0438320 EVINRUDE MOTOR COVER ASSY.

Illustration 1 g00673063
Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Personal injury may occur from failure to adhere to the following procedures.Use ether only in well ventilated areas.Do not smoke while changing ether cylinders.Use ether with care to avoid fires.Do not store replacement ether cylinders in living areas or in the operator's compartment.Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F).Discard cylinders in a safe place. Do not puncture or burn cylinders.Keep ether cylinders out of the reach of unauthorized personnel.To avoid possible injury, be sure the brakes are applied and all controls are in Hold or Neutral when starting the engine.
Test Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect ECM connector J1/P1, machine connector J3/P3, and all other connectors in the wiring harness. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Inspect the following components for damage, corrosion, and incorrect attachment:
Battery posts
Alternator
Breaker
Engine ground
Chassis groundExpected Result:All connectors, pins, and sockets are completely inserted and coupled. The harness and wiring are free of corrosion, of abrasions, and of pinch points. All connections and grounds are tight and free of corrosion.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 2. Check the Switch Status on the Caterpillar Electronic Technician (Cat ET)
Remove the ether canister from the ether solenoid.
Connect Cat ET to the data link connector.
Turn the keyswitch to the ON position.
Press the starting aid switch to "MANUAL". Observe the status of "Ether Switch" on Cat ET.Expected Result:When the starting aid switch is pressed, the status is "On".When the starting aid switch is not pressed, the status is Off.Results:
OK - The starting aid switch is operating correctly. Proceed to Test Step 6.
Not OK - The ECM is not properly reading the signal from the starting aid switch. Proceed to Test Step 3.Test Step 3. Check the Resistance of the Relay
Illustration 2 g00673774
Connector for the ether relay
Turn the keyswitch to the OFF/RESET position.
Measure the resistance across terminal 85 (solenoid return) and terminal 87 (solenoid power).Expected Result:The resistance is between 250 Ohms and 500 Ohms.Results:
OK - Proceed to Test Step 4.
Not OK - The relay is faulty.Repair: Replace the relay.Verify that the repair eliminates the problem. Stop.Test Step 4. Short the Switch Wires
Illustration 3 g00673806
Starting aid switch connector P36
Disconnect the starting aid switch.
Remove the wires from P36:1 (starting aid switch) and P36:2 (digital return).
Observe the status of "Ether Switch" on Cat ET.
Short wire F720-GN (starting aid switch) to wire 998-BR (digital return).
Observe the status of "Ether Switch" on Cat ET.Expected Result:When the wires are shorted, the status is On.When the wires are not shorted, the status is Off.Results:
OK - The starting aid switch is not operating correctly.Repair: Replace the starting aid switch.Verify that the repair eliminates the problem. Stop.
Not OK - The starting aid switch is operating correctly. Proceed to Test Step 5.Test Step 5. Short the Switch Inputs at the ECM
Illustration 4 g00673748
J1/P1 breakout
Turn the keyswitch to the OFF position and install a 7X-1715 Adapter Cable As (40-PIN BREAKOUT) at ECM connector J1/P1.
Turn the keyswitch to the ON position.
Observe the status of "Ether Switch" on Cat ET.
Use a suitable piece of wire to short P1:25 (starting aid switch) and P1:29 (digital return) at the breakout.
Observe the status of "Ether Switch" on Cat ET.Expected Result:When the wires are shorted, the status is "On".When the wires are not shorted, the status is "Off".Results:
OK - There is a problem in the wiring between the switch and the ECM.Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.
Not OK - The ECM is not reading the switch input properly.Repair: Verify your results. Replace the ECM. Refer to Troubleshooting, "Replacing the ECM" before replacing the ECM.Verify that the repair eliminates the problem. Stop.Test Step 6. Check the Resistance of the Ether Solenoid
Disconnect J37/P37 ether solenoid connector.
Measure the resistance between J37:1 (solenoid power) and J37:2 (solenoid return).Expected Result:Resistance is less than 10 Ohms.Results:
OK - Proceed to Test Step 7.
Not OK - The ether solenoid is faulty.Repair: Replace the ether solenoid.Verify that the repair eliminates the problem. Stop.Test Step 7. Check the Supply Voltage to The Ether SolenoidNote: The ether canister must be removed prior to activating this test.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Override Screen" in Cat ET.