0397853 EVINRUDE FUEL TANK ASSY. WITHOUT GAUGE

Illustration 1 g03730757
Schematic diagram for the start relay circuit
Not all connectors are shown. Refer to the Electrical Schematic for the application.
Illustration 2 g02731945
View of the pin locations on the P1 connector for the starting motor relay
(8) Start signal
(27) Starting motor relay return
(53) Starting motor relay control The following background information is related to this procedure:When the keyswitch is turned to the START position, a signal is sent to pin P1:8 on the engine ECM. Power is supplied from P1:53 to the starting motor relay.The starting motor relay supplies battery power to the relay solenoids in the starting motor. This internal relay provides high current battery voltage to the starting motor.
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Check the fuses.
B. Thoroughly inspect the P1/J1 ECM connectors and thoroughly inspect the connector for the start relay. Refer to Troubleshooting, "Electrical Connector - Inspect" for details.
C. Inspect the connections on the starting motor.
D. Perform a 30 N (6.7 lb) pull test on each of the wires that are associated with the start relay.
Damaged wire or connector
Result: A damaged wire or damaged connector was not found. The fuses are OK.
Proceed to Test Step 2.
Result: A damaged wire or damaged connector was found. A fuse is blown.
Repair: Repair the damaged wire or the damaged connector. Replace any blown fuses.
Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
2. Check for Active or Recently Logged Diagnostic Codes
A. Connect the electronic service tool to the diagnostic connector.
B. If the engine will start, then start the engine.
C. Make a note of any active diagnostic codes.
Diagnostic Trouble Codes
Result: Diagnostic code 677-5 is active.
Proceed to Test Step 3.
Result: Diagnostic code 677-6 or 677-3 is active.
Proceed to Test Step 5.
Result: A 1041-2 diagnostic code is active or recently logged.
If a 1041-2 diagnostic code is recently logged, this may be caused by the keyswitch being held in the START position for too long.
If a 1041-2 diagnostic code is active without the keyswitch being held in the START position, proceed to Test Step 9.
Result: An active diagnostic code was not displayed.
There may be a fault with the start signal from the keyswitch or the power circuit for the starting motor. The ECM does not monitor the status of these conditions.
Proceed to Test Step 7.
3. Create a Short Circuit at the Starting Motor Relay
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the starting motor relay.
C. Fabricate a jumper wire that is 150 mm (6 inch) long.
D. Use the jumper wire to connect pin 1 to pin 2 on the harness connector for the starting motor relay.
E. Turn the keyswitch to the ON position.
F. Use the electronic service tool to check for an active 677-6 diagnostic code.
G. Turn the keyswitch to the OFF position.
H. Remove the jumper.
Diagnostic codes
Result: A 677-6 diagnostic code was active with the jumper installed.
Repair: Install a replacement starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install".
Use the electronic service tool to check for an active 677-5 diagnostic code.
Confirm that the fault has been eliminated.
Result: A 677-5 diagnostic code is still active with the jumper installed.
Reconnect the starting motor relay and proceed to Test Step 4.
4. Check the Wiring Between the Start Relay and the ECM for an Open Circuit
A. Turn the keyswitch to the OFF position.
B. Disconnect the starting motor relay connector. Disconnect the P1 connector.
C. Use a suitable multimeter to measure the resistance between the following points:
P1:53 to terminal 1 on the harness connector for the start relay
P1:27 to terminal 2 on the harness connector for the start relay
Less than 5 Ohms
Result: Each resistance measurement is less than 5 Ohms.
Contact the Dealer Solution Network (DSN).
Result: At least one of the resistance measurements is greater than 5 Ohms.
There is open circuit or high resistance in the wiring between the start relay connector and the P1 connector.
Repair: Check all wiring between the start relay connector and the ECM. Refer to the Electrical Schematic for the application.
Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
5. Create an Open Circuit at the Relay
A. Turn the keyswitch to the OFF position.
B. Disconnect the starting motor relay connector.
C. Turn the keyswitch to the ON position.
D. Use the electronic service tool to check for an active 677-5 diagnostic code.
E. Turn the keyswitch to the OFF position.
F. Reconnect the starting motor relay connector.
Diagnostic codes
Result: A 677-5 diagnostic code became active with the starting motor relay disconnected.
Repair: Install a replacement starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install".
Use the electronic service tool to check for an active 677-5 diagnostic code.
Confirm that the fault has been eliminated.
Result: A 677-6 diagnostic code is still active with the starting motor relay disconnected.
Proceed to Test Step 6.
6. Check the Wiring Between the Start Relay and the ECM for a Short Circuit
A. Turn the keyswitch to the OFF position.
B. Disconnect the start relay connector. Disconnect the P1 connector from the ECM.
C. Use a multimeter to measure the resistance between the following points:
P1:53 and all other terminals on the P1 connector
P1:27 and all other terminals on the P1 connector
Greater than 1 k Ohm
Result: Each resistance measurement is greater than 1 k Ohm.
Contact the Dealer Solution Network (DSN).