410 Intermittent Engine Starting

[Captain Adventure]

My 1999 410, I am the original owner, has an intermittent engine start problem. Always starts 1st crank at dock. Then while sailing next crank or after several successful 1st crank starts it won’t star until I turn the ignition key 2 to 10 times. Then it starts.
In a no start situation the yellow wire at the starter motor solenoid reads 12 + volts at no load. When connected to the solenoid terminal this voltage drops to 5.8. The engine always starts when I jump the battery 12 V to starter motor solenoid terminal.
The yellow wire is not directly connected to the 3 wire ignition switch. Where does this wire interface with the 12V heavy gauge ignition wire? Where is the intermittent resistance source that is causing the intermittent voltage drop? Is there a 3 Amp fuse between the motor solenoid terminal and the Ignition terminal as noted in my Yanmar manual?
Jerry

 

[Benny17441]

It has already been determined that your fault is due to a voltage drop caused by aging or old wiring. It is a common malady of Yanmars that may start as early as 7-8 year old models. It hardly makes sense to chase the source as the common solutions involve rewiring and the installation of a relay. Check the archives for a diagram. In most boats the problem evidences itself at the start pushbutton but you seem to have a turn key switch. Some have relocated and rewired the switch to the cabin near the companionway and the engine. I believe others have attempted to locate the source but have in time settled for the tried and proven remedy.

 

[Don Lucas]

There isn't any fuse on my 410's starter circuit. The engine panel has a circuit breaker for protection of the start relay. I have replaced my key switch and both the start and stop buttons on my panel (the start button shut once and burned up my starter).

Your problem sounds like standard corroded connections and I would start by cleaning all the connections on the engine panel and maybe replacing the switch.

I can not picture in my mind what yellow wire you are talking about.

 

[Sailgunner]

Run a new wire from your key switch to the solenoid.

 

[Bill Roosa]

I'd recommend nutering your Hunter of ALL quick connections in the engine and to the engine panel. If the start circuit is going all the others (oil pressure, water temp, alternator has no output, tach....) are also suspect.
I know when I nutered mine the oil pressure and water temp started reading more in line with what I knew was going on.

 

[Tengu]

I have been having the same issues on my 1998 410! Thanks you all for the info. I have replaced the instrument panel and key switch and still have same starting randomness. I was going to replace the starter solenoid next but rewire looks like the way to go.

 

[Tengu]

The intermittent no start became critical last week when then engine would not crank after many attempts. Running a new wire from the key switch to starter relay was going to be difficult so I have a push button installed in the starter circuit located in the engine compartment. So now that I have an emergency start capability of course the engine has started flawlessly since! At least I have some peace of mind that I can start.
Attached is pic of my solution.

 

[Wes Gardner]

Dunno if this will help but I used to have a 454 cu. in. motor in my wakeboat that was notorious for hard starting. The recognized solution was to run a new wire of the next gauge up from the key switch back to the solenoid...problem solved...

 

[Tengu]

Dunno if this will help but I used to have a 454 cu. in. motor in my wakeboat that was notorious for hard starting. The recognized solution was to run a new wire of the next gauge up from the key switch back to the solenoid...problem solved...

Yes you are correct that is my preferred solution... The issue is the difficulty to run a new wire from the cockpit to engine compartment. When I have it hauled out this fall I will see about dropping the headliner in the cabin and running a wire. The existing harness is in convolute and tied so cannot just fish a new on in place of the old.

 

[Rich Stidger]

Running a new wire from the key switch to starter relay was going to be difficult so I have a push button installed in the starter circuit located in the engine compartment.

This is exactly the solution I chose a couple years ago. I haven't had to use the button since! But Bill Roosa is right- I think that eliminating all of the connectors in the engine wiring harness would go a long way to reducing these kind of problems. I have been resisting this solution for a number of reasons. Most importantly not having a connector means that I can't separate and remove my instrument panel. However, I have noticed that if I turn on my instrument panel lights, the additional current draw for the lights is enough to cause a jump in all of my gauge readings. So I know that I have some bad grounds or other wiring. But the issue is a known quantity so for now I am just living with it.

 

[Don Lucas]

I've been having problems once in a while. I'm positive it is that damn start push button and if I wiggle my thumb around it starts. I have a new switch but the last only lasted 3 years before it started having issues.

 

[RHUMB RUNNER]

I have had intermittent starting on my Yanmar. Hunter put a second relay down near the engine, this all works fine. Doing an impeller change my mechanic knocked the wire off the starter solenoid. It turned out to be loose so we crimped down on it to keep it on. This worked for a while until again it wouldn't start again. So I went to replace it with a non slip on connector. Can't do that because the solenoid has a spade lug. I have now put on a new connector and found the old one was corroding up. This is under the engine so I had to remove the alternator to get to it. In doing so it made it easy to change the impeller. Added a Balmar adjustable belt tension bracket, this is really a nice addition for adjusting the belt tension. So far it starts every time!

 

[jrbado]

Had the same problem with my 2001 410. It turned out to be the breaker in the engine panel. A little WD40 and some cleaning of the connections worked.

 

[Tengu]

Had the same problem with my 2001 410. It turned out to be the breaker in the engine panel. A little WD40 and some cleaning of the connections worked.

Where is this breaker? Are you referring to the switch under the Nav table?

 

[jrbado]

the breaker is on the panel where the tack is. it has a little dome cover on it on the right side. unscrew the cover and there is a push button breaker under it.
The breaker under the Nav table is for the windless.