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Old 07-07-2019, 09:04 AM   #1
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Default Starter Issues

200 hp Johnson, 1996. Starter spins but won’t engage. Replaced with new starter, new solenoid, two new batteries, cleaned all connections, but still spins without engaging flywheel. Batteries are charged. Noticed 15 amp fuse blows where the battery switch is connected.
I used jumper cables and jumped directly from battery to starter and it engaged and turned over. Any suggestions? Thanks in advance.
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Old 07-07-2019, 09:29 AM   #2
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Sounds like you have a direct short somewhere when energising starter switch.Try bypassing the battery switch. Dont bypass that fuse it has been saving you big troubles.
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Old 07-07-2019, 02:01 PM   #3
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Not enough current going to the starter. Clean all connections again using a small (toothbrush size) brass brush and lightly oil them from battery to starter to key switch. If they are any wire nuts, taped up twisted wire connections, splices or Scotchlok Electrical IDC connectors, cut then out (if possible) and re-connect them. Check grounding and re-clean those connections, lightly oil to help slow corrosion.
There's corrosion somewhere causing the poor current flow causing a short for the 15amp fuse to be blowing.
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Old 07-07-2019, 06:40 PM   #4
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Wiring … solenoid is not getting power to pull in the yoke to engage the teeth..
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Old 07-07-2019, 07:52 PM   #5
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Bet your switch is a Perko, atwood or one of the like. Junk, shouldn't be sold.
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Old 07-07-2019, 08:45 PM   #6
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Pull the battery switch and see what the backside/inside looks like.
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Old 07-07-2019, 11:35 PM   #7
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Sierra solenoid. Tried two different ones. Used fine grit sand paper to all connections. Battery selector switch looks fine. Any way it could be key switch?
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Old 07-08-2019, 02:56 AM   #8
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2 person job but while cranking, grab pos/neg power wires and see which one is getting hot? Might be corroded internally.
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