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Catalina/Capri 25/250 Sailor's Forums

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Tohatsu 9.8 Wiring

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sweetlou
1st Mate

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53 Posts

Initially Posted - 06/02/2011 : 20:48:09

Hello - My yard re-installed the outboard prior to departure and as an extra special courtesy left me with an electrical issue to troubleshoot. On launch day I hit the electric start button and got zip, zero, nada. I recalled reading about a fuse issue on the board, found the holder, pulled it and surprise...blown. Well with my weather window closing I decided to depart, one pull on the rope starter and I was off (the fact that the battery cables were jammed under the cowl instead of through the cutout/rubber grommet should have given me pause).

I replaced the fuse and viola, it blew again. After doing some research and comparing the owner's manual electrical diagram, I believe the yard hooked up the battery wires incorrectly. I don't see any indication of polarity on the solenoid itself but I noted that the lead to the 20A fuse was hooked up to the negative battery lead/terminal, with the starter motor lead to the positive. I moved the fuse lead to the positive post, replaced the fuse, reconnected the battery lead, hit the starter button and nothing happened (the fuse did not blow this time).

I'm staring at the electrical schematic and can't make any sense of it (EF Type). Can anyone with a Tohatsu 9.8 describe their electrical connection at the solenoid terminals? Is the negative battery lead wired to one of the terminals (as I recall) or to an engine block ground as suggested by the diagram?

Incidentally I am measuring 12.7V at the terminals suggesting zero charge, but that the downstream connection is fine.

Any advice is appreciated.

Thanks.

C25 '83 FK SR
Chicago, IL

Edited by - sweetlou on 06/02/2011 20:50:23

delliottg
Former Mainsheet C250 Tech Editor

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USA
4479 Posts

Response Posted - 06/02/2011 : 21:34:42

I went out and took a look at my Tohatsu 9.8 and tried to take a picture for you but it's too dark and I couldn't get it to focus. It looks like the positive is connected to the fuse block on the left hand side (it's the factory cable attached there with a white stripe going down it to indicate positive, I think), and the ground on the right side about 1-1/2" away. This is looking at the front of the engine with the carburetor & shift assembly on the left side.

Please don't take my word for this, it's dark outside and I was using a flashlight to look.

If someone else hasn't chimed in, I can take better pictures in the morning. The sun's up by about 5am (not that I am if I can help it). I can also put a multimeter on it to test which side is which.

Edited by - on

John Russell
Master Marine Consultant

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3444 Posts

Response Posted - 06/03/2011 : 05:33:18

You mentioned that this was a "re-install". If this wasn't a problem before, is it likely that somebody opened the cover of the motor and re-arranged the wiring in there? Doubtful. Wouldn't it be easier to simply switch the battery cables? I did that a couple of years ago. When it didn't start, I went below and realized I had attached the battery cables backwards. Hard to see the + and - in the relative dark back there. That's why they have fuses in the line.

When you hear the sound of hoof beats, don't turn around expecting to see zebras, it's probably just the horses in the barn.

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sweetlou
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Response Posted - 06/03/2011 : 06:04:00

Thanks David.

Actually John this is exactly what they did. The yard disconnected the motor at the solenoid terminals at the end of last season. At launch the battery leads were reinstalled at the motor end.

In addition to the battery leads there is the starter motor and the inline fuse that go to solenoid posts.

I don't see any indication of polarity on the solenoid (didn't think solenoids cared, the question is polarity in terms of the battery leads meeting others at the terminals).

Edited by - sweetlou on 06/03/2011 06:08:30

John Russell
Master Marine Consultant

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3444 Posts

Response Posted - 06/03/2011 : 08:51:16

I guess I just don't understand why anybody would disconnect the battery at the solenoid end. I must be missing something here. Did they have another reason to open the cover and play with wiring?

But, if they connected the cables wrong at the solenoid end, would simply switching them cause damage other than a blown fuse? That's what it's doing now. I'd probably switch them, after confirming the color of leads at the battery is correct, then push the starter button and see what happens. Understand, I'm not an electrician(or anything close) and my opinion is worth the cost!

Switching the battery wires at the solenoid end, assuming that's all they did, is the same as switching them at the battery end. Isn't it?

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sweetlou
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Response Posted - 06/03/2011 : 09:26:23

<blockquote id="quote">quote:<hr height="1" noshade id="quote">Originally posted by John Russell
 I guess I just don't understand why anybody would disconnect the battery at the solenoid end. I must be missing something here. Did they have another reason to open the cover and play with wiring?
.....
Switching the battery wires at the solenoid end, assuming that's all they did, is the same as switching them at the battery end. Isn't it?
<hr height="1" noshade id="quote"></blockquote id="quote">

It's simply easier to disconnect the leads there as compared to mid way down the quarter birth on the way back to the batteries. They also changed the oil, etc so the cover would have been off anyway.

The issue isn't simply two terminals on the solenoid and two battery leads, there are an additional two leads that connect to the solenoid terminals behind the battery leads that are also at issue (in-line fuse and starter hot, i think).

Edited by - on

cks
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Response Posted - 06/03/2011 : 11:37:48

On my mercury, the negative is ground and not connected to the solenoid, only the + (red).

Edited by - on

sweetlou
1st Mate

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Response Posted - 06/03/2011 : 11:45:13

<blockquote id="quote">quote:<hr height="1" noshade id="quote">Originally posted by cks
 On my mercury, the negative is ground and not connected to the solenoid, only the + (red).
<hr height="1" noshade id="quote"></blockquote id="quote">
<blockquote id="quote">quote:<hr height="1" noshade id="quote">Originally posted by cks
 On my mercury, the negative is ground and not connected to the solenoid, only the + (red).
<hr height="1" noshade id="quote"></blockquote id="quote">

I just had a look at the Electrics exploded diagram in the Parts Manual and this would appear to be the case for the Tohatsu as well.

David - Is your negative battery wire attached to an engine block ground?

Thanks all.

Edited by - on

John Russell
Master Marine Consultant

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Response Posted - 06/03/2011 : 16:21:45

Tohatsu and Mercury are the same motor, diferent gadgets.

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delliottg
Former Mainsheet C250 Tech Editor

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4479 Posts

Response Posted - 06/03/2011 : 16:45:02

Yes, it's grounded right Forward of the air cleaner, up by the pull start housing. I'll take some pictures for you this evening. I rushed out the door this morning & forgot.

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sweetlou
1st Mate

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Response Posted - 06/03/2011 : 18:41:08

<blockquote id="quote">quote:<hr height="1" noshade id="quote">Originally posted by delliottg
 Yes, it's grounded right Forward of the air cleaner, up by the pull start housing. I'll take some pictures for you this evening. I rushed out the door this morning & forgot.
<hr height="1" noshade id="quote"></blockquote id="quote">

Problem solved! Thanks David.

Edited by - on

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