Ignition switch issue?

jim520

New Member
Aug 21, 2015
24
Ormond Beach, FL
Boat Info
2004 Sundancer 260, Kohler 5KW genset, Garmin 741xs
Engines
5.7MPI w/Bravo III
Lately when I go to start the engine turn the key to the right, the alarm sounds but engine doesn't turn over. Fuss around turning the key off and on or just hold it in start position and engine starts just fine. Bad switch? Batteries are all fully charged. Any thoughts? Thanks in advance.
Jim
 
1st make sure all battery connections are clean and tight. Includes battery cable on starter.

open engine hatch when you go to start it listen for click, if it clicks confirm that it is the primary solenoid.. if you have a meter you can test it for output key turned to crank position.

This is the #1 cause of your issue..

If you do not hear a click test yellow primary wire key turned to start position..

if you have power test solenoid output, wire to starter another yellow wire about 10GA . if you do not, you have to test keyswitch.

if you have no power from keyswitch replace keyswitch if you do test neutral safety switch.
 
I have a 1990 350.... have same issue.... for me I jiggle shift lever and turn key at same time..... sloppy connection causes interruption of start.... hope it works...
 
Interrupting from experience. There are potentially 3 causes being talked about here. For jiggling the shifter, that is the Neutral Safety lockout switch. It's usually a micro switch in the shift control assembly. Sometimes, it's just come loose, and needs to be tightened up. It won't allow voltage to the starter solenoid unless it thinks you are in neutral.
The most likely culprit is the start solenoid. As described by Tony357, this guy can go bad, even if you hear clicking. It's most likely oxidized contacts in the solenoid. Easy check (watch out for gas fumes) is to bypass the solenoid by turning on the key switch, and jumping the two top connections with a screwdriver or something similar (remoter starter comes to mind). This creates sparks, so don't do this in a questionable bilge. Replacement is the right thing to do here. The third thing is the ignition switch, which rarely goes "bad" unless it is being soaked with salt water, or is more than 20 years old.
 
To save yourself money and time throwing parts at it start with properly testing the batteries. Get a volt meter beg borrow or steal one to make you testing easier.
 
can anyone tell me where my starter solenoid can be found? I have a 2006 Sundancer with the Merc. 5.0.
 

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