Summer ended shortly for me :( Resto begins.

Hey guys, I was hoping you could help me with something. I am about to reinstall the throttle controls whihc I took out and disassembled before I moved out of my house. I was cleaning and painting and regreasing all the parts in the controls and had everything laid out in order but then I ahd to pack up and move. Needless to say, I forgot where what goes, lol.
I have put the internal parts back together but the part I cant figure out is how the brackets that mount the control cables to the control assembly are suppossed to be aligned. I was hoping somebody had a picture of the back of their controls. I will try to get the parts set up so I can take a picture to shwo you guys what I am tlaking about.

Also, wotan or sybrmike, I think I will be running a 4 gauge wire from the starter to the alternator. My question is, what size fuse did yoiu put in line with that?

Not sure if this is the exact one, but most of the throttles are fairly universal

http://www.teleflexmarine.com/wp-con...ion_manual.pdf

I installed a 140A alternator, so pretty sure I used a 150A fuse?

I just thought I'd address the foam issue mentioned several posts back. Firstly, extruded polystyrene, (blue or pink Styrofoam) cut to fit and glued in place with low expansion foam would be my first choice. The extruded stuff (as opposed to the white expanded polystyrene) is closed cell and does not absorb water. I like the idea that if for some unforeseen reason you punch a hole in the hull, (rock, deadhead, wakeboarder, limpet mine), you will take on water slow enough to get the boat back and out of the water, but if that's open space...

i went with a circuit breaker from blue sea when i upgraded my alt. i don't like carrying spares. looks like this...

http://bluesea.com/files/images/prod...02_182x182.jpg

http://bluesea.com/category/3/10/pro...ne/overview/13

So, I was trying to do some wiring on the boat the other weekend...JEEZ! What a nightmare! I was hoping some of you could help me with some of this.
Back at the gas tank area I have a harness that comes from the helm. In this harness there is three black wires, which I would assume are grounds. Then their is a pink, a yellow, and a gray with black stripe. I see that the pink goes to the fuel tank. However, coming off the fuel tank there are three wires, a black, a pink, and a green. There also seems to be a green wire coming from the underside of the fuel filler cap. Any ideas on what in the heck that is? I was thinking that the yellow wire went to the blowers or the bilge pump? Also, the transom light looks like it wasnt even gonnected, it has a black and a green wire coming from it. Any ideas?

Will, without spending a bunch of time going back and forth between this thread and my records for my comp, I know you have a salt but bear with me here... On the aft harness the following wires go to the following items if installed.

Gray/Black = Transom light
Pink = Fuel sending unit
Brown = Manual bilge
Brown/White= Auto bilge
Yellow/Black = Aft blower
Black = Ground

I don't know if this will help or not, but here's a shot of the wiring around my tank area as found when I first tore into it. The pink wire is going to the fuel sending unit.

http://unumemarketing.com/boat/tank_wires.jpg

Nice boats Looking Great:) the Green and black Wire Connecting one port Wt is this?

Those are fuel sender wires. Whats up with the refrigerator for sale Jerry?

Its been awhile since I have been able to actually install things on the boat but this past weekend that changed. I was able to get some nice weather and get some things done on the boat!!
I finished up wiring the aft harness and bilge harness. Did some clean up on the motor and installed the last couple of things on it. Then I finished up the wiring for the dash and installed it. The new switches required fuses so I also had to install and wire up a panel. I went a little overboard and bought a Blue Sea Systems 12 terminal panel with a ground block on it.
http://i1112.photobucket.com/albums/...psb8bb7e4d.jpg
http://i1112.photobucket.com/albums/...psdc09efe3.jpg
http://i1112.photobucket.com/albums/...ps0d7c0853.jpg

http://i1112.photobucket.com/albums/...ps0aaa046c.jpg
http://i1112.photobucket.com/albums/...ps6fe2e2bf.jpg

Looking real nice there, Will. I like how you changed it up & always been a fan of having all the gauges clustered for a quick glance at the vitals.

wiring, dash, wheel...look fantastic!

what's the plan for the floor?...snap in carpet?

Looking good man.

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Originally Posted by Salty87

wiring, dash, wheel...look fantastic!

what's the plan for the floor?...snap in carpet?

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Im not sure yet, most likely the floor will just get a quick clean and it will stay the way it is. It has been sealed up so that nothing penetrates the floor. This way I can just hose it out at the end of the day. I like simplicity. :)

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Originally Posted by wspeedin

Im not sure yet, most likely the floor will just get a quick clean and it will stay the way it is. It has been sealed up so that nothing penetrates the floor. This way I can just hose it out at the end of the day. I like simplicity. :)

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Snap in carpet would be great in there. You get the benefit of not having water pool anywhere in the boat, less slippery, and soft on your feet yet you can still pull the carpet out quickly to hose it out if needed.

Cool build.. this was a fun thread to read.

So my weekend has pretty much sucked! I decided that it was time to turn this engine over and try to get the boat fired up this weekend! Oh boy! The first try was no success, when I hit the ignition the started didnt budge the engine. So I took the starter off and tried to get it to engage and nothing happenned. So I took the starter apart only to find it was full of water on the inside. So I cleaned it up and put it all back together and the starter is now engaging with no issues.
So I installed the starter back in the boat and the engine turned over about half a rotation and then wouldnt budge again. I took the starter back off and it was engaging fine. So I ruled out the starter being the cause of the non-rotation. I put a breaker bar on the crankshaft nut at the front of the engine. All it would do is tighten the nut and never turn the engine over. By the way, I have taken all the spark plugs out to keep pressure out of the cylinders while troubleshooting.
At this point I was very confused as to why the enigne was not rotating at all. I put a pry bar inside the starter housing on the transmission and was able to rotate the flywheel about a half an inch but no more. So I decided that I would pull the tranny out while the enigne was in the boat, hoping that the alignment of the tranny was binding the engine rotation. After getting the transmission out I put put the pry bar back on the flywheel and have been able to rotate the engine about 90 degrees one way and then back 90 degrees the opposite way. It feels like it gets a little more rotation with every try but still havent gotten an entire rotation. I am at a loss! I did find a little bit of rus tin one of the cylinders but not enough to keep the engine from rotating. I also sprayed the hell out of it with PB Blaster and then poured Marvel Mystery Oil in all the cylinders but this hasnt changed anything.

I guess my next step is to pull the heads off the engine and see if the cylinders are being stopped by debris or something?
Any guess as to what in the heck is going on?

I may have missed it, but has this run since your rebuild? Didn't you pay someone to completely rebuild the engine? If so, I'd take it back to him.

Yea Titan, I paid somebody to rebuild the engine. I called him and he wants me to remove the enigne from the baot and bring it to him. I would rather not have to do that.

I understand. You may not want to drop off the whole boat either, but at this point, I'd say if he wants it out then he needs to take it out. You installed it with the understanding that it was ready to go. It's obviously not.

Not sure on what the issue is. How did water get in the starter? I'd think that was resolved during the rebuild.

Im assuming water got into the starter when the boat had water accumulate in it back when I first started this rebuild.
And Im sure the rust got into the cylinders when I didnt initially install the spark plugs in the engine.

I would take him the boat and tell him to remove the engine but this guy does not have the tools to remove the engine from the boat.

I had this problem on my "fresh" engine when it sat before I put it in the boat. I actually broke the bolt off the front of the engine using a giant breaker bar to try and get it turned over. I ended up taking it to a local mechanic. I'm not sure what they did but they were able to remove the end of the broken bolt, install a new one and get the engine "un-stuck" by using an air-compressor + fitting in the spark plug hole to force the engine over.

I suspect you have a different problem, though -- If the starter was full of water and you can't get it to turn over (even with the spark plugs out), I only see 1 possibility -- hydrolocked.

Do you have a remote oil drain? Drain all the oil and see what comes out. Otherwise -- pump all the oil out and see how much water you find in there.

Well I was able to get the engine to turn over last night. It took about 6 hours of lubing and prying the flywheel back and forth to get the thing to move. I hooked the tranny back up and made sure the starter turned the engine over. After work today I hope I can get this POS to pur!

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Originally Posted by wspeedin

After work today I hope I can get this POS to pur!

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If it fires up and purs, is it still a POS then Will?

I supposed it will not be labeled a POS if it fires up and purs. I've got it all buttoned up and ready to fire when I get home from work today. Its got a new cam in it and will need the break in cycle of 2500RPM for 20 minutes. Any of you ever tried this with the boat not in the water? Im about an hour and a half from the lake and would love to avoid draggging it down there to do the cam break in. Any recommendations?

The only difference comes in how you're getting water into the engine. As long as the engine isn't starving for water (some people have had garden hoses collapse on them), you should be fine.

I'm no expert but every time I fire up the boat in the driveway even at idle I get a real groaning noise from the prop strut bushing if I don't lube it with WD40 first. I don't know what that thing is made of but it doesnt seem to like the shaft turning inside it when its dry. I'd be afraid to run it at 2500 rpm for any length of time without lubing it pretty well.

Your prop shaft shouldn't be turning when on land. The transmission should stay in neutral until you're actually in the lake.

Yea, I dont plan on having the boat in gear while on the trailer. For some reason, lol, that doesnt seem like a smart idea, lol.
Actually, right now my prop shaft isnt even connected to the transmission. I have a new OJ Dripless Sahft Seal to install so it isnt connected. Speaking of that, any ideas on how to get the coupler off the shaft? I have taken the nut off but cant seem to get the coupler to budge off the shaft.

Just have TitanTN come and drive your boat for about 30 minutes...:p This never gets old for me Rob, sorry, had to do it.

Sorry didn't mean to imply that you should run it in gear. My prop turns slowly and makes a growling noise while in neutral. I don't know how fast it might turn at 2500 rpm.

My prop also sometimes turns slowly while in neutral. It's very slow. And I have a dripless shaft seal that uses water to cool it -- so no groaning.

wspeedin -- For the coupler, this just came up in another thread, but the easiest way to do it is to put a socket over the end of the shaft and then bolt it up to the transmission so that the socket "pushes" the shaft out of the coupler. You may need to use longer bolts to make this work and for the love of god, make sure you've pulled out any set screws before you try!

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Originally Posted by inair

Sorry didn't mean to imply that you should run it in gear. My prop turns slowly and makes a growling noise while in neutral. I don't know how fast it might turn at 2500 rpm.

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the growling is the shaft rubbing on the strut bushing. it's made of hard rubber and wants water as a lubricant. soapy water will last longer if you need to run it longer.

my prop doesn't spin out of gear either.

Quote:

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Originally Posted by wspeedin

Yea, I dont plan on having the boat in gear while on the trailer. For some reason, lol, that doesnt seem like a smart idea, lol.
Actually, right now my prop shaft isnt even connected to the transmission. I have a new OJ Dripless Sahft Seal to install so it isnt connected. Speaking of that, any ideas on how to get the coupler off the shaft? I have taken the nut off but cant seem to get the coupler to budge off the shaft.

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Use heat. If you have a torch heat up the coupler all around, not like glowing red, but enough to get it to expand a little, and (with gloves on) pull it off. It should slide right off that way. You can use the same method to put it on. Or i have seen some guys heat it in an oven for like 1/2 an hour. Torch is the quickest way to do it though. Even a propane one will do, but it will take longer.

Growling noise might be transmission related. Check transmission fluid for signs of water. It should be translucent, not milky.

The noise is what Salty87 said, the prop shaft turning slowly inside the plastic/rubber strut bushing. The trany is fine. Had it checked when it was at Bennett's Boat Repair in Maryville TN a few months ago. As far as that goes Donny also checked the bushing for me then as well.

So I tried to start the boat last night with no success!
Im not sure what is happenning but maybe you guys can help me out. When I crank the engine over it doesnt turn very fast which makes me think that the batttery is low. However I have been charging the battery and used a jump box and nothing is giving it enough power to turn it over quickly.
Second, When I turn the key to start and try to turn it over, 5 seconds at most, the pwoer wire at the starter puts out a few puffs of smoke. I know that this cant be normal so Im not sure whats going on there. I took a plug out and grounded it while turning the engine over to check for spark. Im getting spark but it seems to be intermittent.
Any ideas?
BTW, there is no gas in the boat. I have only been trying to get it to crank using starting fluid for now. If I can get the baot to want to start then I was going to add gas.

It definitely sounds like a starter, or starter solenoid issue. Seeing that it had water in it, it's definitely worth taking to a starter/alternator shop and have them bench test it. They'll be able to tell which part is bad and if the starter can reasonably be rebuilt or if you need a replacement. This is all assuming that the engine has been broke loose.

yeah, i was able to get the engine free. Only took an entier day of lubing and small movements, lol.
Arent these starters rebuildable?