Ignition Issue, Need Help/Advice

Bents

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Jul 31, 2023
8
Catalina 27 Sarnia
Hi everyone!

My wife and I bought our first sailboat a couple of weeks ago (catalina 27) and are super excited to get into the sailing life (I've got a decent amount of experience on the water). We have been doing a full clean of the boat and I've been fixing and replacing little things here and there over the last 2 weeks. We ran into our first major issue yesterday...

When the previous owner showed us the boat the engine (atomic 4) fired up right away and sounded great. Yesterday I thought I would fire up the engine myself check out the controls, hear how it sounded. I was told that it starts like a car since its a gas engine. I turned on battery 1, ran the blower for a minute or two, and turned the key. The engine started up no problem but the key basically spun all the way around. I didn't give it a ton of pressure when I cranked it, I don't think anyway. I thought hmm that's weird but OK. I ran the engine for a couple minutes, played with the throttle a little bit to get a feel for it, went to turn off the engine by turning the key in the opposite direction. The key just spun around. This is my "oh no" moment, I have a running engine and cant turn it off. I did the only thing I could think of and turned off the fuel supply. Then engine stalled out a short time later and I felt a brief sense of relief and pride as I just solved my first major issue.

WRONG!

Smoke began coming out of engine compartment. I jumped down, removed the ladder, opened the engine door and I'm met with a ton of smoke. As I peer in it looks like its the electrical wires burning. Time to grab the fire extinguisher. I give it a few short blasts. Panic is over. Went back and grabbed the key and the whole assembly came out with it.

Thanks for reading the back story, here come the questions.

1. Did I some how force the key to hard and break the assembly when turning the engine on?

Repairs, obviously I'm going to need a new ignition, the wiring harness has 1 wire that looks like the coating melted off it, maybe the ground wire?

2. Replace the ignition and just that wire, or replace the whole harness to be safe?

3. Is that all that will need to be repaired or did I eff myself?

4. When all is fixed and I get the courage to try to start it up again do I need to do anything specific procedure wise other than just turning the fuel supply back on?

On a completely different note, my throttle and gear shifters just pull out of the housing, it looks like there are little balls in the housing that should be clipping the shifters in.... any idea on how to fix?

Thanks in advance everyone for helping a first time boat owner noob. Picture uploaded for reference.
 

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May 1, 2011
5,275
Pearson 37 Lusby MD
Replace the ignition and just that wire, replace the whole harness to be safe?
My opinion is to replace the whole harness (and the ignition). That may or may not correct the source of the dead short that caused the fire. Welcome to the forum! :beer:
 
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WayneH

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Jan 22, 2008
1,109
Tartan 37 287 Pensacola, FL
OK, so I got old-timers disease. :huh: Is this that FIX IT NOW wiring problem that can cause you to burn your boat down? I can't recall the article that deals with the issue but maybe someone can remember and say yea or nay.
 
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Likes: Bents
Jan 19, 2010
12,760
Hobie 16 & Rhodes 22 Skeeter Charleston
Sounds scary :yikes:

Glad you are okay.

So you got fire on a gas burning boat. I'd go with "...replace the whole harness to be safe"

... and the ignition key assembly
 
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Likes: Bents
May 27, 2004
2,059
Hunter 30_74-83 Ponce Inlet FL
Yes, it's a fix it NOW.
First, remove the wiring harness connections from any electrical source before you turn on the master switch.
Then you can analyze the next steps.
I don't know what year your boat is, but the engine panel looks like a PO upgrade.
Given the state of the wiring, I don't think it was done by a pro.
It might be salvageable once the new ignition switch is acquired and included in
the rewiring scheme.
 
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Bents

.
Jul 31, 2023
8
Catalina 27 Sarnia
Thank you for the replies everyone!!

Upon further inspection I'm definitely going to replace the whole harness as well as the battery cables. Obviously the ignition as well.

Should be a fun learning project!

Glad you are okay.
Thank you! It definitely got the adrenaline going.

I don't know what year your boat is, but the engine panel looks like a PO upgrade.
Its a 1980. I will probably replace the panel in the off season.
 
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Likes: ggrizzard
Sep 11, 2022
94
Catalina 34 mk 1.5 Rockland ME
Yikes! Glad you and your boat are OK.

The ignition switch issue sounds like a loose jam nut. Unless the panel and switch both have a “D” flat shape, the only thing keeping the whole assembly from spinning is having that nut properly tightened. Smoky wiring when the engine stalled would almost have to come from a battery short-circuit suggesting a second failure somewhere; that it occurred after stall would make me suspect the alternator. Whatever wire was shorted will have melted like a fuse, leaving a broken connection; it should help you find the source.

However, double faults are extremely improbable so you need to look for a common cause. Perhaps as the switch spun, one of the wires on the back of it shorted to something and welded from the resulting arc. Or, the key could be a red herring. For example, on some Universal diesels (such as my C34) there’s a wiring harness that’s prone to melting in such a way that the starter won’t turn off, among other failure modes.

In any case, as others have said, the entire harness is now suspect and should be replaced.
 
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Likes: ggrizzard
Aug 11, 2011
1,006
O'day 30 313 Georgetown MD
I don't have a gasoline engine on my boat, but after reading your posting and looking at the pictures, i have a question. In the pic of the front side of your panel, there is a knob on the bottom left. Is that a choke or is it a snuffing lever.
A suggestion. There is a very good marine electrical book which should be part of your collection for reading and referencing. It is written by Don Casey. Best reading and life saver you'll ever buy.
 

Bents

.
Jul 31, 2023
8
Catalina 27 Sarnia
I don't have a gasoline engine on my boat, but after reading your posting and looking at the pictures, i have a question. In the pic of the front side of your panel, there is a knob on the bottom left. Is that a choke or is it a snuffing lever.
Thats a choke.

As far as an update goes, I replaced the whole wiring harness, put in a brass ignition (it was a plastic one that broke on me), took out the ammeter, put in a voltmeter instead. Put in-line fuses where they should be (there were none before). Replaced the starter solenoid, replaced the starter, and just yesterday got her fired up after putting in the starter and cranking her 5 or so times.

She sounds and runs great, we got to go on our maiden voyage yesterday!!
 

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