I have been having several electrical problems with my 1999 Volvo Penta 4.3GL over the past two seasons. I replaced the starter and relay last season and it worked fine for about three months. Then it started having ignition issues again. I am getting it ready for this season and I have been able to trouble shoot the ignition (by using http://forums.iboats.com/mercruiser-i-o-inboard-engines-outdrives/how-troubleshooting-your-engines-starting-system-167035.html) issue back to the new starter. It is a non-Volvo Penta starter (aftermarket?). It cost $60 as opposed to the VP part price of $350. I never felt very comfortable about the new starter since it did not match up with the flywheel area as well as the original starter. The “teeth” lined up so that it would do its job, but it looked like moisture could get into the flywheel area.
From what I can tell the original starter is mostly in good shape with the exception of the soleniod. I reached out to a local shop that advertises marine starter rebuilds. They wanted $250 to rebuild the original starter. Way too much
Long story short – I have removed the aftermarket starter. My plan now is to buy another aftermarket starter for around $60. Can anybody recommend a good aftermarket marine starter manufacturer?
Also, one of the electrical ring connectors to the starter has signs of corrosion and should be replaced. Any advice on splicing in the bilge area? I have not done any electrical work in “wet” environments.
This website looks helpful