Suzuki DT40 Key Start Conversion

[ombudsman]

Hello all,

I picked up a 1985 Suzuki DT40 outboard the other day. It is currently pull start and I am looking to change it over to key start.

I am just wondering if anybody on the forum here might have any advice fro me on this conversion process. I have access to a cheap starter motor that fits this model but I'm not too sure how the rest of it goes. Do i also need a solenoid somewhere in between the starter and the battery? and are there any other parts i need like the safety mechanisim the pull start has that disngages it from the flywheel?

Any help is greatly appreciated as I would much like to get this baby running and ready to roll, I'm not sure if there are any other owners of this model here but it runs very well and seems to have heaapsss of grunt, so I cant wait to get on the water

cheers

 

[stylesabu]

Re: Suzuki DT40 Key Start Conversion

you need a relay to put battery power to starter. its not hard. are you looking just to add an electric starter? nothing else?

 

[ombudsman]

Re: Suzuki DT40 Key Start Conversion

thanks stylesabu, just an electric starter thats all. Looking at the part list for this model it seems as though its the same flywheel as well.

I am just a little uncertain as to where a 'solenoid' fits in the picture and wether is is necessary. If not then it seems this should be a very simple job. I will just run wires from the starter motor to the key, and rewire the stop button onto the key as well.

Would u go about it this way as well? I am just not too sure what a relay is, having a look online it seems that a solenoid is a relay as well? lol im so clueless with some of this stuff

edit: just had a look online, looks like im going to need a new flywheel as well that has teeth. I am considering doing this myself, has anyone else ever tried converting their old flywheel from pull to electric start? I'm wondering if I'll be needing a new stator assembly as well....

 

[99yam40]

Re: Suzuki DT40 Key Start Conversion

You need to compare all the parts of your motor and a model of an electric start of same year to see what all is different.

Key switch will not carry the amperage needed for starter motor you will have to buy and mount the starter relay

 

[Silvertip]

Re: Suzuki DT40 Key Start Conversion

You CANNOT wire the battery directly to the ignition switch and YES you need a solenoid. Failure to install the solenod would fry the ignition switch in a heartbeat as it does not have the capability to handle the high current draw of the starter. Look at the size of the battery cables going from the battery to the engine!!!! They are the size they are because the starter is the highest current draw item on the boat. So here is the principle:

Battery negative post gets connected via the black battery cable directly to the engine block (any larger bolt with a clean connection will do).
Battery positive post gets connect to one of the large terminals on the starter solenoid. Doesn't matter which one.
The second large battery post on the solenoid feeds the large terminal on the starter.
The 'S' terminal on the ignitiion switch connects to the "S" terminal (the small one) on the starter solenoid. If the solenoid has a separate ground terminal (a second small terminal) it connects to the engine block. If it does not have a second small terminal it gets its ground through the metal shell of the solenoid so it must be bolted to the engine block.
You need a wire that feeds +12 volts to the "B" terminal of the ignition switch.
You need a wire that runs from the "C" terminal (choke/primer) on the ignition switch to the choke or primer on the engine.
You need two wires that connect the two "M" terminals (magneto) to the kill switch and magneto.
You need a wire that runs from the "A" accessory terminal on the ignition switch to any instruments (gas gauge, volt meter, etc).
You CANNOT use an automotive ignition switch.
You would be wise to purchase the engine side and helm side harnesses so it becomes a plug&play. If this is a tiller engine (you didn't point this out), then you have some considerations as to where to mount the ignition switch, fabricate the harness, etc. Good luck.