1987 merc 5.7 will not turn over

[BudL1te]

I have a 1987 sea ray 24s 5.7 merc. Was having trouble starting it, determined it was a fuel pump issue. Put an electric fuel pump on and it started and ran. Drove the boat home about 60 miles. Got some hoes to properly connect the electric fuel pump. Went to turn the key to start it, I hear a beep, but when I try to engage the starter, nothing happens. No click, nothing. Circuit breakers are not popped out, the positive wires at the starter we're dirty. I removed them and wire brush them. I could not get the small wire nut loose from the solenoid, when I turned the nut, it seemed to turn everything. The negative side at the engine looks like very good connections, but I did not remove them and clean them. Battery connections are good.

at this point, I am suspecting the solenoid on the starter. Although typically in my experience, they will at least click. What I short the solenoid, the engine will turn over. It just will not turn over with the key.

any ideas? I really don't relish the idea of trying to get that starter out in the limited space. I'm also wondering about the neutral safety switch on the throttle. I'm not sure how to test it,

 

[Bondo]

Ayuh,..... Is the yellow/ red wire "Hot" from the key switch when in the start position,..??
Through the neutral safety switch,..??
At the slave solenoid,..??
At the starter's solenoid,..??

 

[Scott Danforth]

I have a 1987 sea ray 24s 5.7 merc. Was having trouble starting it, determined it was a fuel pump issue. Put an electric fuel pump on and it started and ran. Drove the boat home about 60 miles. Got some hoes to properly connect the electric fuel pump. Went to turn the key to start it, I hear a beep, but when I try to engage the starter, nothing happens. No click, nothing. Circuit breakers are not popped out, the positive wires at the starter we're dirty. I removed them and wire brush them. I could not get the small wire nut loose from the solenoid, when I turned the nut, it seemed to turn everything. The negative side at the engine looks like very good connections, but I did not remove them and clean them. Battery connections are good.

at this point, I am suspecting the solenoid on the starter. Although typically in my experience, they will at least click. What I short the solenoid, the engine will turn over. It just will not turn over with the key.

any ideas? I really don't relish the idea of trying to get that starter out in the limited space. I'm also wondering about the neutral safety switch on the throttle. I'm not sure how to test it,

why replace a mechanical pump with an electric. did you add the oil pressure switch to the circuit to do it properly?

if the start terminal was turning on the solenoid, you need to pull the starter, take it to a starter repair shop and replace the solenoid

if you were near me, I would give you a mechanical fuel pump and starter just to get them out of my garage.

 

[BudL1te]

Ayuh,..... Is the yellow/ red wire "Hot" from the key switch when in the start position,..??
Through the neutral safety switch,..??
At the slave solenoid,..??
At the starter's solenoid,..??

I will be checking more on this today (Hopefully" Gets hot out here 110 degrees so motivation plays a big part.) I am not great with multi meter and have no idea where the neutral safety switch is (I am sure it is in the throttle assembly but this boat is new to me.

Because the solenoid did not click it makes me think it may not be anything to do with the starter but I don't work on them for a living and have not been in many scenarios.

When I short the solenoid it turns over so starter is working and seemingly so is the solenoid. (My logic could be flawed there..)

Prior owners worked the starter well trying to get it to start I am sure. It gave her trouble once when trying to crank it for me but then seemed to work just after that. She claimed never gave her problems till last lake trip. I would have started with the fuel pump but they started everywhere else.

 

[BudL1te]

why replace a mechanical pump with an electric. did you add the oil pressure switch to the circuit to do it properly?

if the start terminal was turning on the solenoid, you need to pull the starter, take it to a starter repair shop and replace the solenoid

if you were near me, I would give you a mechanical fuel pump and starter just to get them out of my garage.

The electric fuel pump is temporary till I get the mechanical one found and ordered.

I expected the solenoid to at least click if it was bad, if the starter was bad, then, when I shorted the solenoid I would expected it not to turn over. Soooo. Thinking maybe a "hidden" fuse or circuit breaker some where to check although the circuit breaker on the dash is not tripped.

 

[Scott Danforth]

if the terminal spun as you stated in post #1, there is no longer an electrical connection between the start wire and the parts on the inside. no electrical connection, no click.

pull the starter and repair.

 

[BudL1te]

if the terminal spun as you stated in post #1, there is no longer an electrical connection between the start wire and the parts on the inside. no electrical connection, no click.

pull the starter and repair.

Ugh, I was kind of thinking that. but, it was not doing anything prior to me turning it either so no change???

The starter is horrible to reach. Really thinking about cutting a hole in the hull to access then silicone close it lol. (Not really) but it is a wee bit cramped. Even pulling wires from starter to clean was an uncomfortable, longer than necessary process.

I believe I can just get a solenoid from auto parts store to replace yes? Even if by chance it is not the issue, because of the corrosion, I feel it would not be a bad thing to do.

 

[Scott Danforth]

some boats you have to pull the engine to get to the starter

NO, YOU CAN NOT USE AN AUTOMOTIVE ANYTHING ON A MARINE STARTER. get a sealed marine starter solenoid.

Marine starters are similar to, however not automotive starters.

 

[BudL1te]

I will check online for a Marine Solenoid.

 

[Bondo]

The starter is horrible to reach. Really thinking about cutting a hole in the hull to access then silicone close it lol. (Not really) but it is a wee bit cramped. Even pulling wires from starter to clean was an uncomfortable, longer than necessary process.

Ayuh,..... Welcome to the world of wrenchin' on boats,..... Sounds quite Normal,....

 

[achris]

You need to get a circuit diagram and chase down the start circuit with a test light. Have a look in the 'Adults only' section for a description of how the starter system works... Go to a auto shop and buy a 12v test light, not expensive and easy to use. You'll need a friend helping you (just to turn the key to 'START'), and you start at the starter slave solenoid. Check you get power to that, and that it's 'picking' and supplying power down the line, then move to the next device in the circuit and do the same checks. You'll eventually find where the power stops, and you'll have found the problem. I suspect it will be the starter, and you will have to get it out, but do the PROPER troubleshooting first....

Chris.......

 

[BudL1te]

Thanks Chris, I was hoping for a "Typical problem resolution" from others that might have been a common issue. But, The boating Gods did not shine down upon me with that.

 

[BudL1te]

Problem Solved:

Checked for power to the Red/Yellow wire at the Solenoid while a friend turned the key. No Power. Followed the wire back and it went into a coupler with many other wires.

The coupler is a round rubber coupler on the top left of the engine that connects the wire harness together. I separated it and found the pins were black (not burned) but coated and not good for connectivity. I wire brushed them, some of the pins were clamped (they are split in half) so I separated them a little, scraped the holes on the other side, Plugged the harness in and presto. turning the key now successfully engages the starter.

My elation was short lived when I discovered the the Fuel/Water mixture was too high UGHhhhh. But, A known problem is better than the unknown problem and a new filter, draining 3 or so gallons of water from the tank and fuel lines and she started right up.

 

[achris]

Nice... :thumb: