96 Suzuki DT40, some days it starts right up, some days won't start at all

boat-a-roni

Recruit
Joined
Jun 3, 2016
Messages
2
I brought it to two marinas who said, "started right up!" Then launched ti again on Memorial Day and after a bit of cranking, started. Then stall and no more start. Next day, went to the slip, started on first crank. Shut off, started again! Next day, no start after many tries. Then, today, starts on first crank and restarts. Help! Any ideas on where to start looking for the problem? There was a lot of oil/gas in the water on the non-start day. Flooded? But same start procedure all the time. Again, your ideas very very welcome!!
 

tommarvin

Ensign
Joined
Nov 22, 2015
Messages
999
An electrical part is failing, Which part you ask IDK.
When you turn the key,does the starter turn the flywheel hard enough to start the motor? Or is it turn key nothing happens at all no sound,no starter nothing.
If nothing happens when you turn the key, leave the key on and get a large screw drive put on thick rubber gloves, and touch the two large terminals of the solenoid, if the motor tries to start or runs you know it's the ignition switch. If you don't feel comfortable doing this You can test the solenoid with a multi meter it's very easy,u-tube explains if perfectly.
I would remove all you battery cables and clean all connections shinny,coat with dielectric grease reinstall them with nylon locking nuts,never wing nuts
Low odds maybe the neutal interlock switch, it's called something similar for your motor.
Do you have diagnostic software for your motor.
If you get desperate, it's prime boating season, and you have the money to throw at this, this is assuming you cleaned all your battery connections first ,You replace the ignition switch, pull one wire off put it on the new switch, replace solenoid if if didn't test ok or you didn't test it,, replace neutral interlock/safety switch they will know what you mean.
 

99yam40

Fleet Admiral
Joined
Sep 7, 2008
Messages
9,215
test for spark when it is not starting
if no spark then test voltages into and out of CDI to see what is in spec and what is not.

Kill switch and key switch ground the spark voltage out of CDI to keep spark voltage from plugs.
could be the wire grounding out also if switches turn out to be good
 

boat-a-roni

Recruit
Joined
Jun 3, 2016
Messages
2
Thanks, 99yam and TomMarvin. Tom, when it doesn't start it still cranks and cranks just like when it does start. Sometimes it shudders briefly like it wants to start, but no. Again today, started right up. I'm inclined to agree with your electrical part failing theory. Unfortunately I'm leaving tomorrow for two weeks but will try your solenoid test (with a multi-meter!) and a screw driver when I return. This particular motor does have a pull-start. Would using that help me narrow things down? I'm usually using a key start.
Thanks again, this is a great relief to find some help with this.
BTW, you mentioned diagnostic software. Is there such a thing for a motor this old? Does it have a dataport?
 
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