Starter, solenoid troubleshooting 1999 Johnson Ocean Pro 200

[jlemberg]

Tried to fire the engine up the other day....took a while to start, and I think I fried the starter, or solenoid. It makes a loud single click when you turn the key, but the starter doesn't pop up and engage the flywheel. Does this sound like the starter or the solenoid? What is the troubleshooting procedure? Would be nice if it was just a $50 solenoid. Thanks for the help.

[Will Bark]

Sounds like the "click" is probably the solenoid engaging; does the starter even try to spin? If not, then a rebuild of the starter is in order; most generator/starter business can do this for less than a new starter would cost. Good luck.

[Will Bark]

You could try to jump the starter directly from your battery and see if it runs; this will tell you if the solenoid is defective.

[jlemberg]

Sounds like the "click" is probably the solenoid engaging; does the starter even try to spin? If not, then a rebuild of the starter is in order; most generator/starter business can do this for less than a new starter would cost. Good luck.

No the starter teeth don't even move onto the flywheel..no movement. Thats what I thought that noise would indicate- the solenoid is getting juice. Is that a simple bolt on/off type of thing- the starter that is?

[jlemberg]

You could try to jump the starter directly from your battery and see if it runs; this will tell you if the solenoid is defective.

What is the best way to do this? I hear with a screwdriver?

[boobie]

You can go across the big solenoid terminals with a big pair of pliers and see what happens.

[jlemberg]

You can go across the big solenoid terminals with a big pair of pliers and see what happens.

10-4...pliers should work. Thanks all for the help.

[fireman_bob]

If it's not the solenoid, pull off the starter and take it apart. After taking the gears out, try to spin the motor by hand. There's 2 long screws that go end to end that hold the end caps on. Remove the screws depending on the model, you may be able to just take off the rear endcap (where the wires go in). In there you'll find the brushes. You probably just have a bad brush or connection.

[Will Bark]

Pay attention to the marks on the end cap and body of the starter or better yet mark the body and cap so they will line up when you put it back together; otherwise you could have a starter that runs backwards, I won't tell you how I know. Good luck

[daselbee]

It isn't the body and cap mismatched upon reassembly that cause the starter to run backwards...it is the magnet assy inside. If you put that in 180 degrees off from how it came out, it will run backwards.

jlemberg...remember me? I have starters.

[jlemberg]

It isn't the body and cap mismatched upon reassembly that cause the starter to run backwards...it is the magnet assy inside. If you put that in 180 degrees off from how it came out, it will run backwards.

jlemberg...remember me? I have starters.

Hey Doug...hows everything? Yeah it's been running pretty good except for the usual cold start drama. This time though, I got a little impatient, and cranked it dead. Made me feel good. If its the starter, I'll definitely send you some funds. As far as the troubleshooting, what ignition key postion should I be in when I jump the solenoid terminals? I am assuming it's the two smaller terminals on the front of the solenoid?

[jlemberg]

Pay attention to the marks on the end cap and body of the starter or better yet mark the body and cap so they will line up when you put it back together; otherwise you could have a starter that runs backwards, I won't tell you how I know. Good luck

Thanks Will and fireman...rebuilding the starter is out of my patience level. And I wont ask what happens when you crank it the wrong way. I assume the starter gives up first.

[fireman_bob]

You can check the starter by connecting power to the two leads directly. It would be a good idea to remove the starter and do this by connecting it directly to a 12v battery with jumper cables. That way you eliminate any potentially bad connections in the motor head (and you don't have to worry about spinning the flywheel). Connect the battery - to the - connection on the starter (usually the frame), then momentarily touch the battery + to the + connection on the starter. Be sure to hold onto the starter as it will jump when it gets power (if it's still working). Do this away from any fire source as you will generate a pretty good spark with the connection, and if the starter is shorted, a really big spark (that's why you do it only momentarily).
If the starter spins when the battery is connected, your problem is somewhere else in the system. Also, if it spins, you should see the bendix gear go up the shaft then drop down when power is removed.

[jlemberg]

You can check the starter by connecting power to the two leads directly. It would be a good idea to remove the starter and do this by connecting it directly to a 12v battery with jumper cables. That way you eliminate any potentially bad connections in the motor head (and you don't have to worry about spinning the flywheel). Connect the battery - to the - connection on the starter (usually the frame), then momentarily touch the battery + to the + connection on the starter. Be sure to hold onto the starter as it will jump when it gets power (if it's still working). Do this away from any fire source as you will generate a pretty good spark with the connection, and if the starter is shorted, a really big spark (that's why you do it only momentarily).
If the starter spins when the battery is connected, your problem is somewhere else in the system. Also, if it spins, you should see the bendix gear go up the shaft then drop down when power is removed.

Is it better to do all this with a test light, or multi-meter? I have both. I assume that if the starter terminals get juice, that the solenoid is working....And if its not, then could check the solenoid terminal from battery to make sure it's getting juice? And so on.

[daselbee]

If its the starter, I'll definitely send you some funds. As far as the troubleshooting, what ignition key postion should I be in when I jump the solenoid terminals? I am assuming it's the two smaller terminals on the front of the solenoid?

Nope...do not short the two small terminals. Nothing will happen.

If you are testing just the starter function, just leave the key off.

You must use a very large gauge wire (jumper cable, only one lead needed), or very large pliers to span across the solenoid between the two very large terminals on each side. One side is straight to the battery, the other side goes to the starter. When you jump across, you are applying battery power to the starter directly, and have eliminated the solenoid from the picture (for the time being anyway).

Gotta use a very heavy wire or pliers, and it will spark big time. Hold it on there tight, and depending how good the connection is, it might get hot on you. Careful.

Good deal on a starter for you. Much cheaper than a rebuild and I absolutely guarantee it.

We have to talk about this trouble with cold starting....PM me with phone number.

[jlemberg]

Nope...do not short the two small terminals. Nothing will happen.

If you are testing just the starter function, just leave the key off.

You must use a very large gauge wire (jumper cable, only one lead needed), or very large pliers to span across the solenoid between the two very large terminals on each side. One side is straight to the battery, the other side goes to the starter. When you jump across, you are applying battery power to the starter directly, and have eliminated the solenoid from the picture (for the time being anyway).

Gotta use a very heavy wire or pliers, and it will spark big time. Hold it on there tight, and depending how good the connection is, it might get hot on you. Careful.

Good deal on a starter for you. Much cheaper than a rebuild and I absolutely guarantee it.

We have to talk about this trouble with cold starting....PM me with phone number.

Heading down with the multi-meter, see what voltages I get. I see there is a 20Amp fuse in there...where is that located? Maybe I was hearing something else click, and the fuse is blown.

[daselbee]

Jumping it with cable or pliers, you won't need to worry about the fuse.

The fuse is located at the top left side of the electrical connections box...where the battery cable runs in at the bottom, where the engine harness connects.
You do not have to take off the cover (three screws), because fuse is in a fuse holder with a big red plastic tab at the upper left of that box. Pull straight out on the tab.
There is a spare fuse in there also. They are the automotive blade type fuses.

[jlemberg]

If I told you guys that I found a brand new(not rebuilt) starter and solenoid online for $83 including shipping, would you call me crazy?