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Author Topic:   Merc 225 EFI - won't start

jhjelmgren posted 06-30-2011 12:23 PM ET (US)
1996 Merc 225 EFI - 210 hours - ocean use.
Ran like a top until Tuesday.
Problem - I turn key to mid-way point and ringer sounds.
I then complete turning the key and nothing-no sounds
I do hear the sound at the motor of the electronic fuel injection engaged.
There is no starter click - complete silence.
I was able to pull start the motor easily.
I cleaned the battery connections and nothing.
I also hooked up directly to electric and still nothing.
Possible problems?:
1. The starter is completely dead-out. I had no grinding or previous
indications of any starter problems.
2. The key switch is shorted out?
Tough/impossible to get a mechanic any time soon this time of year.
I can change a starter but if there are other possibilities, I'd like to try them first.
Any ideas would be great. Thank you
Tom W Clark posted 06-30-2011 01:01 PM ET (US)
Start with the simple and obvious first:
Are you sure the control was in Neutral? Sometimes, especially with Mercury controls, you need to jiggle the control handle a bit to make sure the neutral lock-out switch is disengaged.
I am glad to hear your 225 HP EFI Mercury outboard was easy to pull-start.
jhjelmgren posted 06-30-2011 04:13 PM ET (US)
Yes, I keyed in on that possibility. Jiggled, twitched, moved, vibrated-just like a key that won't quite fit a lock. What you suggest is exactly what happens when not in neutral and the symptoms are the same.
Do the throttle handles sometimes go bad? Could water get inside the base handle cover and cause problems. We did have some brutal waves the previous day and some water did get into the cabin area.
Bottom line-inside the base of the throttle handle, can the cable or interior parts go bad and not allow the throttle to officially catch in neutral.
When I rope start the motor, the boat stayed in neutral.
At least the halibut are happy! That's for any advice.
Jim
captbone posted 06-30-2011 05:21 PM ET (US)
Take jumper cables and use the positive side cable. Go from the positive terminal on the battery and use the other end to touch the terminal stud on the starter. It should turn over instantly. That will eliminate your starter. You dont need to use the ground cable since it is already always in place.
You can also jump your solinoid if that is the issue.
The neutral safety wires are yellow with black tracer. You connect both of them together to bypass.
newt posted 06-30-2011 10:13 PM ET (US)
To expand on what Captbone suggests, use caution not to short out the hot jumper cable on the motor. I would probably start with a voltmeter checking for power to the starter, then the solenoid. If you get no power to the solenoid when you turn the key, then you know the circuit is broken somewhere in the wiring harness, key switch, or neutral safety switch. Again with a voltmeter or test light, check for power in the right places on your key switch. You will need a wiring diagram for that.
also, check for any fuses on the motor that may be blown, but I think if your alarm is sounding when you turn the key, then you don't have a blown fuse, but I am not familiar with your Mercury engine.

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Author	Topic: Merc 225 EFI - won't start
jhjelmgren	posted 06-30-2011 12:23 PM ET (US) 1996 Merc 225 EFI - 210 hours - ocean use. Ran like a top until Tuesday. Problem - I turn key to mid-way point and ringer sounds. I then complete turning the key and nothing-no sounds I do hear the sound at the motor of the electronic fuel injection engaged. There is no starter click - complete silence. I was able to pull start the motor easily. I cleaned the battery connections and nothing. I also hooked up directly to electric and still nothing. Possible problems?: 1. The starter is completely dead-out. I had no grinding or previous indications of any starter problems. 2. The key switch is shorted out? Tough/impossible to get a mechanic any time soon this time of year. I can change a starter but if there are other possibilities, I'd like to try them first. Any ideas would be great. Thank you
Tom W Clark	posted 06-30-2011 01:01 PM ET (US) Start with the simple and obvious first: Are you sure the control was in Neutral? Sometimes, especially with Mercury controls, you need to jiggle the control handle a bit to make sure the neutral lock-out switch is disengaged. I am glad to hear your 225 HP EFI Mercury outboard was easy to pull-start.
jhjelmgren	posted 06-30-2011 04:13 PM ET (US) Yes, I keyed in on that possibility. Jiggled, twitched, moved, vibrated-just like a key that won't quite fit a lock. What you suggest is exactly what happens when not in neutral and the symptoms are the same. Do the throttle handles sometimes go bad? Could water get inside the base handle cover and cause problems. We did have some brutal waves the previous day and some water did get into the cabin area. Bottom line-inside the base of the throttle handle, can the cable or interior parts go bad and not allow the throttle to officially catch in neutral. When I rope start the motor, the boat stayed in neutral. At least the halibut are happy! That's for any advice. Jim
captbone	posted 06-30-2011 05:21 PM ET (US) Take jumper cables and use the positive side cable. Go from the positive terminal on the battery and use the other end to touch the terminal stud on the starter. It should turn over instantly. That will eliminate your starter. You dont need to use the ground cable since it is already always in place. You can also jump your solinoid if that is the issue. The neutral safety wires are yellow with black tracer. You connect both of them together to bypass.
newt	posted 06-30-2011 10:13 PM ET (US) To expand on what Captbone suggests, use caution not to short out the hot jumper cable on the motor. I would probably start with a voltmeter checking for power to the starter, then the solenoid. If you get no power to the solenoid when you turn the key, then you know the circuit is broken somewhere in the wiring harness, key switch, or neutral safety switch. Again with a voltmeter or test light, check for power in the right places on your key switch. You will need a wiring diagram for that. also, check for any fuses on the motor that may be blown, but I think if your alarm is sounding when you turn the key, then you don't have a blown fuse, but I am not familiar with your Mercury engine.