Will not start....Need suggestions

[Raystownboater]

I have a 1980 mercruiser 228 sitting in a searay. Last week the boat was running alittle rough and the batteries needed replaced. I replaced the spark plugs and batteries and the boat would not start. Everytime I turn the ignition key to start, it clicks but nothing else. I followed another thread by Don S. on tracing the starting issues. I found a few loose and corroded wires and also found the slave soleniod needed replaced. After replacing the slave solenoid, the boat still does not start but there is also no clicking. If I put the old solenoid back on, the click is back but that is all. I am stuck as to what this could be. Any suggestions would be amazingly appreciated!!

 

[jerryb1]

Re: Will not start....Need suggestions

I have the same engine and boat. Since you just replaced the batteries, maybe check your battery connections. The large wires need to be on the big posts and not the wing nut terminals.

You probably don't have good connections. Get yourself a good voltmeter and look at the connections on the starter solenoid and the started when you turn the key. I used alligator clip leads on the posts.
First you obviously need 12V on the small wire(solenoid coil) for it to operate. You say it clicks so you probably do. Next clip a wire(clip lead) to the starter connection(big wire from the solenoid to the starter) you need at least 11 volts when cranking. If it drops to 8-9 volts, you have poor or dirty connections. Ohms law says that E=IR, which means if you have just 0.1 ohm resistance at 60 amps the drop would be 6 volts, so you need very tight clean connections.
You can also jump across the starter solenoid with a screw driver to see if it turns over(Be careful...there will be a spark- so NO gas fumes/leaks!!) . I had to replace the starter solenoid every couple of years. Also, make sure your oil is not milky. If you have a bad riser gasket, water will get into a cylinder and lock it up(you can't compress water).
i hope this helps, that engine and boat is an oldie but goody!

Good luck

 

[Raystownboater]

Re: Will not start....Need suggestions

Thanks JerryB. I ran all the tests and found 12v everywhere it should have been. Then I tried running a jumper to kick over the starter and.............nothing happened. I pulled the starter and took it to Auto Zone for a test. Once she hit the button, the armature lazily extended and stuck there.

After a few phone calls, I tracked one down close to home and I am now taking a break from the heat while Im installing the new starter. Just to be safe, I am replacing the wiring also.

Thanks for the info!

 

[Raystownboater]

Re: Will not start....Need suggestions

The new starter is on and when I hit the key...............NOTHING. I put a jumper on the starter and it turned over so I am guessing its the slave solenoid but that is brand new. Any ideas???

 

[Don S]

Re: Will not start....Need suggestions

Try this http://forums.iboats.com/showthread.php?t=167035

 

[Tommywalton]

Re: Will not start....Need suggestions

Bypass everything. Get yourself some heavy booster cables and go straight to th starter. Jump it there first. With battery only hooked to starter. Make it work there first. Do not cross wires be careful! If you can jump it there pos and neg hooked to starter, pos to large terminal neg to housing and use a starter button to "jump" it then start tracing. Hook cables back to batt but perhaps leave the neg on the housing of the starter hooked to neg on batt. Start eliminating possibiliies you will find your problem. You must be careful when using this method and not short out anything. Don't hook a hot to ground or vise versa. It's just a simple circuit. You starter buttons and ignition switches fail easily in a marine enviroment. Trust nothing check everything. This method I'm talking about is not something lots of people agree with, it works for me regularly so try as a last resort if your not sure what I'm talking about don't try at all.

 

[Don S]

Re: Will not start....Need suggestions

Bypass everything. Get yourself some heavy booster cables and go straight to........................................

You too might want to have a look at that link I posted just above your reply.

 

[Tommywalton]

Re: Will not start....Need suggestions

Very good breakdown Don. It is very informative. What works for me may not work for others. Forget the booster cables

 

[jerryb1]

Re: Will not start....Need suggestions

The new starter is on and when I hit the key...............NOTHING. I put a jumper on the starter and it turned over so I am guessing its the slave solenoid but that is brand new. Any ideas???

It sounds like you are close and probably have it working already. Maybe there was no ground to the solenoid relay? Don's detailed threat is a good one and very detailed.
The relay's purpose is to have a small wiring circuit - the ignition key, nuetral switch etc, control the large current connection to the starter, so it's very basic- 12v to ground on the relay coil and it pulls in a metal plate that connects the two big terminals together. The click is the metal plate closing the circuit.

Good luck.

 

[Raystownboater]

Re: Will not start....Need suggestions

Got everything together and tested. The ignitions switch passed but the solenoid didnt. What I did was bypass the solenoid to turn the engine over and now there is no spark when I try to start the engine. I cant figure this out. The boat ran great about two weeks ago until the starter went. Since then, this is a real problem. Im pretty good, mechanically, but this has me stumped.

 

[Raystownboater]

Re: Will not start....Need suggestions

Out of pure frustration, I replaced the new slave solenoid figuring that I would start the testing all over again and try to track down this problem. After hooking up the old Slave Solenoid, I turned the key to see if I still had the clicking noise and the boat fired right up!!!

Im not sure what the problem is with the new solenoid but IT was causing the issues. I played around with the connections and everything for about an hour and the boat fired up evertime I hit the key.

 

[jerryb1]

Re: Will not start....Need suggestions

Great you got it working, but since you never found the bad connection, it mostly likely will show up again. There is a large black connector that is used basically to connect all electricals in one place when the engine needs to changed or removed. Sometimes the contacts in that connector don't make it. It's somewhere back by the coil on mine.

 

[Raystownboater]

Re: Will not start....Need suggestions

Thanks Jerryb, I found that connection early in this process and took care of it because it did look suspicious. I was out again this afternoon and put the new slave solenoid back on and it wouldnt turn over. Put the old on one and she fired right up. Im still scratching my head over the fact that the new slave solenoid is bad.

 

[Fishermark]

Re: Will not start....Need suggestions

Im still scratching my head over the fact that the new slave solenoid is bad.

It happens. Unfortunately more often than it should.