Starter problems 4.3 GL w/ SX drive

Lou C

Supreme Mariner
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Nov 10, 2002
Messages
13,296
You have a wiring problem (you should get battery voltage, or close to it, when you energize the yellow/red wire at the solenoid) whether you are doing this with the ignition key or the remote starter switch.
When troubleshooting a starter problem the first thing you should be doing is measure the voltage between the big positive connection on the solenoid and the battery negative, this should be battery volts, if not you have a problem with your positive or neg cable or the negative ground stud on the bellhousing for the negative cable. Next, you connect a voltmeter between the yellow red wire at the solenoid and an engine ground, and have someone turn the key, same thing battery volts or close to it, If your are getting 5-7 volts something is most definitely wrong! You need to get a V/P wiring schematic and follow how the current flows for the starting system and find out where you are losing voltage.

First check for batt volts at your big pos terminal on the solenoid
then check for batt volts between your yellow/red wire at the solenoid and ground (or negative return path more correctly stated). Then get the schematic and starting checking each connection. I know its a pain but that's what you gotta do

the only other thing I can think of, is if a mechanical problem is causing the engine to be hard to turn over and that is sucking so many amps through the starter that your voltages are reading low. But, if that were the case the starter would be getting real hot real fast. Sometimes you have to pull the spark plugs and try to turn the engine over by hand, water in cyl can cause this, and so can problems with the outdrive, gimble bearing etc.
did you bench test the starter off the engine?
 

Formula588

Cadet
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Sep 7, 2020
Messages
17
So I exchanged this latest starter for a new one and the boat starts up just fine. I am at a loss. Not sure how long this starter will las
 

rs1lollie

Petty Officer 2nd Class
Joined
May 27, 2009
Messages
194
could be a bad or flaky starter relay, I had one go bad and thought it was my starter as the starter just clicked and didn't engage,
 

Formula588

Cadet
Joined
Sep 7, 2020
Messages
17
Ok new starter did the same thing, lasted a day and now won't eng. I pulled the lower drive unit off. Starter did the same thing, grazing against flywheel. So doesn't appear to be binding on the alignment.

so I pulled all the plugs out, disconnected the coil and the fuel pump, and now the starter will turn the engine over no problem.

​​​​​​​what could cause this?
 

Formula588

Cadet
Joined
Sep 7, 2020
Messages
17
Also no fluid came out of the plug holes when turning the crank. I could turn the crank with a breaker bar with the plugs in.
 

alldodge

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Mar 8, 2009
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43,119
Place a voltmeter on the battery terminals and try cranking
Then connect to starter post

I'm thinking voltage drop
 

Lou C

Supreme Mariner
Joined
Nov 10, 2002
Messages
13,296
agreed that's what I said earlier, you seem to not be getting 100% of the voltage it needs to turn the engine normally, if bench tested with no load it will probably work fine, and when you removed the plugs there is no compression so with even with low voltage it works fine but with the normal resistance of the compression it's not getting enough volts to energize the starter.
you're back to finding a Volvo wiring schematic and tracing how the voltage travels....

in my OMC shop manual the test it shows for measuring voltage drop when cranking is to hook up the positive lead for the voltmeter to the big positive terminal on the solenoid (from battery) and the negative to the starter body. If it cranks the engine at 9 or more volts it's ok lower than that you have a problem.
 
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