Yanmar Starter redux

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Jan 1, 2006
8,008
Slickcraft 26 Sailfish
I am getting around to putting this relay in to improve the operation of my starter button. Does any have a link to an exploded diagram of a Yanmar 3GM30F engine starter and solonoid. I haven't been able to correlate what I see on my engine with various instructions I've received. It is difficult to visualize the wiring on my engine for various reasons. An exploded diagram would help a lot.
 
Jan 1, 2006
8,008
Slickcraft 26 Sailfish
Thanks, so much. That is so far better than I hoped for. I'm a bit stunned.
 
Jun 5, 1997
659
Coleman scanoe Irwin (ID)
Andrew,

In case you are unable to find a copy of the 3GM30F service manual, which should have exploded diagrams of both the original Yanmar-suppied relay and starter motor, or in case these original components were replaced by different after-market components, you could simply treat the solenoid/starter motor combination as a "black box" with two electrical current inputs (to solenoid and starter motor, respectively), one electrical current output (engine and/or battery ground) plus a single mechanical output. In this situation you are only concerned with the solenoid current input. Take the one wire that runs from the wire harness to the solenoid's only external connection point, cut it and connect the harness end to the low current side of the relay you are planning to use, while connecting the solenoid end to the high current side. Then make a reliable, ample current connection between the battery plus and the remaining high current post of the relay while attaching a reliable ground wire to the remaining low current post of the relay and you should be all set.

Before putting in a relay in line with your solenoid, however, you may want to take into consideration that:
(1) your solenoid is itself a relay, meant to operate on the relatively low currents that can be provided by relatively long and thin engine harness wires;
(2) if it fails to do its job properly, the "black box" either has developed internal problems or, more likely in a marine environment , not enough current is being provided by the harness because of corrosion problems and/or poor connections upstream; an
(3) therefore the extra relay is either not going to help at all or only provide temporary relief (till the corrosion and/or connection problems become bad enough to provide insufficient or intermittent current to power the relay).

If and when these future problems arise, you have now managed to add quite a few more wires and connection points that can give problems and thus need to be maintained and checked; thereby violating the time-honored "KISS" principle of cruising.

After having operated our Hunter Legend 43 in the tropics for well over a decade, including the use of temporary extra solenoid relays if I was either too lazy or pressed for time to try and solve the real underlying problems, I fail to see any long-term justification for such relays unless it can be clearly shown that either the manufacturer underdesigned the engine start system (e.g. with regard to harness wire dimensions) or that later modifications and additions (e.g. power-hungry pedestal devices) severely degraded the amount of power available to the harness.

Best of luck;

Flying Dutchman
 
Jan 1, 2006
8,008
Slickcraft 26 Sailfish
Just an update for those following this. I have accomplished the installation of the relay and now the starter button is working again. It had stopped completely causing me to have to start the engine by jumping the solonoid with a # 10 wire. It was an act I liken to trying to do surgery on a patient having convulsions.
Thanks so much to those who lent their opinions, advice and especially photos.
I am a big fan of the kiss rule. This solution has kiss appeal even if it doesn't pass muster as a solution that has the fewest weak spots. I really didn't want to replace the whole harness with all the other wire connections. A replacement wire can still be done if necessary. At least I understand the problem and don't have to chase dead ends like replacing the starter button, buying another new battery etc. That's worth a lot.
 
Oct 14, 2005
2,191
1983 Hunter H34 North East, MD
European and Japanese...

cars have been controlling large current circuits through relays for years. It's a similar application to apply this technology to the Yanmar starter circuit problem. Glad to hear it worked for you!
 
Sep 24, 2006
236
Sabre 36 Express Chattanooga, TN
These is an easier fix

Adding another relay is like wearing a belt and suspenders...just more stuff to get in the way. The easiest fix is to run a new 12 gauge (white) wire from the starter button to the original starter solenoid, bypassing the oem wire which has several couplings in it. These couplings corrode over time causing the problem. After you run the new wire, you'll be back in business without all the hassles you described. I've done it on two boats with Yanmars and the solution in permanent and simple.
Agaliha
 
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