Re: 2001 225 HP Ficht
Tim I think you need to do some voltage tests to identify the problem area. Sounds like you still have a bad connection somewhere. Perhaps your solenoid as that's about the only thing you haven't replaced!<br /><br />Here's some instructions I have given others.<br />Easiest if you have someone else to turn the motor over for you while you take the measurements.<br /><br />Starter problems can be hard to diagnose. It doesn't take much to upset correct operation.<br />There's a big difference in starter motor turning effort for a motor with and without spark plugs. So even a poor starting system will turn over a motor without plugs.<br /><br />I presume you have access to a voltmeter. If so, I suggest you start by measuring the voltage directly across the starter motor during cranking under load, i.e. between the starter motor +ve terminal and the case of the starter motor. If this is greater than about 9.5V suspect a starter motor problem.<br /><br />If the voltage is less than 9.5V you are dropping volts somewhere else. Any resistance in the circuit will lead to voltage drop (and heat build up) and take power away from the starter motor. Check and clean all of the connections from the +ve battery terminal to the starter solenoid and from the solenoid to the starter motor. (As a clue, any bad connection should get warm when cranking).<br /><br />Check & clean also the -ve battery terminal & powerhead earth connection and also the earth connection from the starter motor to the engine.<br /><br />If this doesn't fix the problem, you may have bad cables or a bad solenoid. If you have access to a voltage meter you can use the following tests to isolate the problem. Measuring from a good earth or preferably directly from the battery -ve terminal, work through the starting circuit and measure the voltage at each point in the circuit while cranking the motor under load: battery +, solenoid battery side, solenoid starter motor side, starter motor +ve terminal and starter motor case. The difference between these measurements will tell you where the volts are being dropped and hence where the high resistance is.<br /><br />You can alternatively just measure the voltage across each component, e.g. from the battery +ve terminal to the solenoid,& directly between the solenoid terminals . In any event write down the readings and you should be able to figure out where the problem lies. They key is that the starter motor needs at least 9.5V to operate properly.<br /><br />As a guide you should get no more than about 0.8V drop from the battery +ve terminal to the solenoid, 0.4V across the solenoid and 0.8V between starter motor -ve terminal and -ve battery terminal. The voltage readings may well go up and down a bit as the motor turns over slowly but just try to choose a consistent set of readings.<br /><br />Also make sure your battery is in good shape. The battery voltage shouldn't drop below about 10V when cranking.