My E22 won't start

[2000epic]

I'm at a loss and need you guys help!  Took the boat out this weekend and she was acting goofy.  The voltmeter was alarming and wouldn't stop, I haven't had this problem since I upgraded the dash wires a couple years ago.  Then I'm cruising along and she just dies.  I start it up and she motors right along.  I shut down for a few minutes to change riders and she hasn't started since. 

Sometimes when I turn the key on the gauges work, sometimes not.  The perfectpass always comes on, all the acc switches work like they are suppossed to.  sometimes the starter relay clicks when I turn the key, sometimes it doesn't.  Sometimes the starter clanks when I turn the key, sometimes it doesn't.

I have a new Optima yellowtop that tested out fine today, and I double checked it with the yellowtop in my landcruiser.  I checked all the breakers and fuses that I know of.  I checked the ignition switch and the tether kill switch and they both work fine.  I swithched the two relays in the engine compartment and switched them back to no avail.  And I jiggle the throttle with every test just to make sure I'm not being chumped by the nuetral safety switch.

any ideas??

[masonlk]

Re check the wires going to the ignition and the connections at the battery switch. The inconsistencies sound like a loose wire somewhere.

[2000epic]

OK I found a blown fuse, it's a glass fuse 6inches from the perko switch with about 10 gouge wiring.  I replaced the fuse and turned the key and the starter went "clank" and the fuse was blown once again.  So I did something I know I shouldn't do and jumped the fuse holder   no when I try to start the starter just goes "clank".  I want to verify that the starter works but it looks like a it's a pain to get to.  Anyone know how to get the starter out?

[lilfoo2225]

 intake gotta come off to get to that. 

[masonlk]

Need to disconnect the throttle body cable, remove the intake manifold, and then you can get at the starter. I highly recommend you get the Toyota Marine Engine Repair Manual from Capt. Rick for step by step directions. He can send it to you via email.

[2000epic]

intake gotta come off to get to that. 

ouch!  will regular automotive gaskets for say a gs400, sc400, ect work?

Need to disconnect the throttle body cable, remove the intake manifold, and then you can get at the starter. I highly recommend you get the Toyota Marine Engine Repair Manual from Capt. Rick for step by step directions. He can send it to you via email.

very cool, i'll see if I can get a hold of him thanks

[wakejunky]

Don't sweat the gaskets unless there broken. we rarely replace the gaskets when we change a starter at the dealership. (actually Ive never replaced the gaskets to be honest) never had an intake leak either. most gaskets are steel these days and are reusable. That gasket is layered steel/ thick plastic spacer/ steel. if your mechanically inclined you can replace the starter contacts inside the starter for about $40. beats a $300 starter any day and that tends to be what wears out. if your talented enough to remove the intake the contacts are cake

[2000epic]

very good info guys thanks so much!  wish me luck i'm headed out to dig in!

couple other Q's:  that wire with the 20a fuse...what does it power and would a bad starter kill it?  and where might I buy starter contacts?

[wakejunky]

a bad starter can pop a fuse. You can get starter contacts at a Toyota or Lexus dealership or you can go to a quality aftermarket store. typically the type an aftermarket shop may use. like carquest. i doubt auto zone will carry them or even know what your talking about. Best bet is to remove the old ones and have the parts store match them up. when pulling the manifold remove the throttle body, unplug the injectors remove the bolts and 4 nuts down at the base next to the injectors, disconnect the fuel lines and ground straps and any electrical connectors. you can remove it in one big chunk. dont seperate the manifold or remove the fuel rails.

[2000epic]

Oh crap, I separated the manifolds and removed the fuel rails   is that bad?  On the upside there was a lot of rubber dust that I am assuming came from the acc drive belt in the manifold so it'll get cleaned out.  Also I bench tested the starter and it works fine.  I'll probably replace the contacts anyways.   So now it's back to the multimeter for more testing

[masonlk]

Nothing worse than tearing it apart and finding it's all good.
That fuse has been a problem in boats. Go to the Maint. Section and look up TSB #42 Boat main fuse under the Tech. Serv. Bul.

[2000epic]

Nothing worse than tearing it apart and finding it's all good.
That fuse has been a problem in boats. Go to the Maint. Section and look up TSB #42 Boat main fuse under the Tech. Serv. Bul.

nice thanks, performed the TSB and am now using 30a fuse.

So I bench tested the starter on a garage battery and it worked great.  So then I hook up all the electrical conections to the starter in the engine valley and installed an 8 gauge ground since the starter grounds to it's mounting normally.  I turned the swithch and the gear pops out like it should but the motor turns super slow, this is so frustrating!

[wakejunky]

do a voltage drop test at different points along the large starter wire, sounds like you have an electrical issue. have you noticed any green corrosion on the large wires either at the battery or starter? & i would definilty change the contacts while you have them out.

[2000epic]

That's got it Junky!  I had tested all the wires for voltage but hadn't paid attention to what the #'s were exactly.  Now 7 hours, two beers, 1 fuse holder, one PERKO SWITCH >:(and some sore fingers I'm runnin like a Toyota again. Learned some leasons and learned alot about my engine.  The only casualty: a broken manifold bolt

Thanks to all

[lilfoo2225]

hey good job. but you made it a lil harder then what it really was. lol. oh well you learned something new though.