Park, NY

1997 Four Winns 203 Coast Runner-150hp Ocean Pro Evinrude
"BONA 4 TUNA"
1986 19' Bayliner Capri 125 Force

On my 5.7 gs both grounds are on the back of the motor. Just follow the negative battery ground cable.

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2001 Four Winns Vista 248 by rick2752, on Flickr

Read through the manual for anyone interested, this is what I discovered. The powerpack on the evinrude or Johnson outboard has a black wire with yellow stripe for the ground. The ground wire is separated from the wire harness as is goes to the shift switch before returning to the key switch. I connected the ground from the pack to the block and the engine kept running. My only conclusion is that the power pack is defective and can no longer ground itself to shut down. Seems unbelievable since it still starts right up and runs great. I hope a new power pack solves the problem.

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Mannix2
Hyde Park, NY

1997 Four Winns 203 Coast Runner-150hp Ocean Pro Evinrude
"BONA 4 TUNA"
1986 19' Bayliner Capri 125 Force

Here's the final chapter to my saga. Installed the new powerpack, started it up, turned it off...yup, she kept right on running. Ran a ground lead to the black and yellow wire to the new powerpack, and it still kept on running. Soooo, decided to start from scratch and double checked the key switch. Then got the idea to verify the ground at the key switch by using a lead from the ground side of the key switch and my test light, ground verified. Decided to test continuity from the black and yellow wire on the key switch to the black and yellow wire from the engine wire harness. Test was positive for continuity, this brought me right back to the original amphenol connector that I was connecting my ground lead to the powerpack with. This time I brought my ground lead from the switch and peeled back the insulation to bare some wire after the amphenol connector. Started it up and it shut right down with the key switch. The whole time it was a defect in the female amphenol connector that I had been using to ground the powerpack for testing. I replaced the connector, and can once again shut it down without removing the hood and pulling plug wires. I have a new powerpack too, and a good working spare, just in time for Labor Day boating!

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Mannix2
Hyde Park, NY

1997 Four Winns 203 Coast Runner-150hp Ocean Pro Evinrude
"BONA 4 TUNA"
1986 19' Bayliner Capri 125 Force

Congrats on the fix...you saved alot in mechanic fees even with the power pack purchase. That was wayyyyyy over my head and I would been pulling my hair and talking to myself if I had to figure that one out.

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http://i1339.photobucket.com/albums/o71 ... wqm355.jpg


08' H210SS
VP 5.7Gi