Electric start connections on 9.8 Tohatsu

[Leatherneck]

I just reinstalled my outboard onto the boat and am not sure if I reconnected everything correctly. Pressing the start button results in nothing happening. I connected the POS from the battery to the left terminal along with the wire coming from the fuse. I connected the Red wire coming from the right side (solenoid?) to the other right terminal. I connected the NEG from the battery to the engine block.

Thanks for any help.

 

[MaryEllaRose]

This may sound silly but make sure you’re in neutral. There’s a switch on the shift linkage that has to be closed before you can start. I have a Tohatsu 9.8, I’ll take a look but I have to run over to the storage building do it may be a couple of hours before I can reply.
Tom G

 

[Leatherneck]

Tom, funny you should mention that. The starter lock cable that prevents starting the engine in gear has broken and I ordered a new one. I am able to move the starter lock up on the recoil starter assembly so the pull cord does pull freely. Thanks

 

[MaryEllaRose]

I took a quick peek and some pictures that I’ll have post later.
+ battery connects to left solenoid terminal.
- battery grounds on engine block
Red wire w/ black protective cover to fuse is on left solenoid terminal, same as + battery.
right side solenoid terminal connects to starter. No other wire attached.
Small black wire molded into solenoid connects to engine block, same bolt as
- battery.
Green wire molded into solenoid goes to terminal block, third up from the bottom. It connects to another green wire that goes to the neutral switch. From the neutral switch a slightly lighter green wire goes back to the terminal block, same spot on the terminal block (but a separate wire) and connects to the green wire from the starter switch.
The red wire from the starter switch goes to the red wires on the terminal block, fifth up from the bottom position.

Current flow for the solenoid coil circuit is thus:
From the left solenoid post (battery) through the fuse, to the terminal block, to the red wire on the starter switch, through the switch, to the light green wire on the neutral switch, through the neutral switch, back out on the darker green wire, to the terminal block (third position from bottom) to the green wire that’s molded into the solenoid. If you have a volt meter you can trace it throug

I’ll try to post pictures a little later. PM me if you need help. With my motor in front of me we can walk through it.

Tom G

 

[Leatherneck]

Thanks so much. I'll go down to the slip tomorrow and check it out.

 

[Leatherneck]

I took a quick peek and some pictures that I’ll have post later.
+ battery connects to left solenoid terminal.
- battery grounds on engine block
Red wire w/ black protective cover to fuse is on left solenoid terminal, same as + battery.
right side solenoid terminal connects to starter. No other wire attached.
Small black wire molded into solenoid connects to engine block, same bolt as
- battery.
Green wire molded into solenoid goes to terminal block, third up from the bottom. It connects to another green wire that goes to the neutral switch. From the neutral switch a slightly lighter green wire goes back to the terminal block, same spot on the terminal block (but a separate wire) and connects to the green wire from the starter switch.
The red wire from the starter switch goes to the red wires on the terminal block, fifth up from the bottom position.

Current flow for the solenoid coil circuit is thus:
From the left solenoid post (battery) through the fuse, to the terminal block, to the red wire on the starter switch, through the switch, to the light green wire on the neutral switch, through the neutral switch, back out on the darker green wire, to the terminal block (third position from bottom) to the green wire that’s molded into the solenoid. If you have a volt meter you can trace it throug

I’ll try to post pictures a little later. PM me if you need help. With my motor in front of me we can walk through it.

Tom G

So I looked at mine. Everything appears the same with one exception. The black wire soldered to the solenoid does not go to the engine block. It goes to the terminal block. Otherwise everything is connected properly. But it won't start. I wonder if the broken neutral safety cable is the reason.

 

[MaryEllaRose]

The black wire on the terminal block is electrically the same as the engine block to which the (-) negative battery cable is connected. The solenoid should energize as long as it’s black wire is connected to the terminal block or the engine block. The cam that actuates the starter safety switch also locks out the pull rope (via the cable) if the transmission isn’t in neutral. If the cam is broken / worn out the safety switch may not be getting closed. Trace the shift linkage to the switch and shift from neutral into forward. You should be able to see the cam activate the switch...or not.
The starter safety switch can be bypassed by disconnecting the green wires and then connecting the solenoid light green wire directly to the green wire from the starter switch. Take care! The motor can be tarted in gear if the switch is bypassed.

 

[Leatherneck]

The black wire on the terminal block is electrically the same as the engine block to which the (-) negative battery cable is connected. The solenoid should energize as long as it’s black wire is connected to the terminal block or the engine block. The cam that actuates the starter safety switch also locks out the pull rope (via the cable) if the transmission isn’t in neutral. If the cam is broken / worn out the safety switch may not be getting closed. Trace the shift linkage to the switch and shift from neutral into forward. You should be able to see the cam activate the switch...or not.
The starter safety switch can be bypassed by disconnecting the green wires and then connecting the solenoid light green wire directly to the green wire from the starter switch. Take care! The motor can be tarted in gear if the switch is bypassed.

The cam is activating the switch in neutral. I can pull start the engine by unlocking the

 

[Leatherneck]

Thanks for the pics! the safety switch is closing when in neutral and opening when in gear. I can see the metal tab move in and out to the switch. With the broken neutral safety cable, I am still able to unlock to the pull start by manually moving the black plastic tab to the up position on the pull starter assy. I can even pull start the engine this way. But, with all wires connected properly, the electric start does nothing.

 

[MaryEllaRose]

Have you got a voltmeter? From here on in its troubleshooting with a DVM.

 

[MaryEllaRose]

Any luck with you problem?