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USCG requirements for start-in-gear protection in 33 CFR Part 183

NickD on Mon April 26, 2010 6:55 AM User is offline

Year: 1986
Make: Volvo Penta
Model: 275
Engine Size: 5.0L
Country of Origin: United States

I don't get this regulation, to start this boat to close the neutral safety switch, owner had to move the shift lever forward, just a tad, then pull the lever outward that disengages the shift mechanism to advance the throttle so the choke would close. If the lever was moved forward just a tad too much, couldn't pull it out as the release only occurs near neutral. Been this way since day one. Any easier to start it would be simply to move the lever forward, stay in gear and hit the starter, but with a big 5.0 L engine, boat would take off like a bat out of hell.

I removed the throttle/shift lever control, Volvo calls this thing a control box, didn't know what they are talking about, its a control, but sure isn't a box. A micro switch rode on a cam that was a normally opened form A. In neutral, this switch was open, only way to close it was to move the lever forward while the control lever was in. If you pulled the lever out first, tangs that rotated the shift cam were removed, throttle would open, but the switch was still opened. The cam was low going into reverse, the only way the engine could start would be in a forward gear, unless you attempted to cheat but just moving it forward a tad then pulling the lever out to disengage the shift, but that was very iffy.

My eye caught that USCG label on the controller, but on the inside, no label was installed ever where one could read it. I fail to even understand why the Coast Guard only wants you to start an engine in gear. No reason is giving, but this regulation only applies to outboards, and outboards with a thrust of under 115 pounds. This is a stern drive with over a thousand pounds of thrust.

Found an identical microswitch but with form B contacts, contacts stay closed at the low point of the cam and open, push the lever out of neutral but before the gears engaged, this switch would open. But if the lever was moved to reverse, switch would still stay open. I found a fender washer exactly the same size as the larger diameter of the cam, riveted that to the cam perfectly center, then cut a notch to the smaller diameter using the cam as a guide, and duplicated that for reverse.

With a cold engine, only have move it forward, then return it to neutral to set the choke, engine starts instantly. With a warm engine, just leave in in neutral and hit the key. Before, could have the throttle completely opened forward and the engine would start, that really seems crazy if someone doesn't understand the system. Couldn't do that in reverse, but with the added fender washer with a notch in it, it works the same way.

Not good to assume, but assuming Bayliner put this controller in by mistake, in searching the same controller is used with a different cam, but would cost an arm and a leg to buy one if you could even find one. But you run across the darnest things.

Just to make sense of this USCG regulation, do know on small outboards, easy to kill the engine, but a lot more difficult to start them while in gear, like trying to restart a lawn mower in thick grass.

Its like air bags, in older cars, no warning label was given about a young child getting killed in the front passenger seat and no requirement to add that label. Or the fine imposed by releasing refrigerant, anyone every see that? Immigration is the same way, zillions of laws, but really have to dig deep to find them, and if you don't can be in big trouble. Or reading on a can of hair spray, only use at home at your own risk, but your employer will be fined if you bring this can to your workplace.

Zillions of laws, crazy, and most with no logic behind them and buried deep in some book or a web page.

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