occasional starting problems on 1994 60HP

[Lewis]

Hi,
Getting the boat ready for the summer, and I have had some problems getting the starter to go. I've only had the motor for a year, and it has had this problem as long as I've had it. But it has always started after a few tries until today. Today I tried several times all afternoon and all I got was a solid "click" from the solenoid and nothing from the starter. Here's what I've checked:
- cables are all good, no corrosion, contacts clean
- solid 12.6V to solenoid when trying to start
I tried to check voltage at the starter, but almost every time I tried, the starter engaged and I got 12.6V -- which is why periodic faults are so infuriating! The one time it just clicked I wasn't expecting it and not paying very close attention, but I think I saw a "mV" (millivolt) reading on the meter.
So my questions are:
- does this appear to be a failing solenoid?
- do solenoids fail this way (work fine most of the time, but occasionally not at work at all)?
- if it's not the solenoid, what is the next most likely culprit?
Thanks,
Lewis

 

[jerryjerry05]

Re: occasional starting problems on 1994 60HP

Measure voltage across the solenoid.
OR,use a test lite across the lugs as you turn the key.
Try jumping across the lugs with a screwdriver.Thast supplies direct current to the starter.
That not do it?
Any voltage through the solenoid?Then the starter is suspect.
These are easy to take apart and re-build or replace.

 

[Lewis]

Re: occasional starting problems on 1994 60HP

Thanks, Jerry.
Voltage across the solenoid is 12.6V if I'm measuring it right. I'm reading between: 1) the solenoid terminal connected to the heavy red battery cable; and 2) the solenoid terminal connected to the cable marked with yellow that connects to the starter. The photo shows where I am measuring. I get the 12.6 across here with the key on, off, or start.

 

[hotrod53]

Re: occasional starting problems on 1994 60HP

I would try shorting with a jumper cable or a big screwdriver across red and yellow cable. You should be seeing 12 volts except whan you hit the key. Essentially what happens is you close a switch contact across red and yellow when you hit the key. A closed switch should have close to zero volts across it, if it's bad you will read 12 volts or there abouts across it. Assuming that the solenoid is clicking everytime you hit the key, it sounds like your solenoid is bad. Probably the contacts are destroyed inside and sometimes makes and sometimes doesn't. Shorting across red and yellow will prove this.

If it turns out that the starter is bad, don't be afraid to pull it apart, there's not much in there. You will need to make a sheetmetal tool to hold the brushed in place to re-assemble it, but no big deal.

 

[Lewis]

Re: occasional starting problems on 1994 60HP

Yep, I think that's it. Of course, now that I'm actively troubleshooting, the thing works perfectly every time. But I think I'll order a solenoid to have on hand (and on board) for when the current one completely gives up the ghost.
Thanks for all the help!
Lewis