1984 Searay Won't Start

Nardo1895

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Joined
Jun 23, 2014
Messages
23
I have a 1984 Searay Cuddy Cruiser with a 350 Mercrusier V8 that has been stored for 2 or 3 years. I recently tried to get it running with no luck. I started with new batteries. Most.all of the console features work (wipers, lights, etc) and the trim switches work. But I can't get any activity at the solenoid or the starter. The gauges also do not work.Here are the steps I've taken so far:

Made sure that the battery selector switch was in the "All" position
Pushed the reset button on the engine -- nothing (did this many times throughout my other testing)
Checked all the fuses I could find on the orange hot wire to the console
One terminal on the back of the key switch has power when the key is in off position
Power to key switch stops when key turned to on position or start position - all three terminals dead
Tried jumping across the key switch terminals with key in off position– nothing
Tried jumping directly from battery to solenoid – nothing
Tried jumping directly from battery to main lug on solenoid/starter – nothing
Tried bypassing the neutral safety switch inside the controller – nothing

It is possible I didn’t get a good connection when jumping the neutral safety switch (NSS). Its a lot of work to get at that switch so I'd rather not try it again unless that is highly likely to be the problem (anywhere else it can be bypassed?)

The most puzzling thing to me is how the power at the switch goes away once the key is turned on. I'm not sure how its wired, but something is interrupting the power which makes me suspicious of the NSS. Its also odd that a direct connection between the battery and the starter does nothing.

The batteries are new and when I put my charger on them they show fully charged.

Any ideas before I give up and haul this critter to a real mechanic?
 

alldodge

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Mar 8, 2009
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42,952
You have corrosion every where is my guess. Remove the battery cables on both ends and get them clean and shinny, this does include the ground cable at the engine block

Then start cleaning more connections, the engine plug for another

Hey GA_Boater this one needs to go to the Merc section
 

Nardo1895

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Joined
Jun 23, 2014
Messages
23
Great advice! I had ignored the advise I usually give other shade tree mechanics with an electrical issue "9 out of 10 times its a bad ground". May not really be true but its amazing how frequently the problem is a bad ground.

The positive terminals were not bad but the ground on the engine block was indeed very corroded. I cleaned the ground stud and terminal and did all the positives for good measure (with two batteries and a battery selector switch there are a lot of terminals). I now have working console gauges and the starter turns over. I was running out of daylight so I didn't try and start it yet but at least the starter is now working.

Thanks for pointing me in the right direction.

What is the "ENGINE PLUG"? Appears to not be the problem, but I'm curious what exactly it is.

Mike
 

alldodge

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Mar 8, 2009
Messages
42,952
Its the round 10 pin connector on the rear of the motor (in most cases) that connects the motor wiring to the Helm

Harness Connector.jpg
 
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