2006 Yamaha 150V Outboard - Bendix Not engaging

[Handyman76]

Hi all,
Really need your help. I have read through all the previous threads regarding having issues with the starter as well as watching numerous YouTube videos. I have done most of the suggestions that usually ended up fixing the issue which include the following;
1. Removing the bendix, clearing out all the old caked up grease and applying a 3-N-1 grease. = Failed - bendix spinning, not engaging.
2. Replace the starter. = Failed - bendix spinning, not engaging.
3. Voltage drop test. Voltage 12+ at each testing point with voltage drop test coming out at zero all the way back to the Starter Solenoid relay. Tested the voltage going from the relay to the starter when engaging the switch. Only 7.5 volts output showing. = Fail - bendix spinning, not engaging.
4. Replace the Starter Solenoid Relay. Only 7.5 volts output showing = Fail - bendix spinning, not engaging.
5. Tested the starter directly to the battery = Pass, bendix shot up to engage.

In my mind, the issue is with the relay, but the relay was replaced and still receiving the same result. This is where I am stuck as to what to do next. I have not checked all the wires leading to the batteries yet, just the ones on the motor. Would I even need to do this since the voltage going into the relay is 12+?

Looking for any and all advice to get this issue fixed. Thanks

 

[dingbat]

3. Voltage drop test. Voltage 12+ at each testing point with voltage drop test coming out at zero all the way back to the Starter Solenoid relay.

The fact that your getting no voltage drop at all is suspicious in itself. Usually drops below 12 volts when cranking.

Suggest you check the voltage drop at the battery side of the relay while cranking.

 

[Handyman76]

The fact that your getting no voltage drop at all is suspicious in itself. Usually drops below 12 volts when cranking.

Suggest you check the voltage drop at the battery side of the relay while cranking.

Okay, these are my results with the battery side of the relay.
cold = 13.66
cranked = 4.62 then climbs to 6.5ish

I'm not sure what this means as I am not electrically(?) inclined. I did remove the key switch and it has a voltage drop of zero. The YouTube video I watched to do this indicated this means the switch is good. Any ideas on the next steps to take?

 

[boscoe99]

Is the model a V150TLR?

 

[dingbat]

Okay, these are my results with the battery side of the relay.
cold = 13.66
cranked = 4.62 then climbs to 6.5ish

I'm not sure what this means as I am not electrically(?) inclined. I did remove the key switch and it has a voltage drop of zero. The YouTube video I watched to do this indicated this means the switch is good. Any ideas on the next steps to take?

What does "cold" mean?

Fully charged battery voltage is 12.7 volts. Can't get to 13.66V w/o the motor running?

You either have a bad battery, a dirty battery connection or bad battery cable

 

[boscoe99]

Voltage drop can result due to poor electrical connections or an internal problem within a wire. The battery may be defective as well.

Start with testing the voltage at the positive battery post. Then measure the voltage at the positive terminal of the battery cable, at the battery. Then measure the voltage of the battery cable at the starter relay.

Measure the voltage with the motor being cranked of course.

 

[Handyman76]

What does "cold" mean?

Fully charged battery voltage is 12.7 volts. Can't get to 13.66V w/o the motor running?

You either have a bad battery, a dirty battery connection or bad battery cable

Cold meant just touching the wire without anything running. It started off at 13.66 then dropped to 12.6. I replaced the battery and the same thing happens.

 

[Handyman76]

Is the model a V150TLR?

Yes, V150TLR is the model.

 

[dingbat]

Cold meant just touching the wire without anything running. It started off at 13.66 then dropped to 12.6. I replaced the battery and the same thing happens.

13.66 VDC is a "surface" charge. Your "active" battery is voltage is 12.6 VDC

 

[Handyman76]

Thank you @boscoe99 and @dingbat for your assistance. Thanks to your knowledge and expertise, I found the issue this past weekend and was able to get her running again, purring like a mountain lion.

 

[99yam40]

stating what you found wrong might help someone else down the road when they have a similar problem

 

[Handyman76]

Running the voltage drop tests ended up revealing the main battery was not up to par. The battery which was replaced was the auxiliary battery. So switching the batteries allowed enough 'juice' to get to the starter. This was the fix. Although I did blow a fuse, but was able to replace it and haven't had any issues. Good news is that after cleaning the carburetors, connections, lines, etc., the motor started up and ran like a champ.

 

[99yam40]

thanks for the updated info on the fix