2005 3L TKS Intermittent Starting Issue

[kidafa]

I Have

Have a 3L mercruiser manufactured in 2005 thats a Turn Key Start model...

It has a intermittent starting problem;

When I turn the key on the buzzer sounds, turn it to crank and the buzzer turns off but the starter doesn't kick in or anything. I usually turn it off and try if a few times and it fires up fine. Tends to ONLY happen when the boat is cold and Its just been put in the water.

Would like to get ontop of it before im (touch wood) stranded somewhere.

Thanks in advance,

Chris

 

[achris]

Re: 2005 3L TKS Intermittent Starting Issue

Could be the supply to the key switch, the key switch, starter solenoid or slave solenoid, or the starter itself or a connection on any one of them.. You are going to need to get a test light or multimeter and start probing around and verify each item in turn.

Chris.....

 

[Bondo]

Re: 2005 3L TKS Intermittent Starting Issue

Ayuh,... Sounds like corroded wirin' ends, somewhere's 'round where Chris has mentioned...

 

[ENSIGN]

Re: 2005 3L TKS Intermittent Starting Issue

It's going to have to not crank over for you to find the problem.The key switch,neutral safety switch,slave soliniod,starter or wiring are all possible problems.You'll need a test light and a helper to hold the key switch.When it just clicks,probe the yellow/red stripe wire until you find the open circuit and suspect any part that may have gotten wet.

 

[Don S]

Re: 2005 3L TKS Intermittent Starting Issue

Here is a thread that might help on where to check things.

http://forums.iboats.com/mercruiser...ting-your-engines-starting-system-167035.html

 

[kidafa]

Re: 2005 3L TKS Intermittent Starting Issue

Thanks for the response everyone.... So Ill need to wait until its more consistantly not turning over before I can troubleshoot then correct?

 

[Don S]

Re: 2005 3L TKS Intermittent Starting Issue

You can check all the connections to make sure they are clean and tight, and if it doesn't crank over you might move the shifter around a little to see if the neutral safety switch is just missing by a little, other than that not much you can do.
Hard to find a problem when it's working.

 

[kidafa]

Re: 2005 3L TKS Intermittent Starting Issue

Thanks Don, I will check all the connections and make sure they are all tight Dont fancy being stranded somewhere.

Wouldnt surprise me if it is not quiet in neutral though...

 

[kidafa]

Re: 2005 3L TKS Intermittent Starting Issue

Don,

If it doesnt even make a CLICK from the rear when I crank the key to the "start" position but If i continue to hold it in the start position for about 5seconds then it will turn over and start fine?

Tends to only do it when it hasnt been started at all for the day for the first cold start.

Any ideas?

Thanks again,

Chris

 

[Don S]

Re: 2005 3L TKS Intermittent Starting Issue

It may be a faulty slave solenoid. When it doesn't click, you need to check the yellow/red wire on the small terminal of the solenoid and see if power is getting to it, and make sure the ground is good on the other small terminal. If you are getting power and the solenoid is not clicking, replace it.

 

[kidafa]

Re: 2005 3L TKS Intermittent Starting Issue

Thanks Don,

Where abouts do I find the slave solenoid? Do you have a picture of it?

 

[Don S]

Re: 2005 3L TKS Intermittent Starting Issue

Go to the link I posted above, it shows a picture of the slave solenoid in the first wiring diagram.
Look on the engines starboard side, there is only one of them.

 

[kidafa]

Re: 2005 3L TKS Intermittent Starting Issue

Don,

Had a chance today to have a look a bit deeper into this issue and was surprised. Here are some photos of what I found once I removed some electrical tape that was hiding it!

This first photo shows how one of the wires is being jumped onto one of the main terminals;


This second photo shows how the solenoid has one spare terminal on the top right (you can just see it)


This final photo shows the spare terminal a bit easier


I think I found why its a bit intermittent and thats because there were only a couple of wires from that red jumper wire that were still underneath the bolt. I did also attempt to place that yellow and red wire onto the spare terminal of the solenoid but then the starter doesn't spin and I dont hear any click at all which is going backwards!

What is this small red jumper wire achieving and why would someone place it there?

What do you recommend Don?

Thanks in advance,

chris

 

[dubs283]

Re: 2005 3L TKS Intermittent Starting Issue

the slave soleniod failed and someone bypassed it (pretty terrible job)

the smaller guage yel/red wire with the boot should be on the primary (smaller) solenoid post

go back to post #5 in this thread, there is a link to a VERY useful starting system troubleshooting explanation

once you read through it and fully understand how a starting system properly works, it will make sense as to why your system is faulty and how you can repair it

 

[Don S]

Re: 2005 3L TKS Intermittent Starting Issue

^^^^^^^^ What dubs said.

The solenoid failed, and someone butchered the the bypass.
A new solenoid and put that wire back on the small terminal of the solenoid and you will be back in business.
If that 90? terminal end with the red wire is loose or damaged from the hack, just replace it with a ring terminal and use a nut to hold it on the solenoids small terminal.

 

[kidafa]

Re: 2005 3L TKS Intermittent Starting Issue

Could some one please send me a link or give me the part number for the solenoid, preferably both

I was thinking that the solenoid had failed and a previous owner/mechanic had butchered it up by the looks.... Ill repair it so it will run for the mean time and order the solenoid as soon as someone provides me with the link to what I need to buy and where to get it

Im in Australia so somewhere that will post over seas

 

[kidafa]

Re: 2005 3L TKS Intermittent Starting Issue

Anyone?

 

[Fun Times]

Re: 2005 3L TKS Intermittent Starting Issue

Do you by chance have your engine serial number handy so that we could help find you the correct parts catalog to match your engine model for future reference?

With Mercruiser,Volvo,etc, Just using the year & model without the serial number may not get you "all" the correct parts for "your" engine model.

That said, you need merc part number 89-96158T SOLENOID, Starter.

Google the part number, or iboats should have one.

 

[kidafa]

Re: 2005 3L TKS Intermittent Starting Issue

my serial number is 0W356097

 

[dubs283]

Re: 2005 3L TKS Intermittent Starting Issue

Anyone?

i clicked a link from this page, then another link and found the solenoid you need, right here, on iboats

not sure if iboats ships internationally but using the part number here, i guarantee you someone in australia stocks the solenoid you need

in fact, the merc part number is stamped on the bottom of the metal bracket (if the soleniod is merc)