New starter solenoid kills everything.

[Pamlico Pirate]

I have a 2000 Maxum with the 4.3 Mercruiser. When turning the ignition key, I have been dealing with the intermittent clicking from the old slave solenoid before it will finally engage the starter and then start the engine. That’s the only issue I’ve ever had with this boat. After reading several other’s similar experiences, I decided the solenoid should be replaced. No problem, I can do that. I finally found the time today and installed the new solenoid EXACTLY how the old one was installed and made sure everything was properly connected. Once I reconnected the battery, I put it on the hose and went to turn the key. It sounded like it was going to fire right up. Problem solved, I thought. Then immediately I hear a pop and every bit of power in the boat is killed. Dead. Nothing works. I disconnect the battery, check my connections, Reconnecting the battery also restored power to everything else. So, I try again. The exact same thing happens. It kills the entire power system. I’m beyond frustrated now. I reinstalled the old solenoid and everything returns to the original issue. Intermittent clicking before it engages the starter and starts the engine. Boat runs great once it fires up. What’s the deal? I’ve spent my entire day trying to figure this out. I’m not great with electrical systems and have not hooked a meter up to anything but can’t imagine why the new solenoid completely kills everything. Battery is fully charged and all connections are good. Anyone have any thoughts? Thanks in advance!!

 

[Paintman1960]

Defective New solenoid??

 

[dubs283]

sounds like the new solenoid is the issue. what is most confusing is how after a period of time say, your disconnecting and reconnecting of the battery the system has full power

my immediate thought is the 50A breaker in the engine harness has tripped but it is not a thermal breaker i.e. it does not reset after it cools, you must reset it manually

my guess is the new solenoid is faulty and shorting the main power (red/pur) to ground and tripping a breaker. there is a ground on the primary side of the solenoid that may be causing this

is the new solenoid oem?

 

[Scott Danforth]

Stop throwing parts at it

Your issue is most likely a bad connection.

Start at the battery and clean every connection to the motor and then up to the helm. Clean and shiny enough your mother in law would eat off them. Then when they are all tight, seal with marine electical varnish

 

[Pamlico Pirate]

Stop throwing parts at it

Your issue is most likely a bad connection.

Start at the battery and clean every connection to the motor and then up to the helm. Clean and shiny enough your mother in law would eat off them. Then when they are all tight, seal with marine electical varnish

But I don’t really like my mother in law. In all seriousness, all connections are clean and tight. Can’t say the same about my mother in law.

 

[Paintman1960]

But I don’t really like my mother in law. In all seriousness, all connections are clean and tight. Can’t say the same about my mother in law.

LMFAO !!!

 

[Scott Danforth]

But I don’t really like my mother in law. In all seriousness, all connections are clean and tight. Can’t say the same about my mother in law.

Every connection from the battery to the block and starter? Usually its the ground. Did you use a wire brush in a die grinder, or 150 grit?

 

[Pamlico Pirate]

The possibility of it being defective crossed my mind. I’ve got a supplier here who I think can get me another tomorrow. I’m willing to spend the few bucks on trying a another new one. Thanks!

 

[Scott Danforth]

Test first, dont simply waste money and throw parts at it

 

[Pamlico Pirate]

Every connection from the battery to the block and starter? Usually its the ground. Did you use a wire brush in a die grinder, or 150 grit?

I wire brushed. I thought that would be sufficient but I’ll go back over it all with what you e suggested. Thanks!

 

[Pamlico Pirate]

sounds like the new solenoid is the issue. what is most confusing is how after a period of time say, your disconnecting and reconnecting of the battery the system has full power

my immediate thought is the 50A breaker in the engine harness has tripped but it is not a thermal breaker i.e. it does not reset after it cools, you must reset it manually

my guess is the new solenoid is faulty and shorting the main power (red/pur) to ground and tripping a breaker. there is a ground on the primary side of the solenoid that may be causing this

is the new solenoid oem?

It’s aftermarket from Sierra Marine.

 

[achris]

It’s aftermarket from Sierra Marine.

Everytime!

A) is it the RIGHT part, or just one that Sierra says 'will work'?
B) Sierra... Sort of says it all.

Given the time and effort you have put into the job, a genuine part would have saved you time and money. Cheap parts aren't.

Old Chinese proverb... Cheap no good, good no cheap.

We can direct you to the right Merc part, but we're going to need the engine serial number ("2000 Maxum" tells us nothing). And are you looking at the slave solenoid (the one near the top of the engine), or the starter solenoid (on the starter motor itself)?

What's the Sierra number of the one you got?

Chris......

 

[Pamlico Pirate]

Everytime!

A) is it the RIGHT part, or just one that Sierra says 'will work'?
B) Sierra... Sort of says it all.

Given the time and effort you have put into the job, a genuine part would have saved you time and money. Cheap parts aren't.

Old Chinese proverb... Cheap no good, good no cheap.

We can direct you to the right Merc part, but we're going to need the engine serial number ("2000 Maxum" tells us nothing). And are you looking at the slave solenoid (the one near the top of the engine), or the starter solenoid (on the starter motor itself)?

What's the Sierra number of the one you got?

Chris......

Sorry for the delayed reply. I’m talking about the slave solenoid. The engine serial number is 0L625005. I attached a photo of serial numbers. The Sierra part I have is 18-5817.

 

[achris]

... the slave solenoid. The engine serial number is 0L625005. I attached a photo of serial numbers. The Sierra part I have is 18-5817.

Here's the Merc genuine part...

Mercury-Mercruiser 89-96158T SOLENOID, TRIM PUMP

Mercury-Mercruiser 89-96158T SOLENOID, TRIM PUMP genuine factory part not aftermarket. Fast shipping - Click here to see live inventory status

www.mercruiserparts.com

 

[Pamlico Pirate]

Ordered the OEM part and finally had a few minutes to replace it tonight. Problem solved. Lesson learned. Thanks guys!