Starter testing with damaged solenoid...

[hoowahfun]

Hi all, been reading this site for a while and recently got a new to me boat in need of some work. Boat is a 1987 Sea Sprite 195. Engine is a 1987 3.0 Mercruiser, 130HP, S/N B515218.

When I turned the ignition switch I hear a click/clunking sound coming from the general area where the starter is located. I first checked the battery voltage and charged it up, then tested and got the same result. My next approach was to check and clean the electrical connections and of course the first one I try to remove breaks part of the back end off the starter solenoid. The threaded bolt that connected the big red cable and another one broke apart and now the inside is exposed. Obviously that will need to be replaced. Although I'm pretty good mechanically, I'm not the best at following along with electrical stuff so hope these aren't previously answered questions. I tried some searches, but didn't find anything matching my situation. My questions are as follows (will upload pics when I get to the 3 post minimum):

1) Is there a way to test the starter as it is to see if it operates correctly? On or off the boat? Trying to avoid buying the whole starter assembly if I just need the solenoid. I could buy a solenoid and check, but then if the starter is bad I would have to buy a whole unit since I can't seem to find just the starter without the solenoid.
2) Can I also test the other relay/solenoid/switch thing next to the circuit breaker without fixing anything at this point? Trying to get an idea of the scope of my starting problem.
3) What position is the 50A circuit breaker reset button supposed to be in? Not sure if it's tripped or not. Doesn't easily push in like I expected and I don't want to force it and break it if its fine. How hard are these to push in to reset?

Many thanks!

 

[Bt Doctur]

Being that you busted the cover you need to remove the starter .Remove the bolt that carries the motor lead, the 2 mounting screws, push in and twist. Solenoid should pop right out.

Yes, If you turn the key and get nothing, jump the large Red/Purple to the yellow/red stripe connection. slave should activate and operate the main solenoid and starter. If not jump the 2 large studs. if starter works, the slave is bad

Really no, with the starter hooked up you will (if the slave is bad) get a soft click , by jumping the 2 large studs you will activate the main starter solenoid and starter motor. If you get a loud clank, then suspect a hydro-lock condition or a bad starter.

The red button is more of a click instead of pushing the red button in like a normal breaker. Push hard with your thumb. if it clicks it was tripped. If it dosent ,it wasnt tripped

 

[hoowahfun]

Bt Doctur,

Are you describing removing the starter or the solenoid? Or both? When you say remove the bolt that carries the motor lead, are you referring to the bolt on the back of the solenoid that has the main positive (red) cable attached?

1) I'm assuming this applies even with the back end of the solenoid busted up?
2) Thanks, I'll get the starter issue worked out then go from there.
3) I'll check this out after work today.

 

[Bt Doctur]

 

[hoowahfun]

Thanks, that helps. Will try to post pics.

 

[hoowahfun]

With the solenoid off, is there a way to test the starter then with the main lug for the positive connection broken off and also the connection with the purple/white wire?

 

[hoowahfun]

Here's what I'm working with..

 

[Bt Doctur]

Looks like some serious water intrusion at some time, too much rust. Remove the 2 bolts for the starter and get it on a bench.
If it was wet ,the water may have got to the inside of the starter and the starter is seized up
Apply 12v to post C ,that should make the starter motor spin, if not water intrusion took out the starter

http://www.boatfix.com/merc/Servmanl/13/13A4R2.PDF

 

[hoowahfun]

Well, I got the solenoid removed. There was also rust inside where the solenoid mates to the starter and on the little plunger thing and the spring. Also looked like someone had it off at one point because there was that cheap clear bathtub silicone around the mating surface....I'm hoping the starter isn't junked out, will hopefully pull it tonight and post some pics.

 

[Bondo]

I'm hoping the starter isn't junked out,

Ayuh,.... Welcome Aboard,.... As much saltwater that motor appears to have seen, Ya don't wanta get yer hopes to high for that starter,...
If it ain't already junk, it's probably nearly so,...

When ya replace it, go to the smaller more powerful permanent magnet style,....
Just make sure ya get new starter bolts with it, as they're slightly shorter,...
Put it in with the old bolts, 'n the bolts bottom-out, before the starter is tight to the block,....

Btw,... If the 50 amp breaker don't push in, it's because it's already "In",.... it's Workin',...
A test light on the backside of it will tell ya so,...

 

[hoowahfun]

Thanks Bondo, I'll have to look into the starter recommendation if it comes to that. I forgot to mention the circuit breaker seemed okay. I pushed in pretty hard and it didn't do anything, so I'll take it as good unless something else comes up to make me think otherwise.

Regarding saltwater, the previous owner said it was a freshwater boat, but he did take it to Key West one time and had it flushed by the marina afterward. He's already proven to have lied about quite a number of things regarding the boat already so you may be on to something :lie::disturbed:

 

[Bt Doctur]

Flushed it with salt water because it went under water

 

[hoowahfun]

Sure hope not, but at this point anything is possible.

Well, looks like the weather is not cooperating tonight. One thing worse than working on a boat in the dark is doing it in the rain. We'll see if it lets up or may just have to wait. :blue:

 

[hoowahfun]

Well I got the starter off last night just before a huge thunderstorm came through and knocked the power out for several hours. Will have to wait till next week to diagnose this since I'll be heading to Bermuda this weekend for the 35th Americas Cup

 

[hoowahfun]

Well I squeezed in a test before packing...first bad sign was that water poured out of the starter. I then used jumper cables from my car battery to the starter with the negative side grounded to the starter and the positive side to post C. Got nothing. Guess I'll need a new starter. I found one for a good price that's a permanent magnet version from DB Electrical...should have them back in stock in a couple of weeks.