Challenger 1800 - ignition issue

[Rikh]

Hoping someone can help with an electrical issue with the ignition. I have a 2001 challenger 1800 with the merc 240. While trying to change out the ignition I accidentally shorted the ground (black wire) to the black with yellow strip wire - it made a tiny spark and now there’s no voltage on the main red wire, which I believe goes to the stator. I can’t find any blown fuses and now I’m not sure what else to check. Everything else seems to be working, lights, blower, etc.

Any help is greatly appreciated.

 

[Dr Honda]

OK... none of that tells me what you were actually working on. Please tell me the actual part you were swapping.

Also... what part was the "Black wire" coming from... and what part is the red wire coming from? (I can't assume they were all from the same part)

 

[Rikh]

Thanks for responding Dr. Honda!

Sorry I wasn't more specific. I was trying to replace the ignition key switch that starts the boat. I've attached a pictures of the switch before I cut the wires and took it out.

While attempting to put a new switch in, that wasn't a direct replacement, I touched the black to the black with yellow stripe wire. I was trying to figure out where all the wires needed to go but should have known better than to take any of the wires to ground. That caused a small spark and then there was no voltage on the red wire any longer.

I now have a direct replacement switch (which I should have started with) but I'm sure it won't work until I can figure out what happened and get voltage back on the red wire. As I said, I've checked all the fuses I could find and none are blown.

 

[Dr Honda]

OK... the black is a ground... and the black/yellow is your kill wire. THey actually go together with the switch in the off position. The Black/yellow is a direct feed from the CDI packs. When it's grounded... that shorts the power, and the spark shuts off. SO... the spar was residual energy, and shouldn't have caused any issues. The red should have power on it to feed the switch.

SO... this may sound obvious... but is your battery switch on?

If it is... verify that the fuses are all OK. There is one way back by the battery disconnect, and is in-line. It's a pain to get to on some boats.

 

[Rikh]

Yes the battery was on and I checked that fuse back by the motor and the ones by the disconnect. Unless there’s more fuses back there? I checked all the fuses that I could find and they are all good. As I mentioned everything else is working, lights, horn, blower, etc.

I’m looking at the new key switch and it says the black with yellow stripe is the magneto. It lists the following.
Red=battery
Black=magneto ground
Yellow w/red stripe=solenoid
Black w/yellow stripe =magneto
Purple=ignition
Yellow w/black stripe =choke

I have all the wires stripped back and there’s no power on the red wire.

 

[Rikh]

I found the fuse!!! I’ll try to post a picture of it later but it was inside a what looked like just a connector.

 

[Dr Honda]

OK... sounds like there's just a bad connection somewhere in the harness.

You said.... "Checked THE fuse by the engine". There is a single by the lift pump... but there is a block on the starboard side of the engine with 4 fuses in it. Did you check those?

 

[Dr Honda]

Guess I should have refreshed my browser. LOL. Glad you found it.