How the heck do you get this starter out!?

[b4tn]

I have recently developed an intermittent starting issue in my merc 5 sitting in a 2000 searay. It's one of those issues where the boat beeps, fuel pump primes, then click and nothing. It started yesterday, I launched the boat, cruised around for a bit and when my party arrived it was just click. Just after I told everyone to go home I decided to try one more time (after several tries) and she fired right up! I called everyone back and we decided to head out and just not turn the boat off. All was well all day and she even fired up twice right before bringing her in. I was hoping!! It was the solenoid so I went ahead and replaced that but got the same issue. Just to make sure I put jumper cables on it to make sure it was not the battery but same thing. I jumped the solenoid while over the engine and the starter does the chunk sound then nothing. I have done many starters years ago but this thing is so deep down! How do I get to it? Any tips?

 

[muskyfins]

What is the model Sea Ray?

My son and I have put 3 starters in 2 different Rinker cruisers in the past 3 years. It's damn near impossible, but can be done. Lucky for me, he is a wiry kid (22 years old). It's definitely a job for a young person or a very small one.

If it was me by myself, it might be easier to pull the motor.

 

[b4tn]

It's a 2000 searay bow rider 210 signature. I'm learning that working on boat V8's is nothing like my old chevy.

 

[camalot]

First check the slave solenoid that's the first one to go, and as you replaced the start solenoid and it did nothing it kinda points to that.

 

[alldodge]

Just replaced mine with a permanent magnet type.
Recommend
Get 2 pieces of threaded rod or bolts with heads cut off about 4 inches long same thread as exhaust bolts (BBC 3/8-16)
Get exhaust manifold gasket
Remove the exhaust manifold and riser
Replace starter
Screw the rods into the outside holes for manifold
Note how the exhaust gasket will go on manifold. If gasket has complete holes on the out side bolt holes instead of slots cut a piece out of gasket bolt holes so gasket can be slid in between motor and manifold
Slide manifold on to rods
Slide gasket in between
Install other bolts, then remove rods and install bolts
Torque to spec (BBC 25 ft lb)

 

[Bt Doctur]

A soft click is a slave relay and a louder "clunk" is the starter trying to turn the motor over from:
a wet starter or one that went swimming
a hydo-lock condition

 

[b4tn]

All this would not be an issue if I had more room to work with. To get to the starter my head is litterally down the small space with my legs up in the air lol. I may look into removing the back seat.

 

[Bondo]

All this would not be an issue if I had more room to work with. To get to the starter my head is litterally down the small space with my legs up in the air lol. I may look into removing the back seat. I'm learning that working on boat V8's is nothing like my old chevy.

Ayuh,.... Welcome Aboard,.... It's actually quite alot like yer ole Chevy,....

The trick to workin' on boat motors is knownin' enough to remove enough "Boat" that's in yer way,....
'ell, many times I unbolt anything, 'n everything that's bolted down,....

When I design boat lay-outs, I make Alota room around the motor, 'n drive, or very easily removable panels,....

 

[b4tn]

A soft click is a slave relay and a louder "clunk" is the starter trying to turn the motor over from:
a wet starter or one that went swimming
a hydo-lock condition

Motor is for sure not hydro locked. Like i said it ran fine about 50 clicks later lol. We had it out for several hours just didn't turn off anything. However I will admit. This being my first boat i made a rookie mistake and I forgot to put the plug in when I first got it. Got it ashore, drained, and dried with no issue until now. I kind of wonder now if this is why the starter quit.

 

[b4tn]

Ayuh,.... Welcome Aboard,.... It's actually quite alot like yer ole Chevy,....

The trick to workin' on boat motors is knownin' enough to remove enough "Boat" that's in yer way,....
'ell, many times I unbolt anything, 'n everything that's bolted down,....

When I design boat lay-outs, I make Alota room around the motor, 'n drive, or very easily removable panels,....

I'm pretty stubborn. I have been looking up diagrams and techniques for getting to this damn thing all night.

 

[b4tn]

Just replaced mine with a permanent magnet type.
Recommend
Get 2 pieces of threaded rod or bolts with heads cut off about 4 inches long same thread as exhaust bolts (BBC 3/8-16)
Get exhaust manifold gasket
Remove the exhaust manifold and riser
Replace starter
Screw the rods into the outside holes for manifold
Note how the exhaust gasket will go on manifold. If gasket has complete holes on the out side bolt holes instead of slots cut a piece out of gasket bolt holes so gasket can be slid in between motor and manifold
Slide manifold on to rods
Slide gasket in between
Install other bolts, then remove rods and install bolts
Torque to spec (BBC 25 ft lb)

I didn't think to remove the manifold. I would really rather not. But as a last resort...

 

[kenny nunez]

I used to do warranty work for a Sea Ray dealer and came to the conclusion that Sea Ray lays the engine on the floor and builds the boat around it! I do not miss those days. I once told a Sea Ray rep that his boats must be perfect because they cannot be worked on by the way they are jammed together and never need repairs.

 

[bman440440]

I didn't think to remove the manifold. I would really rather not. But as a last resort...

I have found that 9 times out of 10 its easier to remove the manifold for that job... $10 gasket and 45 mins of work or 4+ hours of bitching and busted knuckles... for me its an easy choice... but that just my 2c take it for what is worth... also more than likely yes your first time out when you forgot the plug it did your starter in... we all make mistakes.

 

[gm280]

Maybe, just maybe, you could cut a hole in the bottom of the hull and replace it and then patch over the hull. Yea I know, that sounds like a lot of work, but could be easier then removing the engine. :facepalm: :noidea:

 

[Chewer D]

I just did mine last week. I had to remove the back seats and bench in order to get to it. Even then I was only able to do it because I'm 6'4" and have long arms. I was able to get my arm underneath from the opposite side of the engine to get to the bolts. It was not the easiest starter replacement I've ever done.

 

[b4tn]

It's been pouring rain all day and supposed to tomorrow as well so I have not had a chance to take a closer look. The back seats and bench are going to have to come out at a minimum! To save me a little stress.. can anyone tell me the wrench size and bolt locations? I'm guessing 9/16? Looking at replacement starters the bolts are not in a standard location. I have not had a chance to get in there with a flash light yet.

 

[alldodge]

You could help me if not us out by saying what motor this is, we know its a V8 but they make a lot of different sizes.

Standard GM staggered pattern, 9/16 and 50 ft lb for BBC and 30 ft lb for SBC

 

[b4tn]

I'm going wrenching tomorrow. I need to kno myself.

 

[enginesilo]

Did you try to jump the slave solenoid posts first? That would be an easy fix if it were only that.

 

[b4tn]

All, sorry I just finished. Once the bolts where broke credit was easy. I used a "16 swivel head ratchet with a 1/2" deep socket. It was a royal pain because I was standing on my head. Being claustrophobic my lovely wife was rubbing my legs and making sure I didn't get stuck lol. I found it was easiest to get the socket on the bolts then put the ratchet on and tug. It's tight and a pita, but once the bolts where free I used a stubby ratchet to get them out. Take the wires you see off first but take a picture to make sure you get them back on right. Any other wires you can't see take off after the starter drops. It's not an easy job but with persistence it's possible lol