2001 Mercury 240 EFI V6 Slave / Start Solenoid Issue

[MattZ]

I'm hoping someone can verify or correct my troubleshooting logic on the problem I'm experiencing. I searched the forums and couldn't find anything similar

Boat starts and runs fine, shut it off and I hear the starter spinning. Just spinning fairly quietly, not turning over the motor. Starter is one year old, I had the boat out 3 times since it was replaced. Hopefully the starter solenoid was replaced as well but I can't tell by looking.

When I turn off the battery, the starter stops spinning. Turn the battery back on and it engages the bendix drive and turns the motor over. Turn it off and back on, and whatever was stuck has unstuck itself, and the engine starts fine using the key except the starter is spinning quietly when I shut it off.

I'm thinking the problem is the slave solenoid since the bendix drive isn't constantly engaged which I assume would be the case if the starter solenoid was stuck. Maybe centrifugal force engages the bendix gear when I turn on the battery, and the quick on/off battery switching is unsticking the slave solenoid.

The boat is a Seadoo Speedster with the Mercury M2 jet drive.
Any advice would be greatly appreciated.

Thanks,
Matt

 

[Sportster-2001-951C-Stock]

I agree it's likely the solenoid is sticking, I believe the Mercury p/n for that is 8996158 which is usually stamped into the metal mounting plate of the solenoid.

I have a whole drawer full of them that I took apart and repaired (Perfect for the poor guy who just spent his whole paycheck on gasoline, charcoal and picnic supplies and his kids are sitting in the boat at the ramp and it won't start)..

Most people buy new ones if they can afford to, they want the peace of mind.

So anyway, often the solenoid sticks intermittently but if you don't measure 12V across the two small terminals and the starter is running then the solenoid is sticking. Alternatively, if smacking the solenoid with a screwdriver handle causes the starter motor to stop running, it's 99% certain the solenoid was stuck.

Incidentally, if the start switch at the helm is sticking (not nearly as likely) and holding the solenoid on continuously, the solenoid will be very hot from the high current.

This stuck solenoid is very bad for the starter motor of course (continuous running) and consumes a lot of electrical power from the batteries and charging system.

Happy Boating!

 

[Dr Honda]

As above... the solenoid is stuck.

The bendex drive on this starter IS NOT a forced engagement like an old car starter. It's purely centrifugal or inertial. SO.. it's the acceleration of the motor, that pushes the gear up. AND... once loaded on the engine gear... it stays up. Then... when the engine starts... the gear will drop regardless if the starter is still spinning.

Because of that... I'll go out on a limb, and say the starter is fine. Just need a new solenoid.

 

[MattZ]

Thanks very much Sportster and Dr Honda for sharing your expertise.
The manual shows both a slave and a starter solenoid, with the starter solenoid forcing the engagement but I don't know that I'm looking at the right manual, and can't get my fat head in there far eough to see. I'll do the screwdriver test later, maybe even take drastic measures and get the multimeter out. I have a new solenoid ordered that should be arriving today but it would be good to know I'm replacing the right part (for a change).

Thanks again

 

[Dr Honda]

you are looking at a newer engine's starter. The early starter's drive gear doesn't get pushed.

 

[MattZ]

Yes Dr Honda you're correct, I'm looking at a 2002 manual.

The solenoid did the trick. However I seem to have created a new problem, maybe. With the key on I hear something ticking, it sounds like the fuel pump. It didn't do that before. It starts and runs fine, but I can hear the ticking even with the engine running.
I was careful with putting all the wires back in the same place. The only possible difference is the solenoid is "upside down". I don't think that matters but I could be wrong. The new solenoid had an "I" stamped next to one primary connection, and an "S" stamped next to the other the primary connection. The original had no markings.

The only other change is that the previous owner had disconnected the run time meter, purple wire was connected, black was disconnected. I reconnected the black to ground, and that's when the ticking started (after replacing the solenoid and checking that it started and ran fine). At first I thought that's the loudest clock I ever heard, no wonder it was disconnected. But after disconnecting it again, the ticking it still there. Very puzzling.

 

[Dr Honda]

OK...

I'll have to double check the schematic. But... the "Ticking" fuel pump should only be pumping while cranking. SO... it sounds like you have it on the wrong terminal.