150 Montauk Ignition Key Switch Loose

Repair or modification of Boston Whaler boats, their engines, trailers, and gear
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Joined: Sat Oct 08, 2016 8:35 am

150 Montauk Ignition Key Switch Loose

Postby Dean » Sat Oct 08, 2016 8:51 am

On a 2012 Boston Whaler 150 Montauk with Mercury 60-HP, the locking nut for the ignition key switch on the outside of the helm dashboard sometimes is lose. This causes the wiring harness on the inside to spin into a tight knot. I had this problem in the spring, and after unwinding the harness, the engine started. I have recently had the same problem with the boat not starting and un-wound the harness, but the engine will not start. There is a loud BEEP when the key is moved on ON and a quick quiet clicking sound from the Mercury 60-HP engine when you turn the key to Start. The battery is fully charged. Any suggestions?

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Joined: Fri Oct 09, 2015 12:25 pm
Location: Michigan, Lower Peninsula

Re: 150 Montauk Ignition Key Switch Loose

Postby jimh » Sat Oct 08, 2016 9:28 am

Tighten the loose ignition key switch. Typically the ignition key switch is an encapsulated assembly and cannot be repaired. If the switch or its wiring has been damaged--which is likely if it has been repeatedly wound up by rotating the switch while the wiring is fixed in place--then replace the switch and any damaged wiring assemblies. Some wiring assemblies can be repaired if you have skill at repair of wiring and connectors, can find replacement connectors, and can accomplish the repair without introducing too many unreliable in-line butt splices into the wiring. Generally butt-splices should be avoided if at all possible.

The clicking sound from the engine that occurs when the ignition key switch is moved to START is most likely from the solenoid.

The failure of the starter motor to operate when the solenoid that controls it has actuated is an electrical problem. For help with electrical problem please use SMALL BOAT ELECTRICAL forum.

I have written a detailed description of the engine starting circuit at

http://continuouswave.com/whaler/refere ... Start.html

The article describes about 50 circuit elements that can cause a failure in engine starting. If you are familiar with basic electrical testing and diagnosis of circuitry, the article will give you more than 50 suggestions where to look for a cause of no cranking.

To understand the meaning of any aural alert sounds from the outboard engine consult the operator's guide; it will explain the meaning of any alert.

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Joined: Thu Oct 22, 2015 2:58 pm

Re: 150 Montauk Ignition Key Switch Loose

Postby flymo » Sun Oct 09, 2016 6:17 am

The spinning switch has broken one of the wires that leads from it. You will need to find the broken wire and repair it. The damage may be obvious or the wire may have pulled out of the connector just a tiny bit and be hard to find.