Intermittant electrical problem... HELP?

[Champster]

1993 190 DCX Elite.
On ocassion I have a power drain when cranking or trimming the motor. It stops if I disconnect either lead that supplys power from the battery to the console. Also if I jiggle the wires were they run thru the conduit. Once, when at full throttle, and in light chop, the problem killed the motor instantly. After messing around with the wires all was good again. It seems like a ground problem, not shorting out with the positve side though or I think the wires would heat up and brakers would start popping. Maybe the ground is bleeding between the motor and boat power causing a drain off. (finding a different ground source?).
Does anyone know if the main ground wire running from the battery to the console has other grounds spliced into it along the way i.e lighting gnds etc? I tried to replace the gnd wire but I can't isolate where it comes into the console. When pulling on it (slightly) from one end, there is no movement at the other leading me to believe there are other gnds attached? If I can isolate it I will run a new wire. I may have to pull the fuel line from the aux tank as it seems to cause an obstruction from pulling new wires. What a paine! Any ideas would be a help. Thanks

[Tx Champ]

There is a ground point under the console where the black wire from the cranking battery ties. From there, the grounds go out to various points and some grounds in the instrument cluster all tie back to one gauge before going to the ground point.

Similarly, the red wire goes to a buss that has breakers for the various switches. anything that is powered without the Power switch being turned on will also be connected to this buss and should be fused.

Sounds like something is turned on. Do you have an auto bilge pump? It will be wired hot if not through a switch.

Good Luck & holler if I can help.

[Champster]

Nothing turned on, no auto bilge. The only things wired direct are the sonars and they have inline fuses. When the situation occurs, the power drain is excessive and acts like an extermely low battery until either console power wire is disconnected or I jiggle the wire harness. When it happened while underway it shutdown the motor instantly as though the coil was not grounded at that moment. Again once I disconnected the console power wires and all was fine.
I understand the red wire coming from the battery and 20amp breaker goes directly to the breaker bus and the ground wire should go directly to a ground point with nothing attached . I am having trouble with identifying that main ground wire from the battery to the console. Where is that ground point normally located? Is it a ground buss of some sort or just floating with all the ground wires crimped togehter? I am suspecting there may be a problem in the harness involving the igniton ground and console ground as though the ignition ground is chaffing with the console gound. Does that make sense? I just don't understand how or where the ignition harness would be compromised or chaffe if thats the case.

[Tx Champ]

It's been a long time since I've been under the console, but it sould be easy to find. When you are my size, you don't make any unnecessary trips to the floor and under the console ...

In the Champ wiring harness, all grounds are black, all unswitched +12v are red, all switched +12v are purple and panel lights are blue.

You might also check the connections on the back of the ignition switch. To me, this would be the only place other than the ground post or positive buss that would have any affect on the motor running. Could also be a contact inside the ignition.

Send me your e-mail address and I'll send you a copy of the manual for my 93. It has wiring diagrams in the back.

[Champster]

I not at home so I can not check this yet, but I am wondering if the kill switch is bad or shorting to ground would cause this problem.

[shrshot]

You took the words right outta my mouth...... I had a kill switch go bad a couple of years ago, and it did all sorts of crazy things kinda like what you described what yours is doing. Easy way to check it.... Disconnect the ground wire from the tether/kill switch to the ignition and take it out, run it and see if it acts up at all.... If it seems fine replace the kill switch... Also check the ground wire from the kill switch to the ignition with an ohm meter.... Make sure the wire has good continuity and not shorting to ground.... Any doubt on the kill switch wire, replace-it... Faulty grounds can cause some really crazy chit...