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Author Topic:   Evinrude 48SPL - Sparking at housing

kenpla2 posted 11-20-2013 09:57 PM ET (US)
I have an [Evinrude 48SPL outboard] engine. While scraping the housing to paint it, I made contact from the lower cushion mount to the lower pivot housing. The scraper lit up like shorting a battery from positve to negative with a screwdriver. I dropped the positive lead from the battery side of the solenoid; it no longer sparks-up anymore. Put [the positive lead from the battery] back, and the whole engine is alive when crossing housings again. Got any steps to save me time in [diagnosis of the cause of this electrical problem]? [The presence of the battery positive current on the outboard engine chassis] is oxidizing the submerged housing when operating the vessel, with the energy releasing into the saltwater. Thanks in advance.

jimh posted 11-21-2013 11:42 AM ET (US)
Based on your narrative there are portions of the outboard engine block or other large metal components that are connected to the battery positive terminal. Look for some source of this connection, such as a pinched wire or failed insulation.
kenpla2 posted 11-21-2013 07:25 PM ET (US)
I roger that idea. I am starting on it tomorrow. Starting with the wires on the solinoid battery side. Figuring one of the hot positive secondary wires that lead off the hot side could have the issue you have mentioned. I don't know yet what circuits they feed current to, but it seems the most likely starting point. If that checks out "OK", then I have to go to the other side of the solinoid & see if there is current already there. I have never had a solinoid short accross internally, but who knows ? Thanks again for the help.
jimh posted 11-23-2013 10:34 AM ET (US)
I do not think there is any issue involving electricity at work here. Electricity follows the laws of Physics and there is not much imposition from rules or regulations that can affect how electricity works. You should ignore the notion of an issue and just look for a simple circuit wiring problem.
kenpla2 posted 11-23-2013 08:45 PM ET (US)
I pulled off the lower engine housing so I could see things a little better. Then I started poking around all the harnesses and wires. And I found the problem in about five minutes. What happened: when someone got in there last, and put things together again, they pinched the primary positive feed wire going to the solenoid between the housing and the lower engine shroud halves when bolting them together. No wonder I got the boat with brand new batteries, as they certainly kept discharging the old ones with a dead short to ground. It cut the insulation through to the copper enough to make a contact. Thanks again for your help, and "So long" to SPARKY
jimh posted 11-25-2013 11:32 AM ET (US)
Excellent repair! You found the wiring problem by using a close visual inspection of the circuit. A close visual inspection of electrical wiring and circuitry is a very good method for finding problems. Thanks for following-up with an explanation of the cause of your problem and the remedy.

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Author	Topic: Evinrude 48SPL - Sparking at housing
kenpla2	posted 11-20-2013 09:57 PM ET (US) I have an [Evinrude 48SPL outboard] engine. While scraping the housing to paint it, I made contact from the lower cushion mount to the lower pivot housing. The scraper lit up like shorting a battery from positve to negative with a screwdriver. I dropped the positive lead from the battery side of the solenoid; it no longer sparks-up anymore. Put [the positive lead from the battery] back, and the whole engine is alive when crossing housings again. Got any steps to save me time in [diagnosis of the cause of this electrical problem]? [The presence of the battery positive current on the outboard engine chassis] is oxidizing the submerged housing when operating the vessel, with the energy releasing into the saltwater. Thanks in advance.
jimh	posted 11-21-2013 11:42 AM ET (US) Based on your narrative there are portions of the outboard engine block or other large metal components that are connected to the battery positive terminal. Look for some source of this connection, such as a pinched wire or failed insulation.
kenpla2	posted 11-21-2013 07:25 PM ET (US) I roger that idea. I am starting on it tomorrow. Starting with the wires on the solinoid battery side. Figuring one of the hot positive secondary wires that lead off the hot side could have the issue you have mentioned. I don't know yet what circuits they feed current to, but it seems the most likely starting point. If that checks out "OK", then I have to go to the other side of the solinoid & see if there is current already there. I have never had a solinoid short accross internally, but who knows ? Thanks again for the help.
jimh	posted 11-23-2013 10:34 AM ET (US) I do not think there is any issue involving electricity at work here. Electricity follows the laws of Physics and there is not much imposition from rules or regulations that can affect how electricity works. You should ignore the notion of an issue and just look for a simple circuit wiring problem.
kenpla2	posted 11-23-2013 08:45 PM ET (US) I pulled off the lower engine housing so I could see things a little better. Then I started poking around all the harnesses and wires. And I found the problem in about five minutes. What happened: when someone got in there last, and put things together again, they pinched the primary positive feed wire going to the solenoid between the housing and the lower engine shroud halves when bolting them together. No wonder I got the boat with brand new batteries, as they certainly kept discharging the old ones with a dead short to ground. It cut the insulation through to the copper enough to make a contact. Thanks again for your help, and "So long" to SPARKY
jimh	posted 11-25-2013 11:32 AM ET (US) Excellent repair! You found the wiring problem by using a close visual inspection of the circuit. A close visual inspection of electrical wiring and circuitry is a very good method for finding problems. Thanks for following-up with an explanation of the cause of your problem and the remedy.