Yamaha 115 kill switch

davej · 23 July 2017, 21:23

Hi, I have a 1994 Yamaha 2S V4 outboard that appears to have a starting problem that points to the Kill switch. Does anyone know, which wire effectively disables the kill switch on the switch box/CDI unit?

I am proposing to remove/unscrew or cut the wire and splice in a bullet connector into this wire, to check if it really is the kill switch causing the starting problem.

We have checked out the stator, switch box and trigger, so that only leaves the kill switch. Even this looks OK and when dismantled but maybe its some of the wiring.

I have a workshop manual but cant see the colour for this wiring.

Thanks for the help.

Dave

ShinyShoe · 23 July 2017, 22:07

Have you tested it with a meter?

ribber · 23 July 2017, 22:54

Have you ruled out the 'in neutral' micro switch in the control box. The micro switch often gets stuck in making the controls thinking it's still in gear and wont start.

davej · 23 July 2017, 23:15

[QUOTE=ribber;753810]Have you ruled out the 'in neutral' micro switch in the control box. The micro switch often gets stuck in making the controls thinking it's still in gear and wont start.

Great idea about the micro switch, will check that when I get home at the weekend.

The control box is only 3 yrs old but I guess in a salt water environment corrosion happens!

Dave

simonl · 24 July 2017, 01:28

From distant memory, I think it's white (but don't know at the CDI?)
Many years ago I isolated it because of a control box issue & it started fine. We then had this loose end kicking round it the boat, It was a bit lively. One chap was leaning over the edge, hands in water & had said wire placed somewhere around his nuts. He jumped. That was maybe 10 years ago. His revenge was executed only last week when he pushed me off the pontoon before I'd zipped up my drysuit.

ribber · 24 July 2017, 09:27

It wasn't so much corrosion, but grease that's lubricating all the ratchets etc. becomes hard and if its all over the micro switch stops it from popping back out. Then when the sun warms up the controller (and the grease) the fault doesn't happen....becoming an intermittent problem that was hard to diagnose.

simonl · 24 July 2017, 09:37

Quote:

Originally Posted by ribber

Have you ruled out the 'in neutral' micro switch in the control box. The micro switch often gets stuck in making the controls thinking it's still in gear and wont **start**.

Won't **crank***, rather than won't start.
Slightly pedantic, but I assumed this one's cranking...

davej · 24 July 2017, 18:00

Ours cranks fine but wouldn't start, not all the time but intermittently.

We have looked at everything we could think of but will look again at the micro switch for the control lever.

Thank you.

David

ribber · 24 July 2017, 19:33

As simonl points out, if the engine is 'cranking' then it's not the micro switch in the neutral position. It wont do anything when ignition turn on if micro switch is faulty. Sorry.

Davie · 27 July 2017, 21:07

Its the white wire at CDI that stops the engine, try disconnecting that first.

Your fault is a perfect description of the engine not cranking fast enough. Get a mega battery on it first. Take off the air box and make sure the choke butterflies are shutting properly. They are half spring loaded and stick. Squirting a small amount of fuel into the carbs will rule out this theory.