Starter solenoid not passing current

[kungpaoshizi]

Engine is a 76 Mercury 1150~

I believe I've located my startup problem.

It was intermittent starting, from no sound to full startup. Then a click started happening.

If I measure voltage from the battery, the wire harness is good, (when it works) volts/amps are good to starter positive.
But I've found, when I hit the ignition and it clicks, there's zero current passing thru the solenoid to the starter.

I assume this defective and needs to be replaced, or is there another thing I should check?

 

[gm280]

Re: Starter solenoid not passing current

Try jumping a wire from the starter solenoid (the large positive terminal that the battery is connected to) to the same place that the ignition key wire is connected on the starter solenoid. If the starter turns and engages, you don't have a starter solenoid problem...period!

 

[kungpaoshizi]

Re: Starter solenoid not passing current

Just got done with the 'test cranking motor solenoid' troubleshooting, connected voltmeter to ground and Number 3 post, got something more in the millivolt range, but the manual says "if there is a slightest indication of a reading, replace solenoid".

 

[Timestep]

Re: Starter solenoid not passing current

How are you measuring the current ?

 

[kungpaoshizi]

Re: Starter solenoid not passing current

The above troubleshooting step was in the manual I have...
As a breakdown, the battery was tested by 2 places as good, I sat and poked around with the voltmeter, though cracked and slightly corroded (I ended up cleaning what I could with vinegar and sealing the insulation of the wires with self sealing silicone tape) the wire harness from the battery to the internal harness is ok, the same amps and voltage are detected from the top of the battery(.9 amps?) all the way to the solenoid. I also tested the button that is the ignition key switch, all the voltage/amps from the battery is present until I hit the switch, then it zeroes.

I did notice the internal wire harness has 2 smaller wires that connect to the solenoid, and they're in horrible shape, but I cleaned what I could and silicone those points too.

As it stands, the solenoid contacts (tested with my triplett 9045)
big terminal from batt: 12.6+v
small terminal on the left: 12.6+v
small terminal on the right: 0 (unless the solenoid clicks and starter doesn't turn over, then it's >0v)
big terminal-positive cable to starter: 0 (solenoid clicks:0v, regular starting:12.6+v)

 

[gm280]

Re: Starter solenoid not passing current

I think we still have some miscommunication going on here yet. This could be a neutral starting switch issue. Do you know if your setup have a neutral safety switch or not? Sounds like it could be your problem. IF that switch is not adjusted right, it could keep your engine from starting easily. You need to find out and see. Rarely do starters work and then not work and then work again. It is usually something else being the true problem... And my uneducated, unable to see and test guess is you haven't located that problem yet...

 

[oldman570]

Re: Starter solenoid not passing current

If the solenoid is acting up at times , it would be best to replace it. It is not a costly item and a simple job to do. With the readings you have taken, it looks to be the trouble to me. JMO
Oldman570

 

[kungpaoshizi]

Re: Starter solenoid not passing current

Anyone happen to know the correct part number for it?
The one I have is the 4 post on top style, but number 28/29 in the diagrams I've seen looks like something else, but mine looks like this:
Used Starter Solenoid Assy 817109A 2 for 1998 Mercury V 200 Outboard Motor | eBay

Engine serial is:
2931xxx

 

[kungpaoshizi]

Re: Starter solenoid not passing current

Sorry gm280, as far as a kill switch, the previous owner disabled that. Not sure how, but the plug for the lanyard prong is in the MercControl box.
Then there's a 2 position switch on the console that lights and is the on/off for main engine power.
Then there's a push to start rubber button. (This has been replaced ~2 months ago because of a short, the repair shop said. Though if it really is the solenoid acting wonky, the starter and the push to start button were unnecessary)

I'm going to get new wiring harnesses though, the internal is a freakin mess with a couple horrible spots of corrosion. The external is all cracked and some corrosion already starting...

 

[kungpaoshizi]

Re: Starter solenoid not passing current

Yup, solenoid, starts every time like a charm now
Thanks fellas!