Intermittent Starting Problem (Maybe) Traced to Throttle/Shifter

[nervouslizard]

This Forum is an excellent resource. I recently joined so I could post my current issue. I have already performed diagnostics discussed in other places on this forum (Don S HOW TO)

Boat:
2006 Four Winns Horizon 183 Fish&Ski
Volvo Penta 4.3 CXI-F (3869306)

Issue:
Intermittent Start. It used to happen occasionally, now it happens more times than not. When key is turned, no click, no start, no reaction at all.

• Battery is brand new, fully charged, shows 12.6V, all connections are tight.
• When key is turned to Aux, all electric stuff works
• When key is advanced to start, nothing happens. No click from starter relay.
• Putting a meter on ignition switch: 12.6V at power lead, 12.6V at aux connectors when key is advanced to Aux. 12.6V at starter connector when key is advanced to start (yellow/red cable)
• Pulled starter relay and tested. When 12V applied (85/86), I get a click. Checked resistance on 30/87 and get 0 Ohms when 12V applied to 85/86. Infinite resistance when 12V removed from 85/86.
• With relay removed, I put the meter on slot 86 (C on Don S's diagram). I noted that this is an intermittent issue. I had the opportunity to observe both conditions today. When the boat would not start I was seeing 7.5 to 8V at this location (when the switch is advanced to start). Then the boat decided to start and so I pulled the relay and re-checked. Now ~12.5V at this location (when switch advanced to start).
• Jiggling, messing with the shifter/throttle does not seem to have any bearing on whether the boat starts or does not. Some times I can mess around with it for 10 minutes to no effect, then come out the next day and the boat will start. At best there may be a very loose correlation between the boat starting and messing with the shifter/throttle.

So it appears to me that I am getting correct voltage output of my keyed ignition switch and when the boat does not start I am seeing ~8V at the relay (not enough to trigger it) and ~12V at the relay when the boat is starting normally.

So my questions (hopefully someone can help with):

• What is between the ignition and the relay that could cause this voltage drop?
• Am I correct in thinking this has to be something in the shifter/throttle?
• Could this be the neutral safety switch in the shifter? This strikes me as odd as I think of switches as either being off or on, not half way.
• If it is the neutral safety switch, can this be replaced without replacing the entire throttle/shifter assembly
• Is replacing the neutral safety switch (and/or the whole shifter assembly) something a moderately competent DIYer could do or am I headed to the shop?
• Can anyone point me to some guidance as to how to get into the trottle assembly and do further troubleshooting or repairs?

Thanks in advance for any input. I can post pictures if that would help.

 

[GA_Boater]

Welcome aboard.

Neutral switches do go bad and instead of clean contacts, they can corrode or not make good contact and the contacts develop high resistance. The low voltage to the solenoid is an indicator of this happening. The switch seems like a good place to start.

Yes, you can replace the switch. What remote control is in the boat?

 

[nervouslizard]

GA - Thanks for the response. I am unsure what remote control it has. It is the stock model that came with the boat. I can't find any markings on it to indicate the model. I have attached a picture if that helps at all. Any additional advice would be much appreciated.

 

[oldboat1]

Believe that would be a Teleflex/Morse side mount control. Do a google search.

 

[nervouslizard]

That does indeed look like the correct designation. The version I find online that appears to be pretty close is the Teleflex SL-3. I will continue to google getting this pulled off to take a look at the internals. Any guidance would be most appreciated.

 

[oldboat1]

Try this: http://www.nauticassistance.com/Cms...E_/_Leva_comando/teleflex sl3 user manual.pdf