1975 mercruiser with chevy 250 straight 6 ignition/power issues

Canadianboomer

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Hi Everyone. I just found this website and have been reading for hours and have learned many cool new things. I figured I try posting my issue to get some idea's.

I have an older 1975 Glastron boat with a mercruiser i/o and a chev 250 - 165Hp straight 6 motor. It runs great year after year but a few years ago while testing in my driveway with the rabbit ears, I turned the key off and the motor kept running. We couldn't find the exact cause but suspected the ignition relay or solonoid. A few taps on that seemed to make it all better. Never had an issue since.

This year it seems to be doing the opposite. I have purchased two new batteries, cleaned all connections, replaced one semi worn wire, made sure my battery switch was good, and as usual, the never die engine roared to life. It ran for about 10 minutes like a dream and then stopped by itself with no fuel problem at all. When I tried to turn the key to the "run" position, I noticed that my instruments did not come to life as they normally would. It was dead of power. We turned the switch on and off, tapped the solonoid thing again as well as the second solenoid thing? and the power came back on and it started with no problem. Right now it is all working well but I am worried it will show up again at the worst possible time.

I am thinking of replacing whatever it is that is intermittent. I'm pretty sure it's the cylindrical looking thing that sit's on top of the starter with the big pos wire. Starter solenoid? I always thought the starter solenoid was only responsible for pulling the gear over to engage the flywheel and start the engine. I didn?t know that it distributes the 12v power in the run position. I don't suspect the actual key ignition switch. I'd love to find some kind of electrical drawing showing me where the 12 volts go after I turn the key to the run position. It must go to some kind of relay which sends power to have my instruments come to life. And then it would send 12 volts to starter when I turn key to start. So is it the starter relay or solonoid or could it be the second solenoid ? Because I can see some other module looking thing with wires as well. Anyone have a link or info for a service manual for this old Nova type motor?

Thank you,
Boomer
 

Lyle29464

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Re: 1975 mercruiser with chevy 250 straight 6 ignition/power issues

jump from the + side of your battery to the + side of your coil and try it again. If it keep running move that jumper from the + side of your key switch "B" to the 'I" and try that. If it still runs replace the switch.
 

achris

More fish than mountain goat
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May 19, 2004
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27,468
Re: 1975 mercruiser with chevy 250 straight 6 ignition/power issues

Ah, a man after my own heart. My introduction to the I/O world was a 1972 165... I did have some fun with that engine.... Learned a lot too...

Anyway... enough nostalgia.. Here's the manual you'll be needing.. Download it and SAVE it to your hard drive (we never know when they are going to get 'disappeared' by our 'friends' at merc. :mad:)

https://docs.google.com/open?id=0B1TAvwZ3TjhfOTI5OTMyZTMtNDNkZi00MDAyLWE5MTYtMTI5N2MyNDM3NjZm

Now, as for your problem.. There is no relay in the ignition circuit. If you had no instruments when you turned the key ON, then that can only mean one thing, no power getting passed the key (or to it)....

Unfortunately intermittent faults like this one are the hardest in the world to fix. You have to be ready to diagnose them when they pop up... I would have a test light ready to go... If it happens again, put the negative lead on the engine block and probe the main power terminal on the starter solenoid. If you have power there, move up to the instrument panel and check for power going into the red wire on the key switch. Got power there, check the purple wire on the key switch....

You have the manual, check out the circus diagrams and you'll see the power path... And don't ignore negative leads (incorrectly called 'grounds'. You only find grounds in your house wiring, not on a + and - DC system like a car or boat.... But we'll keep that to ourselves. :D)... They can knock an electrical system just as dead as a blown fuse... Check they are all clean and tight...

Chris.......
 

Canadianboomer

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Re: 1975 mercruiser with chevy 250 straight 6 ignition/power issues

Thanks so much guys! I downloaded the awesome manual. I'm sure that's gonna help. I also talked to the local marine shop and the mechanic there said that when I turn my key to "run", there is a wire from the key that actually powers up my instruments. That made me think that perhaps the key switch may be the issue.

I'm assuming that as long as my battery switch is on, there should always be 12volts at my key switch ready to distribute to the instruments when I turn to "run" position. If that is the case, then I have a problem somewhere between the battery and where the power first goes to the switch, or the switch itself. Do you know if it is just a simple wire from battery to switch or does it go through neutral sensors and other things first that may be causing the issue?

Thanks again from BC Canada
Boomer
 
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3,028
Re: 1975 mercruiser with chevy 250 straight 6 ignition/power issues

Look thru that manual, there is the wiring diagram for the helm/ gauges as well as the engine. Should be able to figure it out with it.
 

achris

More fish than mountain goat
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May 19, 2004
Messages
27,468
Re: 1975 mercruiser with chevy 250 straight 6 ignition/power issues

Check the fuse in the red wire that goes to the key switch. I've fixed a few with corrosion on the ends of the fuse that caused intermittents... I usually just change the complete fuse holder over to a water-proof blade fuse nowadays... Cheaper, easier and problem gone forever....

Chris......
 

Canadianboomer

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Re: 1975 mercruiser with chevy 250 straight 6 ignition/power issues

Thanks for the tip!

Trying to find this problem I ended up replacing many wires and connectors that really needed to be replaced anyway so that was good. With the help of the manual, we traced the problem to somewhere after the ignition key switch. The switch checked out ok. I noticed a 12 or so wire connector under the dashboard. We followed the 12 volts past the key switch and into this connector. Once we moved the connector around, the problem came and went. The connector under the dashboard was the problem. I'm guessing it is corroded so I will see about replacing it if I have enough wire slack. If not, is there a good spray or some other good way to clean it?

Thanks again everyone! One major issue down, 1 minor one left.

Boomer
 
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3,028
Re: 1975 mercruiser with chevy 250 straight 6 ignition/power issues

They do sell an electrical contact parts cleaner, in a spray can similar to carb cleaner but made for electrical.
Should be able to get it at an auto parts store.
 

achris

More fish than mountain goat
Joined
May 19, 2004
Messages
27,468
Re: 1975 mercruiser with chevy 250 straight 6 ignition/power issues

They do sell an electrical contact parts cleaner, in a spray can similar to carb cleaner but made for electrical.
Should be able to get it at an auto parts store.

It's called 'CO Contact cleaner'....
 

Canadianboomer

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Re: 1975 mercruiser with chevy 250 straight 6 ignition/power issues

The fun continues! I guess it wasn't the wire connector after all! I cleaned it and it wasn't really dirty, sprayed it and plugged it back in. Now, I can turn my key to the "run" position, my instuments power up and things look normal. But as soon as I try and operate anything electric, like my blower motor, bilge pump or trim my leg, the power falls away. We even got it to crank over and start and run a few times, but as soon as I introduced anything electrical, the engine stalled. I am totally confused now. Can't really make heads or tails of the wiring diagrams in that book. Most if not all don't pertain to my engine. And when I do find a diagram of interest, I folloow the wire in question aand the next thing I know it goes to some round connector which I don't even have and then it's gone........I'm running out of wires to replace. We have 12volts at the key switch, we have 12volts on the other side of the keyswitch when I turn it to "run", but as soon as I turn any electrical device on, it's gone. Sounds like a bad connection too me but I've checked or changed just about every one!

Boom
 

achris

More fish than mountain goat
Joined
May 19, 2004
Messages
27,468
Re: 1975 mercruiser with chevy 250 straight 6 ignition/power issues

Yep, that's a bad connection somewhere.. Possibly the battery terminal, and don't forget to check the negatives too...
 
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