Service Manual 25-30 HP E-TEC Electrical And Ignition [Electric Start Circuit]

1. Marine battery
2. RED wire (POS)
3. BLACK wire (NEG)
4. Starter solenoid
5. Fuse (10 amp)
6. RED/PURPLE wire
7. Key switch connectors
8. Ignition switch
9. PURPLE wire (switched B+)
10. Battery charge module connector
11. Engine Management Module (EMM)
12. YELLOW/RED wire, start
13. BLACK wire, start signal ground
14. Neutral Safety Switch (remote control)
15. RED starter motor cable
16. Electric starter motor

The starter must engage and turn the flywheel. The outboard must crank a minimum of 300 RPM to start.

Starter performance depends on the following:

• Proper battery and cable capacity.
• Clean, tight cable connections.
• Solenoid activation through the key switch and neutral safety switch.

Refer to Battery Installation on p. 25 for battery, terminal, and cable requirements.

Solenoid Wiring

The positive (B+) battery cable connects to a large terminal of the starter solenoid. This terminal also provides the 12 V power supply to the engine harness (red wire) and the 10 A fuse. The red/purple wire from the fuse holder (10 A) provides 12 V to terminal “B” of key switch.

The negative (B–) battery cable connects to the main ground stud on the starter housing.

Engine Wire Harness

Contains the following circuits:

• Red/purple output wire from fuse provides 12 V to instrument harness.

• Purple wire provides switched 12 V to EMM.

• Yellow/red wire provides switched 12 V to solenoid (terminal “A”).

• Black wire provides ground (NEG) to starter solenoid (terminal “B”).

Instrument Wire Harness

Contains the following circuits:

• Red/purple wire provides 12 V to key switch terminal “B”.
• Purple wire provides switched 12 V to engine wire harness.
• Yellow/red wire from terminal “S” of key switch provides switched 12 V to solenoid (terminal “A”) (key switch in START position).

Key Switch, ON position

12 V is applied to the accessory circuit. Key switch ON:

• Switches 12 V to terminal “A” of key switch and to the purple wires of the wire harnesses.
• Provides 12 V input to terminal 3 of EMM J1-A connector. EMM turns ON.

1. Key switch, ON position – Continuity between terminals “B” and “A”
2. Terminal “B”, 12 V (Red/purple)
3. Terminal “A”, 12 V (Purple)

Key Switch, START Position

Key switch START:

• Switches 12 V to terminal “S” of key switch and to the neutral safety switch (in remote control).
• A closed neutral safety switch provides 12 V to the engine wire harness yellow/red wire and solenoid (terminal “A”).

1. Ignition switch, START position – Continuity between terminals “B” and “A”; “B” and “S”
2. Terminal “S”, 12 V
3. Neutral safety switch

Starter Solenoid Test

Disconnect the B+ (POS) battery cable at the battery.

IMPORTANT: Disconnect all wiring from solenoid terminals before proceeding with this test. Use a digital multimeter to measure resistance.

Put one meter lead on the starter positive (+) cable terminal and the other lead on the battery positive (+) cable terminal:

• Meter must not show continuity (high reading).
• If meter shows continuity (low reading), replace the solenoid.

1. Battery positive cable (B+) terminal
2. Starter positive (+) cable terminal
3. “A” terminal (yellow/red)
4. “B” terminal (black)

Apply B+ to terminal “A” of solenoid and ground (NEG) to terminal “B” of solenoid. Measure resistance between the starter positive (+) cable terminal and the positive battery (+) cable terminal.

• The solenoid must close with an audible click.
• Meter must show continuity (low reading).
• If meter shows no continuity (high reading), replace the solenoid.