Solonoid problem?

[JAOLSON2016]

As I said in another post I don't have an ignition key to a 1975 85hp Evinrude. I saw a guy in YouTube bypass the ignition system by connecting jumper cables to the solenoid motor, and the solenoid rod pushed up and engaged the top large gear "cog" on top of the motor. When I did the same thing, nothing, but when I connected the cables to the solenoid unit, its "cog shaft" spun quickly but did not go up to engage the upper gear cog. How do I use a multimeter to see if either or both units, especially the solenoid motor, are weak or need repair or need to be replaced? Or what else can I do?

 

[flyingscott]

Lets get some of your terminology straight here that is not a solenoid motor that is a starter motor. If you have no key the motor will not start because the ignition is not on. Did you connect the jumper cables correctly or did you reverse them and make the starter motor run backwards. That is not a cog shaft it is called a bendix it could be stuck down. The upper gear cog is called the ring gear and it is attached to a flywheel. You need to get the FACTORY MANUAL for your motor before you do anything else.The starter solenoid is off to the side of the starter and will have 2 heavy cables on it and 2 smaller ones and is round.

 

[jakedaawg]

yep, now that we have the terms straight now we need to get you a key. Cheapest way would be to take either the whole boat (recommended) or just the key switch to a well provisioned shop. They should have a master key set if they are worth their salt. They will figure out which key you need and sell you one for about $6.25 plus labor. It actually takes time to try 68 or whatever different keys.

Next thing you need to do is have your battery load tested. They can do it while they are busy sticking keys in the switch.

Now that you have a known good battery and a key you should do the following:

1. Clean all battery cable terminal ends with a wire brush. This should include the ends at the battery and the ends at the solenoid and engine block. They are easy to find, just follow the cables.

2. Throw away any wing nuts that are used to secure cables to the battery. Replace with a star washer that bites into the terminal and a hex nut (usually 5/16" x 18). Tighten with a wrench.

3. Lube the bendix shaft. I think a light lithium grease would be fine but many others will chime in and give their manuals suggestion on this. Whatever you use make sure its not a thick sticky grease.

4. Try your new key and see if it now turns the engine over.

5. If it doesn't, search some of racerones' posts. He has explained to many people how to disassemble and inspect their starter motors.

Report back if still having difficulties.

 

[F_R]

Good advice. But if I may add one thing, look at your present key switch. Hopefully, it will have a number stamped next to the keyhole. That number identifies the key that fits. Your dealer can provide a new key from that number. Now, if the key switch has been replaced with a generic switch at sometime in the past, that is a different story.