Solenoid has voltage to it with key off

[bobandsherryboaters]

Had an ignition switch go bad and stuck in start position. Replaced ign switch and now have constant voltage to solenoid and starter. Pulled the starter relay and there is no continuity between the two main terminals which I assume is correct until it is triggered. I think the brown wire going to the relay is being engerized constantly causing the relay to stay activated. How can I troubleshoot from here?? Engine is a 90 hp 4s mercury 2001 model.

 

[Texasmark]

Two strokers of that yearmodel used a red/yellow stripe to energize the starting solenoid. Comes off the ignition switch in the Start position. Since the wiring harnesses that come with the Commander control boxes are designed to operate most any Merc. you may have the wrong wire connected to the solenoid energizing terminal. Only brown wire on a 2 stroker is for the Over Temp/Low Oil alarm and it's tan and not brown and may have a lt. blue stripe in it. That wire, if you are on the cable harness side of the engine to remote connection has 12v on it when there is no alarm requirement....aka the alarm sensors are open circuit and not grounded. Between the 12v and the connector is the alarm transducer. I don't know what the resistance of that is and don't know how much voltage would be available at the solenoid, but a 12v solenoid will pull in down around 8 volts.

That may be your problem: Wrong wire to solenoid.

 

[gm280]

Easy way to determine the correct wire and color is to just look at the small terminal on the starter solenoid and make that same color wire hookup to the start terminal on the key switch...

 

[Texasmark]

Easy way to determine the correct wire and color is to just look at the small terminal on the starter solenoid and make that same color wire hookup to the start terminal on the key switch...

Considering a used boat like a used farm tractor, anything is possible. That would be the surest solution.