1982 Evinrude 140hp starter / solenoid issues

[nphilbro]

OK, so I'm a bit stumped here. I was working on this motor a guy wants running to sell and at first it would crank over as I checked spark and compression on each cylinder (which were fine). I pumped fuel into the carbs and the starter slowed, then wouldn't engage. I took the starter to the rebuilder and it was burned out.

I pulled the solenoid to clean the poles and I put a new starter on, wired it back up so I could get the motor back into shape, turned the key - nothing. Perhaps this Chinese starter was bad out of the box? Ok, pick up the rebuilt starter, installed it - nothing!

I messed with it for a while, checked and traced the wiring from the diagrams, and then realized what I thought was just an aftermarket solenoid was more than that - it was from an auto shop! While I was trying to get the mounting holes to line up (which wasn't going to happen) I recalled that all the other solenoids had a strap with a dielectric rubber sleeve to isolate the ground from the housing.

This solenoid's mounting bracket was connected directly to the back of the solenoid - grounding it directly to the block. It still had 4 poles but there was nothing I could do to make it work. It must have been wired differently before I removed it so when I put it back on - correctly (by OMC wiring diagram) - it wouldn't function. When I turned the key there was no voltage to the starter, however, the choke would engage when I pushed in the key at the "on" position. I monetarily jumped the starter once directly to the battery just to see if it would engage and it did (plugs were out). I tried it a second time but nothing happened. In hindsight I don't recall if the red plug was connected the second time, but that shouldn't matter since I bypassed the solenoid (right?).

Tomorrow I'm bringing over a couple OEM solenoids I have in the garage that match the motor and see what happens. I'm also bringing a complete working remote with red plug and working battery leads, in addition to TWO starters (one new, one not).

Is there something else I'm missing here on the motor side I need to check? I expect that by changing out the solenoid, cables, battery, and remote that I should be able to get the starter turning. I've never had this type of problem before - and I've changed out many starters and solenoids that were bad.

I can't believe I didn't catch that the solenoid was so different - similar shape, though with four Poles (3/8" top and bottom, 2 smaller in the middle). I'm extremely curious how it was working to begin with.

 

[Will Bark]

Re: 1982 Evinrude 140hp starter / solenoid issues

Did you check the fuse by the solenoid?

 

[nphilbro]

Re: 1982 Evinrude 140hp starter / solenoid issues

Seems like a likely culprit, but yep. fuse is good. I also checked it with the meter just to verify. I should have mentioned it, but I checked it numerous times after I tried different failed schemes.

 

[emdsapmgr]

Re: 1982 Evinrude 140hp starter / solenoid issues

After you check the fuse, check the starter. To test any starter for functionality, use automotive jumper cables direct to a known good battery. If it turns over normally, the problem is elsewhere in the start circuit. A marine type starter solenoid is setup to monitor the shift switch in the control box. If the engine is not in neutral, it won't energize. An old solenoid can go bad. The contacts get burned inside and can cause a couple of problems: burned contacts may not transfer enough current to properly rotate the starter. Also, the contacts can weld themselves together, causing the starter to constantly rotate, draining the battery and causing tremendous heat buildup in the starter.

 

[nphilbro]

Re: 1982 Evinrude 140hp starter / solenoid issues

I suppose then, that the solenoid could weld shut then too. I'm just baffled that it didn't start having problems until I reinstalled it. As I said, I've got two actual OMC solenoids to try out.

My battery was reading 12.6V and this is the one I brought from my shop that I use all the time. I was only getting 11.8V on the one off the boat but wasn't sure about Amp health.

To the best of my knowledge, there's no neutral start circuit on the motor, right? I've poured over the wiring diagram and can only locate one in the remote. (Hence, the reason I'm bringing another working remote).

Is there a way to bypass it in the motor for sake of troubleshooting? It appears from the diagrams that it's grounded when in gear, open in neutral. Unplugging the red plug is how I test spark issues for a bad kill switch but I've never used this method to test the starter or solenoid.

The new "dead" Chinese motor wouldn't even turn when directly jumped with the cables while bolted to the bench. I haven't tried it with the rebuilt one, but I have to assume it's good since he just got done rebuilding and testing it an hour earlier.