Kill Switch Troubleshooting

[@TheNoyz]

Thank you! Couldn’t get a spark! It was the black and yellow wire.. unplugged.. started right up! Must of been loose.. plugged it back in.. bingo!

[@daco8252]

Clark...we still have a problem. After your suggestion about the stator it didn't look good on all aspects, so we replaced it with a cdi electronics stator. It started twice no problem until we got braver and went 2 miles out on the lake. No start again, got ramp in sight and hit the key for laughs again, it started. Back home tried again, no start just quick hit, removed ground from neutral switch ran great with muffs, touch the ground to ground motor dies. Thought that was the problem, got confident again taped ground off went to the water and ran perfect, until we started back after a 3 mile run. No power-up with full throttle just a wake, 11/2 miles later pulled throttle back to no wake speed and you could here the motor change in power at this point we knew it would run so full throttle and 75 mph we go to the ramp. For another check on that ground for the neutral as back on trailer running we connected that wire back to ground and motor died. Something is good for a moment then bad again, Any more suggestion please? Thanks!

[@RustyShakleford1]

DACO could be your trigger coil, I am in a similar scenario right now would only go half speed or work for a while. Now it won't start at all. I replaced Cdi now I'm going to replace the trigger coil next

[@daco8252]

Thanks, we changed the power pack and it is running and starting good now, only one problem now the quick start idle is taking too long to idle down from the higher idle. Will be working on it next.

[@TheSecretVault]

i have amariner maraathon 40hp which is running rough as guys on 2 cycinders. Sparks health on both cylinders and is present in both spark plus... but runs badly on 2. Runs smooth purring when i remove one spark lead. Same thing when I remove the other spark lead. on both leads connected, rough again. Someone mentioned i May have apartial short on my kill switches which is how I got to your video. Ive not isolated the kill switch at the closest point to engine as you have shown but just wondering if you had any other magic ideas?

[@gracelutherangreenwood7499]

Hi Clark, I just “inherited” an old 1970 Mercury Thunderbolt 7.5hp outboard. I’ve been fixing it up; new/rebuilt fuel pump, carburetor, etc. New stator, new ignition coils, plugs, etc. Excellent compression on both cylinders. However… the wiring was completely shot. I need to re-wire EVERYTHING, and I can’t find a wiring diagram anywhere. Please help! Even a simple explanation of the new stator (with orange and green wire) would be helpful.

[@petedunleavy1749]

Hi Clark I have a 1982 merc 115 can't get spark since I shut off the kill switch how can I disconnect thank you

[@jshdtrch1]

Hey I got a 2005 mercury 90 2 stroke. There is a brown wire and a brown/white wire that seem to have disconnected from each other but I’m not certain. Do these 2 go together?

[@LuisRodriguez-ud2ch]

Hi my name is Luis I have a 2013 Lowe 17.5 stinger bass boat it has a relay started clicking I had to disconnect the battery for it to stop the relay # is 882751 what does that relay run I replaced it and the new one is clicking too

[@noahcassard1667]

i installed a new kill switch on my bass boat it has a 225 mercury on it im still having the same problem the engine starts and runs well but the kill switch does not kill engine any idea what the problem is ?

[@amandairlbeck7608]

are you still active on this if so i have a question 2003 mercury 50 efi big foot should there be any voltage at black wire with yellow tracer when key is on also at fuse block 4 fuses should there be 12 volts at all 4 fuses

[@daco8252]

Clark...we have a problem that is puzzling us. 1999 Evinrude 225 Vindicator hard start, but when it starts you have to throttle up or it will die, also now it hasn't been starting back up after running up-down lake after sitting for a while. It sometimes hits very briefly, then just cranks not hit. Occasionally, after a few hours it will start. Need to mention that it runs great when it is running up-down lake. We have installed a new key kill switch, no change. It has hit before with the kill cord off the switch, that's why we changed the kill switch. Any suggestions please? Thanks!

[@daco8252]

Yes it has carbs.

[@brandonhebert5485]

Bad power pack.

[@daco8252]

Hi Clark, We have installed a new CDI pack on a 99 225 Evinrude Vindicator and are still having more troubles with our engine. First, engine hard to start when first starting up; second the engine light comes on at 3/4 trottle and up if you back off trottle the light will go out and run find; lastly the engine takes 5-10 minutes seems to idle down from above idle for shifting. Would really appreciate any help and thanks!

[@skynineUK]

I am looking at a Mercury Optimax 115 that replaced a previous engine. Now the engine runs with the kill switch set. As I understand it the earth (black wire) operates the kill switch by earthing the ignition. Where should I look on the engine to check if the kill switch has been bypassed? I am checking the kill switch itself to make sure that it is not the problem. I understand that with the lanyard engaged the switch should be open and the lanyard pulled the switch should be closed.

[@barthageman4146]

MY 06 90hp johnson suddenly lost spark at all cylinders. i unplugged blk/y kill wire and no change. Ohms reading on stator brown-brown865 dva reading 219 on orange to orange ohms 56 dva maybe 4.5 this is if im reading on correct settings on meter. not sure how to ck optical sensor ,trigger or power pack. Any help would be appreciated. thanks

[@kevinlatham6432]

What if the engine starts and runs with kill switch in either run or off positions?

[@shawnsaunders5436]

So why does my motor turn on when I have the kill circuit disconnected from my power pack. But when its connected to the power pack it won't start. How do I fix this or put my own on to bypass harness

[@deplorablechump8758]

What is the power pack? Rev limiter?

[@greenrover1]

Thanks, for the record it was the 'rev limiter that killed the switchbox in this case. The rev limiter, switchbox and Vreg were all surged by bad a starter.

[@deltaflossy5848]

how did you figure out the bad starter....voltage drop?

[@andrewsmith941]

on a 4 stroke would a faulty kill switch effect the voltage to the high pressure fuel pump

[@thomasflynn642]

i have a 1987 70 hp mercury with a commander remote with a run stop switch, Every time i put the lever back into neutral cuts off the motor? is the kill switch bad? any ideas? RSVP THANKS

[@deplorablechump8758]

Darn, I’ve been pulling my hair out to get my motor to start. Replaced the flywheel and stator because small chunks of magnets under the flywheel broke off. Still no or intermittent sparks. I didn’t put the kill switch in when turning the key. Could it be the problem? I hope it is.

[@troywayne8759]

You will not get spark if the emergency kill switch is not in the proper position. Other no-spark problems could be the trigger coil under the flywheel, the CDI box, or the ignition coils. I'm hunting down this problem right now for myself.

[@deplorablechump8758]

@@troywayne8759 I have ordered the trigger, the ignition coils, and the Rev limiter. Will test the motor with the kill switch key in today. I hope it starts. My old stator may be good.

[@deplorablechump8758]

I found the problem. It was the bad black/yellow kill switch circuit. I unplugged it and the motor started. After cleaning the plug of the harness, I reconnected the wire and the motor started again. Thank you!!!!!!

[@troywayne8759]

@@deplorablechump8758 that’s always a great feeling!

[@fishingthemidwestwithsheam8096]

How do I replace a kill switch on my 96 Johnson 6.0hp a piece of switch broke off and I. Could probably super glue it back on but in case that doesn't work how do I install one

[@michaelcrouch4248]

We have a 2012 pontoon with a Mercury 115 EFI Four Stroke that runs perfect but last year an issue began- At high RPMs the engine will occasionally shut off/die, alarm beeps once, but then is able to start right back easily. This used to happen just occasionally at RPMs over 6000 only when hitting large waves when the trim was slightly up and pulling a tube, but now occurs occasionally when over 5000 RPMs or less with no load behind the boat at all. Each time the engine dies, alarm beeps for a couple os seconds, then I take it back to neutral and it can start right back up. Any help would be much appreciated???

[@richward2288]

Did you ever find the problem? I'm having almost the exact same issue on my 1995 115 2-stroke.

[@richward2288]

I found my problem. It was the rev limiter. I replaced it and haven't had any problem until today. The engine will sometimes start and run after it sits for a while. I'm suspecting something in the kill circuit

[@allenstout5650]

Is it my switch motor turns over but starter pinion spins

[@noes.castillol.4935]

hello everyone, I bought a boat and it comes with a 1990 150 hp Evinrude, the boat has kills switch and no spark, my question is if anyone knows what color in the motor is the kill switch clable to know if this (kill switch) works? thanks to everyone!.

[@terrydoner5957]

My boat will start and run fine but when I cut the switch off it won't kill it I'm having to choke it out is there a another way to ground it out if so what wires do I run together when I want to kill it

[@greenrover1]

Blk/yel is grounded at kill? open for run? true or false. My CDI has a Blk/Yel and a blk under the same terminal should I open both circuits for kill test? Thanks.

[@cdielectronics]

Hi Ron, Sorry for the delayed response. Traditionally, the Kill circuit on American built engines has been Black with a Yellow stripe. The Black/Yellow wire is connected to engine ground through the key/stop switch in order to stop the engine. Disconnect the Black wire and see if it is connected to engine ground or to a emergency kill switch.

[@southdevondiver]

Great video!!

[@tintdr]

1990 merc 50hp ,,, just fixed was the kill switcj

[@david6toe953]

Cutting the kill wire would be stupid. All you have to do is pull apart the wires at the switch, add a jumper wire and then take a multimeter and check for continuity at the motor end of the harness.

[@MrRonluker]

Good man

[@scottmarkham9466]

But FWC all boat including tiller motors must have a kill switch .

[@michaelgriffith862]

Trying to bypass my neutral switch and my kill switch on my 1980 XJ650 Maxim anybody got any ideas or know how

[@RandyWatson80]

Wtf would you cut the wire, just free the pin on the wire...

[@prasanthnelson1173]

Sir, pls give your number just i have one dout for mercury engine..

[@tonisarsero4499]

I have a pull start outboard motor and I wont to fit a electric start motor ( serial number 0N045091 ) MERCURY MARINE ( 2005 ME30 EMLH ) ( 30HP) I hope you can help me thank you Joseph