Starter solenoid arcing

[jbutler67]

1998 Evinrude 40 hp E40TLECR Outboard Motor

Turned key and starter engaged for 2 seconds and then the Starter solenoid started arcing. When I remove the red power to the starter and turn key, solenoid clicks.

I had removed starer to get to shift rod connector, to drop lower unit.

To remove starter, I disconnected the ground on the battery, disconnected the red power, removed the 3 bolts holding the starter in place and lifted it out.

During reassembly, I attached the red power to the starter, returned starter in place, bolted it back in-place, reattached the ground on the battery.

Am I missing something? Or a bad solenoid?

 

[jbutler67]

This is the part that baffles me most.... when I disconnect the power to the starter (disconnect the red wire between solenoid and start) and turn the key, I hear the click in the solenoid. So, the solenoid (relay) sounds like it is working. But the solenoid arcs.sparks (not the starter) when the red wire connects the starer and solenoid.

 

[GA_Boater]

Why does it baffle you? A solenoid still works if the power cable to the starter is disconnected and the key is turned to start. Disconnect the wire from the key switch to disable the solenoid.

 

[jbutler67]

Sorry.... my first comment was not finished when I saved it.

Full comment is as follows...

This is the part that baffles me most.... when I disconnect the power to the starter (disconnect the red wire between solenoid and starter) and turn the key, I hear the click in the solenoid. So, the solenoid (relay) sounds like it is working. But the solenoid arcs/sparks when the red wire is connecting the starer and solenoid. The solenoid sparks, not the starter.

 

[GA_Boater]

Double check the wiring to the starter and on the solenoid. Also the solenoid contacts may be burned causing the arcing.

 

[Fed]

I'm guessing you don't have a see through solenoid so the sparks you are seeing are probably coming from a high resistance connection on one or both of the large terminals on the solenoid.

Remove the wires off the two large solenoid terminals, clean them (shiny), give them a little Vaseline and reconnect tightly.

With the starter motor disconnected there is no current flow but when you connect it you are looking to pass at least 150 Amps.

 

[oldboat1]

Are you seeing sparking (at the large post to the starter, perhaps), or are you hearing the solenoid stutter -- fast clicking that might sound like sparking? If the latter, it's either a loose or corroded connection, perhaps at the battery leads, or the battery doesn't have the life to crank the engine. An auto parts store will usually do a battery test for you (load test).

 

[jbutler67]

Are you seeing sparking (at the large post to the starter, perhaps), or are you hearing the solenoid stutter -- fast clicking that might sound like sparking? If the latter, it's either a loose or corroded connection, perhaps at the battery leads, or the battery doesn't have the life to crank the engine. An auto parts store will usually do a battery test for you (load test).

That was EXACTLY the problem.
1) did not SEE sparks, heard the solenoid stutter... SOUNDED like sparks
2) ground terminal and connections on the battery had a lot of corrosion. Cleaned up the terminals and connections and it fired right up!

Thanks!

 

[oldboat1]

Glad you have it handled. :thumb: