VP 4.3GL/SX 190 HP starting issue - intermittent

[Debusan]

2001 Four Winns 180 Horizon, VP 4.3L GL/SX. Started last summer, boat was running fine then on the water after shutting off, wouldn't crank at all. Turned key, gauges moved, alarm beeped (which is normal) but wouldn't crank. Sounds like neutral safety switch, shut off switch. Took to mechanic couldn't find problem, started fine. This year ran 3 or 4 times, no problems. Then took out and same thing happened. Checked neutral safety switch, emergency switch, replaced started relay and fuse reset button as well as ignition switch. Well today took boat out ran around for an hour or so, shut off 3 times and it restarted. Then after stopped same condition. So I disconnected the wires to the battery and then put back on and low and behold it started!!!! Ran around for another two hours stopped and re-started it was fine. I do have a battery shutoff switch connected so maybe that's bad but power is not the problem which leads me to think it's the starter solenoid. Would taking wire off the battery really do anything unless I have a bad or corroded wire. It's really hard to access the solenoid / started without dismantling the boat and I just wonder WTF is going on that it happens intermittingly. Any ideas or suggestions would be great!

 

[Lou C]

You may have to go through all the wiring between the ignition switch and the starter (start with a Volvo wiring schematic) to find the bad connection that may be causing high resistance. There is usually an extra assist solenoid between the ignition switch and the starter, check connections there too. Esp if it is in a place where water can drip right on it, as it is in some boats. Remember dc electricity has to travel in a circle (circuit) it must be able to go from the battery positive to battery negative, any weak links along the way and you can have that kind of intermittent problem. If the starter is original the solenoid could be getting corroded, I have seen boats where the water drain for the exhaust manifold is right over the starter, when you drain it for winterization guess what happens unless you put a plastic bag over the starter, it get wet every time and that will corrode the connections.

 

[Debusan]

Thanks for taking time to reply and the advice. I was afraid you would say that....lol... Yes, sounds like that is what is needed to find the source problem. I am beginning to hate I/O's and vow to never own one again because it is really difficult to get to the starter or anything even with disassembling the boat.

 

[Lou C]

Might have to remove exhaust on that side to get at starter. I would never buy a boat with bad access

 

[Lou C]

In fact years ago when I still had my original OMC exhaust manifolds the drain was right over the starter. One year the drain on that side leaked slightly and turned the solenoid terminals into a ball ‘o rust. Got the intermittent no crank issue and wound up removing the starter replacing the solenoid and re-terminating all the wires . Made sure that damn thing didn’t leak again. When I converted over to the later exhaust style no more worries because the drain is on the rear end of the manifold. To get access on my boat I can move the rear seats out and then remove the wood supports and I have wide open access. I reconfigured the whole rear of the boat to make it easier.