4.3 mercy starter problems. sluggish or just ticks

ryan04

Petty Officer 1st Class
Joined
Jan 26, 2005
Messages
212
hey fellas i have a 1996 Mercruiser 4.3 liter with alpha one generation two drive. I was out last weekend and the boat started acting funny. it was very sluggish to start at first but finally did start and then drove great. We even shut the engine off for a couple hours and floated around then started it back up and it was very sluggish to start but it did start. I went out the following day and it was extremely sluggish the start but did start and then drove ok until we shut it off. Then went to start the motor again it would only turn over once or twice then click. I tried again, just click click click then a sluggish one or two turns of the engine then back to click click click. I felt the starter wires and they were getting hot. Got towed back. Today in my garage I unhooked all the starter cables.they were extremely corroded, dark black and green. I guess that explains the resistance in the heat build-up. I use jumper cables in place of the original starter cables.I jumped positive from a perfectly charged battery to the slave solenoid and it did nothing. that was to the yellow wire with red stripe. Then I tried the positive battery cable on the other side of the slave solenoid and it just clicked. Then tried the positive side of the battery cable to the yellow wire with the red stripe on the starter which is the starter solenoid. When I did that it just clicked as well. So is it the starter, or the solenoid or the slave solenoid or a combo of some kind? Remaining connections are all tight and not corroded and the battery is fully charged. Its just weird it does the same thing with new jumper cables as it did with crappy corroded cables. Any thoughts would be appreciated.
 

NHGuy

Captain
Joined
May 21, 2009
Messages
3,631
When you jumped the boat I assume (bad thing, I know) that you ran a cable to boat ground too?
Couple of things to do. Test the charge level of the boat battery. Pull the spark plugs and spin the motor over, it could have water in the combustion chambers holding back the starter. Clean up all the battery and starter connections.
If it does start, check the volt gauge reading, you want to see 13.8 to 14.8 volts once the engine is above idle.
Let us know how you do.
 

Bt Doctur

Supreme Mariner
Joined
Aug 29, 2004
Messages
19,344
given the corrosion of the battery cables, was the starter ever underwater
 

ryan04

Petty Officer 1st Class
Joined
Jan 26, 2005
Messages
212
I don't know if the starter was ever under water, I just got this boat in march. I did run the negative as well. I pulled the plugs and spun the engine by hand. No water on any plugs and the engine turned with a wrench with ease, felt very smooth. I think my slave solenoid is still good. I know in the original post i said when i touched the positive jumper to the slave solenoid it did nothing, but it actually clicks inside the slave solenoid. Then when positive is touched to the other side of the slave solenoid it clicks down by the starter. I removed the engine cover and the back wooden boards that it butts up against so now I have complete access to the engine. I might just pull the starter and have a look. Thoughts?
 

ryan04

Petty Officer 1st Class
Joined
Jan 26, 2005
Messages
212
So i just removed the starter finally. The solenoid on the starter was shot. The red cable that hooks onto the solenoid was heated due to a bad connection on the inside of the solenoid. I took off the solenoid and found that the positive terminal was very loose, I could wiggle it back and forth and could hear the crunch of burned contacts on the inside. I opened it up and sure enough it was completely black and all pitted. That coupled with the terrible shape of the wiring gave me the heat through the cables. I just bought a new starter and slave solenoid and am going to pop it in this weekend.
 

NHGuy

Captain
Joined
May 21, 2009
Messages
3,631
Great, bullet dodged in my opinion. So many times I hear that kind of story and it's water in the cylinders.
 

ryan04

Petty Officer 1st Class
Joined
Jan 26, 2005
Messages
212
Got the new starter in, along with the slave solenoid, dist cap, and the "thingy" on the inside of the dist cap, along with new 4 gauge wiring. After it was all in, this thing fired up super aggressively at barely one turn! Love it. Now on to the remaining list of annoyances! Thanks guys!
 
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