OMC 235 starter problems

WD0331

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I just purchased a brand spankin' new Arco starter from this website for my 1976 OMC 235. I hooked the new starter up according to the supplied directions. (It must be noted that the supplied directions are different from the way the original starter was wired). The new Arco starter came with a 12G wire, that according to the directions was to be placed on the solenoid post were the original starter cable was attached. The other end of the 12g wire was to be placed on the spade connection on the starter itself. The original starter cable was to be moved to the post on the solenoid that the battery cable is attached to, and the other end connects to the large post on the starter. (the original configuration did not have the 12g wire). Like I said, I hooked this all up according to the directions, and when I went to start the motor, I got nothing but a sizzle sound, and the positive battery cable melted in half! I replaced the battery cable and reconnected the new starter like the original configuration, leaving out the 12g wire, and putt the starter cable back on the other solenoid post. Now I get absolutely nothing except for the occasional click when I try to start. Any ideas what the problem may be?
 

WizeOne

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Mar 23, 2008
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Re: OMC 235 starter problems

What did you get, one of the gear reduction PMR starters? I did that for my 302. The old starter always rubbed against the motor mount stringer and if any water ran over it into the bilge, it would wash right over the starter,

That PMR starter is smaller in diameter and turns that engine over like a whirling dervish. However, like yours, it is wired different . The original OMC starter relay is now just used as a switch to supply power to the onboard starter relay.

It's been a few years since I did mine so I'll have to root around and find the wiring diagram.
 

WD0331

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Re: OMC 235 starter problems

The new starter is smaller than the original one, and it does have a solenoid attached to it. It is nothing like the original one, but the bolt pattern fits perfect. It is Arco model 70100. and is listed as the exact replacement for the 75'-77' OMC 235.
 

totx

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May 10, 2009
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Re: OMC 235 starter problems

(It must be noted that the supplied directions are different from the way the original starter was wired).

The new Arco starter came with a 12G wire, that according to the directions was to be placed on the solenoid post were the original starter cable was attached.

The other end of the 12g wire was to be placed on the spade connection on the starter itself.

The original starter cable was to be moved to the post on the solenoid that the battery cable is attached to, and the other end connects to the large post on the starter.

(the original configuration did not have the 12g wire).

when I went to start the motor, I got nothing but a sizzle sound, and the positive battery cable melted in half!

I'm not following....

Something wrong here, this could not have been the instruction.
This is a big short termination.

Is the terminal on the starter ground?

Check if you have a multimeter.
 

WD0331

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Re: OMC 235 starter problems

I did a little research on the starter itself. I have the Arco 70200 that is used as a replacement when the 70100 inventory is exhausted. The 7200 is a high performance gear reduction starter. Hence, why it looks so different. Here is what the supplied directions state:
1) Remove the starter cable from the starter relay and re-install on the same terminal post as the battery positive cable.
2) Attach the 12GA red wire to the starter relay post where the starter cable was removed.
3) Attach the other end of the starter cable to the large post on the starter solenoid (mounted on the new starter).
4) Attach the other end of the 12GA wire to the spade terminal on the starter relay (mounted on the new starter).
5) Installation complete.

I followed these directions exactly, and it fried the positive battery cable. Nothing else was changed or altered in any way except for what the directions stated. Before this starter change, everything functioned properly. (I was just getting tired of tapping the starter with a hammer to get it to engage).
 

totx

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Messages
82
Re: OMC 235 starter problems

1) Remove the starter cable from the starter relay and re-install on the same terminal post as the battery positive cable.

2) Attach the 12GA red wire to the starter relay post where the starter cable was removed.

3) Attach the other end of the starter cable to the large post on the starter solenoid (mounted on the new starter).

4) Attach the other end of the 12GA wire to the spade terminal on the starter relay (mounted on the new starter).

5) Installation complete.

THEY ARE MIXING.....

1 Starter relay (are slave solenoid) Not on the starter
2 Slave solenoid
3 On the solenoid starter
4 Starter relay (mounted on the new starter)

And this instruction are looping the starter cable from big terminal to big terminal..........??????????????

  1. How many wires did you have in to the old starter?
  2. Do you have a drawing?


I still think the terminal on the starter are ground, that where you got the short.
 

totx

Petty Officer 3rd Class
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Messages
82
Re: OMC 235 starter problems

1) Remove the starter cable from the starter relay and re-install on the same terminal post as the battery positive cable.

And this instruction are looping the starter cable from big terminal to big terminal..........??????????????

I don't know the OMC start relay (slave solenoid)
Does it have a battery terminal?

Then it make sense :cool:
 

WizeOne

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Mar 23, 2008
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2,097
Re: OMC 235 starter problems

WD0331, did you get it figured out yet? If not, I will root out my wiring diagram. You do have the same setup that I have!
 

WD0331

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Jul 19, 2009
Messages
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Re: OMC 235 starter problems

Wizeone, I have nor figured it out yet. I just got home from a B-day party, and will be tearing into it when it cools off alittle. I'll keep ya posted.
 

WD0331

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Re: OMC 235 starter problems

Hello, I'm Back. I have not been able to post because I've been away from the computer. Here is an update to this problem. I called the tech lines for ARCO, and they told me that I did everything correct. They also told me that my problem sounds like bad wiring connections. I purchased a new starter cable, battery cable, and a new solenoid. I cleaned up ALL the connections, and cable ends, and hooked everything back up. I still have nothing! WizeOne, you didn't happen to run across that wiring diagram did ya? Anyone else have any ideas?
 

WD0331

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Jul 19, 2009
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Re: OMC 235 starter problems

I found the solution to the problem to close this thread. The new starter was defective.
 

KRH1326

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Sep 22, 2007
Messages
491
Re: OMC 235 starter problems

How did you determine defective starter? Just asking because I'm in the same boat, well motor and drive anyway.... I might have to deal with this down the road.
 

WD0331

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Jul 19, 2009
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Re: OMC 235 starter problems

After replacing all the cables, the solenoid, and cleaning everything up. I still had no start. I checked everything with a meter, and had 12 volts everywhere I was supposed to. I decided to take the starter off, and took it to a mechanic so he could bench test it. When he hooked it up, the solenoid on the starter threw out the gear like it is supposed to, but the darn thing wouldn't spin. He said it was a bad starter to begin with. I called Arco, and they confirmed. Now I am in the process of getting the iboat store to replace it for a good one.
 

WizeOne

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Re: OMC 235 starter problems

Glad you got to the bottom of it. It's a shame to have to go thru so much BS with a new product, but s*** happens.
 

WD0331

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Jul 19, 2009
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Re: OMC 235 starter problems

Yes, sometimes s**t happens, But there is always a silver lining. In this case, I now have new cables, ect. and everything needed a good cleaning anyway.
 

KRH1326

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Sep 22, 2007
Messages
491
Re: OMC 235 starter problems

I have no interest in using truck parts in my marine rig. However, I was "told" by a mechanic at a motor winding shop, an armature shop, that the ONLY difference with the FORD starter for a truck and for marine use is that there is a stainless steel band ( similar to hose clamp ) around the marine starter that holds that side cover ( I forgot what he called that hump shaped cover) so that it cannot fall off and expose internal parts to bilge or engine compartment atmosphere. He also stressed that that was the case for the starter ONLY, not any other usual suspect ( dizzy, alternator etc. )

He also said that FORD "Industrial" motors ( generator, special use etc ) is the same block, intake manifold and prestolite dizzy that are used for marine.

I haven't researched any of this for myself, and would not advise anyone to just accept "someone's" word on it. He did say that if you take the FORD numbers "DLJ8-xxxx" and not the OMC numbers and search them through Ford, they will show up as "Industrial / Marine". I just haven't looked any thing up yet.
 

WD0331

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Jul 19, 2009
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Re: OMC 235 starter problems

It's funny you should mention that. Before I purchased the Arco, I did just that. Purchased a ford truck starter that the guys a NAPA cross referenced off my marine starter part number. Took it home, changed out the covers, and put the band around the new one. However, the outside diamater of the new starter was a little to big to fit in the hole. (hope that makes sense). So when I tightened down the bolts, the starter housing broke in half. The guys at NAPA wouldn't take it back, so I thought I better get the right one. Hence the Arco. This entire ordeal has been a royal pain in my ARSE!
 

KRH1326

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Sep 22, 2007
Messages
491
Re: OMC 235 starter problems

When I first got this boat, I pulled and rebuilt the engine. I put it on a set of steel "artificial" stringers in my shop. I had an old '74 ford pick up, at the time. She had a 351w in her. Before I bought all of the marine gear, I borrowed starter and alternator from my truck, just to run the marine engine in my shop. It all fit and ran like a charm.

I don't know why yours gave you trouble.
 
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