2004 Volvo Penta 5.0 GXi intermittent starter problem

[lfmichael]

I've been having an intermittent problem with starting the motor. Usually starts first time, but after several more starts (stopping the motor for water-skiers to enter the boat), Motor will not start. Turn the key and get the warning beeps and hear 'boost pump' I think, but motor doesn't crank. Sometimes after several tries it will start other times have needed a tow, and it starts the next day. Thought it was starter relay, so replaced it. Worked well for a week, than had same issue. Got it to work by moving throttle and pushing button to remain in neutral, so thought it could be the neutral safety switch. Replaced the switch and worked for two outings than last night happened again after skiing. After several tries, installed original starter relay and boat started. Returned to dock and tried starting 6 or 7 times and started each time without fail. Where to look from here?

 

[gbeltran]

Battery voltage? Connections at the switch, battery and starter. Ground connection at the engine. That's the stuff I'd look at. Start with the voltage check, next would be the switch for me.

 

[lfmichael]

Thanks, i did check the ignition switch and battery voltage. Both were good. I look at grounds and connections at starter next.

 

[further]

I've been having an intermittent no start issue as well. First thing to do is follow all the tests on the attached PDF taken from here
http://forums.iboats.com/forum/engi...uiser-i-o-inboard-engines-outdrives/366271-vp

I did the test and everything checked out ok. Culprit may be my original control box and neutral start switch being out of adjustment.

 

[lfmichael]

Great troubleshooting document. Thanks - hopefully I can figure this out this weekend.

 

[lfmichael]

So I followed the troubleshooting guide and found that it is an intermittently bad ground on the starter relay socket.