2002 mercruiser 3.0 issues starting

[cubajorge_2008]

Guys i have ran out of ideas. Changed the starter solenoid. Changed the starter but when i attempt to start from ignition key it just clicks. I starter it with a screw driver on the starter and same time with the key and it works but not with just the key. I Notice there is a cable on the battery terminal that has a 20amp fuse if i hold the key to long trying to turn it on it will blow the fuse

The engine is a 2002 mercruiser 3.0 with stern drive
seriao D851715

 

[alldodge]

Slave relay on the motor item 17 part number 89-96158T, old part number is 89-96054T which also works just fine

https://www.mercruiserparts.com/bam/.../30914/1604/70

The relay sends main power to the starter solenoid so the power to from the key doesn't have to go so far

 

[cubajorge_2008]

Thats the first part i changed. Can a bad ignition switch cause the same issue?

 

[alldodge]

Thats the first part i changed. Can a bad ignition switch cause the same issue?

Yes

Turn key to ON
Use a jumper wire and connect red/purple wire to yellow/red on the key, if its starts its the key switch

If it does not turn over/crank then check your neutral safety switch, while holding key to start move the throttle handle a bit F/R

 

[alldodge]

I Notice there is a cable on the battery terminal that has a 20amp fuse if i hold the key to long trying to turn it on it will blow the fuse

Find out where this wire goes

 

[cubajorge_2008]

Ok so this is what happens. I attempt to start it and it clicks. I try again and it clicks and again and again and eventually it will crank. I check the wires and they seems ok im going to do a voltage test i have the feeling that is not getting enought voltage on the slave solenoid. When i jump it from battery to solenoid it cranks every single time

 

[alldodge]

I could have some corrosion on bat cables, maybe ground is loose or engine connectors (like main 10 pin)

Have you tried jumping the key switch yet?

 

[cubajorge_2008]

How to jump the key switch?

 

[alldodge]

The key has 3 post with wires Red/Purple, Purple and Yellow/Red

Red/Purple is main power and has power all the time. Use a jumper wire and connect to Red/Purple and Yellow/Red and the starter should engage and motor will crank over. If key is in the Run or ON position when cranking the motor will start and run

 

[cubajorge_2008]

It clicks aswell. So i did a voltage test and the voltage goes to the solenoid intermitently from 7.9 to 12 volts. But it takes a few second to reach 12.56v. So as soon as the signal gets sent it reads 7.8 then few second 12.56. However it clicks when that happens. Does it mean i have an open wire from ignition to selonoid? What size wire does it use? Im going to run there wire new if needed

 

[alldodge]

"Please"

get to the back of the key switch and jump across the 2 terminals mentioned above

 

[cubajorge_2008]

I did and it works sometimes. Most of the time just clicks like usual

 

[alldodge]

OK thanks, didn't understand the previous post

voltage goes to the solenoid intermitently from 7.9 to 12 volts. But it takes a few second to reach 12.56v. So as soon as the signal gets sent it reads 7.8 then few second 12.56. However it clicks when that happens.

if you can get to the neutral safety switch, jump across it and try it

Since it will crank sometimes and not others, then I'm seeing corrosion, bad connection or both.

Check ohm value between yellow/red wire on key switch to small terminal yellow/red wire on the slave solenoid. Should be no more then a few ohms.

Can also, if you can get to the neutral safety switch, jump across it and see if it works. If unable to get to the safety switch, run a long wire from the yellow/red post on the key switch to the small terminal where the same wire is connected

 

[cubajorge_2008]

As a desperate attempt i ran a big wire from the ignition key to the slave solenoid directly and it does same thing. One long click then stops. Or sometimes starts. I think issue will be the starter what you guys think?

 

[alldodge]

As a desperate attempt i ran a big wire from the ignition key to the slave solenoid directly and it does same thing. One long click then stops. Or sometimes starts. I think issue will be the starter what you guys think?

I don't think so because you said in post 1 about using a screw drive at the starter and it works. Unless this is not the case

Look at the battery cables and don't forget the ground end on the block. Then pull the 10 pin engine connector off and look at the pins

 

[cubajorge_2008]

Can i try a long cable straight from the battery positive to the ignition key + terminal and see if that will work? if it still clicks i will also run a long cable from the ignition key to the slave solenoid and see if with 2 brand new cables it will work or not. I will report results tomorrow time to sleep for today

 

[cubajorge_2008]

I changed the ignition key to a new one and still nothing. Can i tun new wires straight from the battery and another new wire directly to the slave solenoid?

 

[alldodge]

You can, but don't know what it will prove compared to what you have already done. In previous post didn't you run a wire from bat to key, and back from key to slave?

The slave needs a ground and power to energize

Check the larger yellow/red wire going from the top terminal or the slave to the starter for corrosion. Could even connect another wire to/from.

Is there any rust or corrosion on the connections at the starter?