Yanmar electrical problem.

DStegs49

DStegs49

.
Feb 22, 2011
75
Hunter Legend 37 Muskegon, MI
I have a Legend 37 and from the day I bought it, I've had an intermittent problem with the starter. Of course the surveyor never mentioned it but he is a different story and the broker was no help either. The starter functions intermittently and I've got my problem narrowed to either the starter button or the wiring to it. I replaced the button once. I also have run new wire from the button to the solenoid and replaced the solenoid also. Do I have to increase the wire size? It still has the same problem, push the button and nothing. If I rapidly push the button it usually starts after about 5 or 6 pushes. Once the starter connects, the engine starts immediately. I have heard this is a typical Yanmar problem and I tried the cures I've found but it's still a problem. Anyone else in the same boat, so to speak? Any cures or fixes you have come up with. The starter works immediately if I cross the terminals with a screwdriver but that takes me away from the helm.
 
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dlochner

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Jan 11, 2014
11,832
Sabre 362 113 Fair Haven, NY
DStegs49 said:
Do I have to increase the wire size?
Click to expand
Yes. this is known issue with some Yanmar's. The voltage drop over the wire does not provide enough power to activate the solenoid. For some reason, repeatedly pushing the start button sometimes works, but it is unreliable. I used 10g wire when I replaced mine.

The other related issue is the wiring, the circuit goes from the starter to the switch and back to the solenoid. That wire from the starter to the panel carries all the current for the gauges/idiot lights and anything powered through the key switch. I rewired it so power for the panel and solenoid comes directly from the DC+ bus bar. (fused of course). Haven't had a problem since.
 
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kloudie1

kloudie1

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Nov 6, 2006
9,947
Hunter 34 Mandeville Louisiana
Pretty much the same here.. I used 10 ga wire from the starter "hot" terminal to bypass all of the sketchy multi-pronged connectors .. I had tried cleaning the connections and that would work for 6-8 months.. If you look at the wiring diagram, you can see that the original power to the panel and back to the solenoid has to get through 4 connections that used to be sometimes clean and waterproof..
 
duck21

duck21

.
Jul 17, 2020
153
Hunter 376 0 Washburn, WI on Lake Superior
Here's a previous thread from this form that also details this out with some photos:

Fix for Hunter Starter Wiring Harness issue

I found a number of posts on the forums for a wiring issue that Hunter had with the starter wiring, where the switch or the wires would prevent the starter solenoid from starting the Yanmar (or other engines?). This was apparently due to small wires in the harness or bad contacts in the...
forums.sailboatowners.com

I followed a this schematic/procedure for my dads Yanmar on his Hunter 340, it's been working great.
 
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Ralph Johnstone

Ralph Johnstone

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Jan 4, 2006
6,703
Hunter 310 West Vancouver, B.C.
Solution attached :

1722270256933.jpeg


1722270327345.jpeg


The reason for installing a booster relay is to avoid the complication of running heavier wire from the starter button down to the engine starter solenoid. All wiring is localized at the engine and within 2 ft. This relay is mounted on the bulkhead beside the engine.

1722270610901.png


1722271743579.png


The alternator has no significance other than having large convenient (+) and (-) posts as a power source in the "as built" drawing.
 
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DStegs49

DStegs49

.
Feb 22, 2011
75
Hunter Legend 37 Muskegon, MI
Thank you all for being VERY HELPFUL. I was on the right track but wrong train. I used some tinned 2 strand from Home Depot. Apparently it wasn't a bigger gauge than what was installed when built. Next trip to the boat, that wire is getting pulled and #10 red and white is going in. I am going to KISS and just start by replacing the wire. If that doesn't work in the long run then I'll delve into the relay suggestions. Thanks again.
Dave
 
ggrizzard

ggrizzard

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May 27, 2004
2,013
Hunter 30_74-83 Ponce Inlet FL
Don't buy wire from HD. Corrosion 'creeps'.
Get "tinned" copper wire from a chandlery.
 
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dlochner

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Jan 11, 2014
11,832
Sabre 362 113 Fair Haven, NY
ggrizzard said:
Don't buy wire from HD. Corrosion 'creeps'.
Get "tinned" copper wire from a chandlery.
Click to expand
Yep, probably good advice. Especially for wire going into the engine room where heat and oil are present, only buy oil resistant Boat cable with a high temperature rating, 105°C. Wire labeled as such is built to UL 1426 standards.
 
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ggrizzard

ggrizzard

.
May 27, 2004
2,013
Hunter 30_74-83 Ponce Inlet FL
2 strand: 1 Black, 1 red, an example of 12v boat wire.
3 strand: 1 Hot, 1Ground and 1 Neutral, aka 115v House wiring.
 
DStegs49

DStegs49

.
Feb 22, 2011
75
Hunter Legend 37 Muskegon, MI
Not going to get to the boat for a while now so I'll be checking back to see what else comes in before I do anything. I knew nothing of the UL rating for marine wire so I learned something today. Thanks for the info.
Dave
 
Ralph Johnstone

Ralph Johnstone

.
Jan 4, 2006
6,703
Hunter 310 West Vancouver, B.C.
1722295799254.png


@DStegs49 , I sure wish this was available in Canadian Home Depots. These are top of the line brands of marine wire and I'll bet the prices beat the can off your neighbourhood chandelry for the same brand wire..

This is definitely where you want to shop for marine wire.
 
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dlochner

.
Jan 11, 2014
11,832
Sabre 362 113 Fair Haven, NY
ggrizzard said:
2 strand: 1 Black, 1 red, an example of 12v boat wire.
3 strand: 1 Hot, 1Ground and 1 Neutral, aka 115v House wiring.
Click to expand
That's duplex and triplex cable. Strands generally refers to the individual strands of a single wire inside the insulation. Boat cable (AWG) has more and thinner strands, than Auto (SAE) wire which has more and thinner strands that AC wire (THN) used in buildings inside of conduit. The gauge of the wires is also not consistent, AWG 10 ga is fatter than SAE 10ga.
 
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jviss

jviss

.
Feb 5, 2004
6,970
Tartan 3800 20 Westport, MA
Ralph Johnstone said:
Solution attached :

View attachment 226410

View attachment 226411

The reason for installing a booster relay is to avoid the complication of running heavier wire from the starter button down to the engine starter solenoid. All wiring is localized at the engine and within 2 ft. This relay is mounted on the bulkhead beside the engine.

View attachment 226412

View attachment 226413

The alternator has no significance other than having large convenient (+) and (-) posts as a power source in the "as built" drawing.
Click to expand
Hey Ralph, where does that red wire on the left of the pushbutton go?
 
Tally Ho

Tally Ho

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Jan 7, 2011
4,985
Oday 322 East Chicago, IN
Is there a tutorial on how to bypass the existing wires to the pushbutton with new wire? (Yanmar 2GM20F)?

The distance from my engine to the starter button is about 4 feet, yet my Raspberry Pi restarts whenever I start the engine (running off the same bank). I assume that could be due to the poor wiring issue.
I am not sure If fixing the wiring or adding the starter solenoid is the best fix.

Greg
 
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dlochner

.
Jan 11, 2014
11,832
Sabre 362 113 Fair Haven, NY
Tally Ho said:
Is there a tutorial on how to bypass the existing wires to the pushbutton with new wire? (Yanmar 2GM20F)?

The distance from my engine to the starter button is about 4 feet, yet my Raspberry Pi restarts whenever I start the engine (running off the same bank). I assume that could be due to the poor wiring issue.
I am not sure If fixing the wiring or adding the starter solenoid is the best fix.

Greg
Click to expand
Both options work. I chose the rewire because it was straight forward and there is no extra relay or solenoid to fail.
 
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BigEasy

BigEasy

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Jun 21, 2004
2,567
Beneteau 343 Slidell, LA
ggrizzard said:
Get "tinned" copper wire from a chandlery.
Click to expand
Try Gregg’s marine wire supply, online. Good quality & prices. They stock marine grade tinned wire & cable as well as a variety of crimp type connectors, lugs for cable, shrink tubing, etc.
 
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Ralph Johnstone

Ralph Johnstone

.
Jan 4, 2006
6,703
Hunter 310 West Vancouver, B.C.
Tally Ho said:
I am not sure If fixing the wiring or adding the starter solenoid is the best fix.
Click to expand
I would say it depends on the complexity of rewiring with heavier wire.

Mine was an SOB with the number of plugs and complexity of the run so I chose the booster relay. Either will perform 100%.
 
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