E-TEC Booststrap Cable

[jimh]

Evinrude Special BOOTSTRAP Cable

Below is a diagram of the wiring of a bootstrap cable adaptor for an Evinrude E-TEC engine. This cable is inserted into the normal wiring harness at the Engine Key Switch connector at the engine end of the wiring harness. Once inserted, the EMM will then go into the bootstrap mode when the ignition key switch is set to ON. In this mode the firmware in the EMM can be modified. Use extreme care if doing that.

----from HELM--------------//---bootstrap cable ---//--Engine Key Switch Conn 6-pole

         STOP CIRCUIT     POLE                   POLE   EMM STOP CIRCUIT
BLK/YEL  ----------------> 1 >-------------------> 1 >----J1A-P9-------  BLK/YEL

         START CIRCUIT                                  EMM START CIRCUIT
YEL/RED  ----------------> 2 o--n.c.      n.c.---o 2 >----J1A-P26------  YEL/RED

         GND (B-)                                       BATTERY NEGATIVE
BLK/WHI  ----------------> 3 >---------x----------> 3 >-MainHarnessGnd-- BLK
                                       |
         SWITCHED B+                   |                EMM POWER INPUT
VIOL     ----------------> 4 >-------------------> 4 >----J1B-P21------ VIOL
                                       |
         FUSED B+                      |                POS. BATTERY FEED
RED/VIOL ----------------> 5 >-------------------> 5 >-----Fuse, 10A---- RED/VIOL
                                       |
         OLD CHOKE CIRCUIT             |                BOOTSTRAP ENABLE
                n.c. ----> 6 o--n.c.   x-to Pin3--> 6 >-------J1A-P8---- BLK/ORG
                
                             Deutsch        Deutsch
                             DT06-6S        DT04-6P

Fig. 1. ASCII art of wiring diagram, Bootstrap Cable Adaptor. Expand browser window horizontally to see the entire drawing.

The wire insulation colors used to construct the bootstrap cable are not significant, but should mimic the wire insulation colors of the circuit being carried, when possible, just for consistency of the wiring. Wires with two-color insulation are generally not readily available. A suggested wire insulation scheme for the six positions:

1. Black with yellow tape;
2. no wire needed;
3. Black;
4. Violet;
5. Red;
6. Black with orange tape.

Notes:
On the helm side of the adaptor cable the sockets at poles 2 and 6 are omitted, and on the engine side of the adaptor cable the pin at pole 2 is also omitted. On the engine connector side there is a jumper between the wire for pin 3 and the wire pin 6. Do not try to connect two wires to the pin connector at pole 3, as two wires will not fit through the seal on the connector backside. You must splice the wire from pole 6 into the wire at pole 3.

The notation "n.c.'" indicates no connection (and no contact necessary).

The characters "-->" indicate a pin connector; the characters ">--" indicate a socket connector; the characters "o--" or "--o" indicate no contact is needed at that position.

The cable performs the following modifications to the wiring:

• the engine start circuit is disabled;
• the bootstrap mode is enabled by having a ground at pin 6 toward the EMM;
• the EMM power is still controlled by the ignition key switch

When ordering the connectors, they are often sold as three separate parts: the connector body; the wedgeplate; the individual contacts, either pins or sockets. The individual contacts are available in several different types, including the metal used, and the type of crimping tool needed.

SOURCES

The circuit diagram follows one published by Gavin B. (GEB) on his archive of E-TEC information website. See

Cf.: https://drive.google.com/file/d/1hl0mHp ... 2zqs7/view

The above linked resource contains much more information about the process of using the bootstrap cable.

[jimh]

Here are the components for the connector for the engine-side of the bootstrap adaptor cable. The links are to a vendor that has these parts in stock and has reasonable prices for low quantities of the parts.

DT04-6P Receptacle with Pins

Connector Housing

Fig. 2A. Front view DT04-6P receptacle housing

DT04-6P_Front_.jpg (19.7 KiB) Viewed 1067 times

FIG. 2B. Back view DT04-6P showing wire entry seals and pin position embossed identity marking.

DT04-6P_Back_.jpg (25.52 KiB) Viewed 1067 times

DT-04-6P 6-pole Gray Receptacle, Pins
$2.87 each; one required
https://www.buydeutsch.com/collections/dt-series/products/dt04-6p

Wedgelock

Fig. 3. Wedgelock 6-pin

W6P_.jpg (24.69 KiB) Viewed 1067 times

W6P Wedgelock for 6 pin receptacle, green
$0.28 each; one required
https://www.buydeutsch.com/products/w6p

Solid Pin Contacts

Fig. 4. Solid pin contact.

pinContact_.jpg (18.35 KiB) Viewed 1067 times

0460-202-16141 Solid pin contacts AWG-16 to AWG-20 13-Amperes Nickel
$0.25 each; five required
https://www.buydeutsch.com/products/0460-202-16141

The solid pin machined contacts are the most durable and very inexpensive from this vendor. To use them as intended as a crimp connector, a special circumferential crimp tool (that is very expensive) is recommended. However, with careful technique a wire conductor can be soldered into the connector, but you must certain to not leave solder residue on the outside diameter of the contact as it will interfere with the press-fit or snap-in fit of the connector into the housing and wedgelock. I have used these with solder with good results with a micro-tip and low wattage soldering pencil, but I have about 65-years of soldering experience which may have helped. This vendor also has conventional crimp-style stamped pin contacts available if you prefer those.

[jimh]

Here are the components needed for connector the helm cable side of the bootstrap adaptor cable.

DT06-6S

DT06-6S Plug 6-pole Housing Gray

Fig. 5A. DT06-6S front view.

DT06-6S_Front_.jpg (31.33 KiB) Viewed 1063 times

Fig. 5B. DT06-6S back view showing wire seals and embossed contact position number markings,

DT06-6S_Back_.jpg (20.11 KiB) Viewed 1063 times

$3.30 each, one required
https://www.buydeutsch.com/collections/ ... ts/dt06-6s

WS6 Wedgeplate, orange

Fig. 6. Wedgeplate

W6S_.jpg (26.97 KiB) Viewed 1059 times

$0.25 each, one required
https://www.buydeutsch.com/products/w6s

Machined Sockets

Fig. 7. Machined socket

machinedSocket_.jpg (17.83 KiB) Viewed 1059 times

0462-201-16141 Solid Socket 16-20 AWG 13-Ampere Nickel Plated
$0.54 each, four required
https://www.buydeutsch.com/products/0462-201-16141

[jimh]

The same vendor as linked above also has a package of parts for the necessary two housings, two lockplates, 6 pins, and 6-sockets at $12.99. You will get two extra sockets and one extra pin, which might be very useful for assembly for a first-timer.

See

https://www.buydeutsch.com/collections/deutsch-connectors/products/dt06gy-k

This vendor is located in New Jersey, and they have been selling Deutsch connectors for 25-years.

[jimh]

Assembly of the Deutsch connectors is straightforward:

• each individual conductor is terminated onto its contact;
• the wire with its contact is loaded into the housing, sliding through the back side seal;
• the contact will snap into the final position and lock in place when pushed farther into the housing;
• when all contacts are installed and locked in place, the wedgelock is installed on the front side of the connector and is press-fit in place until bottomed-out.

If a contact is inserted into the wrong position, that contact can be removed from the front side of the housing (without the wedgelock in-place) by accessing and releasing the small retainer mechanism using a very small screwdriver to release that contact while simultaneously pulling out the wire from the housing at the rear seal.

Complete details about Deutsch connectors are available from their comprehensive catalog document, which can be downloaded at

Deutsch DT Series Connectors
https://continuouswave.com/whaler/refer ... Series.pdf

For illustrated assembly instructions of DT-series connectors, refer to Folio 31 (page 15 of 15) of the above document.