mercury 240 efi starter engage in neutral

[poc780]

Hi,

I have a strange problem. I have a seadoo chalenger 1800 2001 with the merc 240 EFI. When I go in neutral, I can hear a loud click (starter relay I think) and then my starter engage ???

As soon I go fwd or neutral, the starter will disengage if I give a bit of gaz.

Is any body have any idea ?

 

[Dr Honda]

sounds like a short in the key switch. As long as it's in fwd, the neutral switch opens, and turns off the starter.

 

[poc780]

I would think so me too. How can I check the key switch. The wiring I have is too small to read.

Is the starter solenoid could cause this you think ?

 

[poc780]

You just remind me that last week end, I started the boat and I was in on idle in FWD. The engine shut down and as soon I put the lever in neutral, the engine started by it self without turning the key !!!

That almost confirm something wrong with the key switch. is there any way I can test the switch ? Do you have that part of the wiring diagram ?

tomorrow I will do the test again.

Thanks, we are getting there.

 

[Dr Honda]

Nope... sorry, I don't have the wiring schematic for the Merc boats.

I would start by disconnecting it, and using a meter to check the internal contacts.

 

[poc780]

This is going to be hard for me to meter without wiring...

 

[WAJetboating]

This is going to be hard for me to meter without wiring...

There is a schematic for the console wiring in the manual for your engine. I'm told that manual is available on this site as part of the premium membership. I have the printed version and the wiring is very clear. Basically the keyswitch just switches 12VDC and ground around based on its position. This should be very easy to troubleshoot with the schematic and a multimeter.

I wouldn't run the boat until you resolve this. It's possible the starter motor is being powered 100% of the time, and even when the bendix gear disengages from the flywheel that starter pulls significant current - enough to heat it up and potentially damage it. No point in replacing your starter if you can avoid it.

Report back!

 

[poc780]

Hi,

today I did a test: I started the boat, put in fwd and pull the kill switch to kill the engine. I put kill swt back in, still in fwd and nothing happened. As soon I put the lever to neutral, the engine started by itself without turning the key.

I removed the key switch and blow air in and now it is working fine. I'm now pretty sure the problem is located to that switch. What can I use to clean the switch ?

It is close switch and I have no access inside to inspect the poles.

I dont want to use contact cleaner as it can damage plastic component.

I also have the engine manual but I cant find the wiring for the key switch ? what page ?

If i want to replace that switch with a universal, how should I wired it. I dont want to pay 290$ for a switch !!!

Thanks

 

[WAJetboating]

I removed the key switch and blow air in and now it is working fine. I'm now pretty sure the problem is located to that switch. What can I use to clean the switch ?

I don't believe it's possible. As I recall the switch is a sealed unit. Opening it to "clean" it would likely destroy it.

I also have the engine manual but I cant find the wiring for the key switch ? what page ?

I'd dearly love to post it but have been asked not to by the forum administrators. In the official Mercury manual for your 2001 engine, it is on page 1D-7. I'm looking at it this very moment. The keyswitch is item (b) in the drawing and shows six wires coming out. I believe there is a seventh wire (intended for manual enrichment by pushing in the key during startup) but it's not normally used on this engine and not shown on the schematic.

Hope this helps!

 

[poc780]

Today I replaced my key switch, because it was an intermitent problem, for NOW it is ok...

I found a big rock between my impeller and the vane... no damage but needed to remove the pump to have access to remove rock.

cant understand how I saw it without damage.

 

[WAJetboating]

I found a big rock between my impeller and the vane... no damage but needed to remove the pump to have access to remove rock.

I presume you mean you removed the stator, not the entire pump (jetdrive), correct?