How to replace the starter relay

[FLCERIK]

I have a 01 Super Air and about every 10th start I get the click sound and the engine does not start. I then turn off the stereo, blower, ect and after trying a few more times the engine starts. After reading other threads regarding this topic I have determined that I need to replace the starter relay.

Today, I took a look at the starter relay and it looks difficult to reach on the GT-40 engine. Is there a thread or can someone give me instructions on what I need to take it apart in order to replace the relay. Photo's and or instructions would be great.

I plan on purchasing it from skidm tommorow. Thanks in advance for the help.

[davidr]

RE: How to replace the starter relay

Unbolt the relay, draw a picture to make sure you know which wires should go on which contacts, as you unbolt each contact use zip ties to temporarily group wires that go on that contact then cut the tie when you are ready to bolt that set onto the contact of the new relay (not essential, but helpful).

I've got a SKI, not a Vdrive so my reach will be different than yours... Perhaps you can post a picture of where you think the relay is?

[FLCERIK]

RE: How to replace the starter relay

The relay is buried under the black panel where 3 red relays are located and a bunch of wiring harnesses. It looks like 3 bolts which are difficult to get to hold the black panel brackets. I think I need to disconnect th wiring harnesses and take out the 3 bolts. Then flip the pannel upside down.

Is this correct?

[davidr]

RE: How to replace the starter relay

Assuming your newer GT40 is accessorized similarly to mine -

OK, the objective here is to give you sufficient access to the two bolts (and corresponding nuts) holding the relay to the panel. I found I could get to them from the side (box wrench on the nut, ratchet w/socket on the bolt head) without undoing anything, you may be able to do the same albeit working partly by feel.

If not, then try:

That black panel of thick sheet metal is held at the top by a single, vertical bolt that threads into a corner of the aluminum intake manifold, and the bottom is held by the upper two bell housing bolts that thread horizontally into the engine block. One of those two bolts has large ground wires running in front of it to the next bell housing bolt (if I recall correctly), undo that bolt so you can move the ground wires out of the way, then remove the three bolts attaching the panel. You may need a ratchet with an extension to get to all of those bell housing bolts.

At this point I would suggest simply pulling the top of the panel towards you, so from the top you can get to the nuts on the inside of the panel for the two bolts that are holding the starter relay to the other side of the panel. One of the bolts holding the relay is actually double-nutted to hold a wiring harness clamp... Hopefully you'll have sufficient access and won't have to disconnect any wiring harnesses.

Does that help?

[FLCERIK]

RE: How to replace the starter relay

I went out to the boat garage and took a look at what needs to be done. I am going to take the entire bracket off since my hands will not fit in the small area of where the relay is. The relay is under the bracket which is surrounded by wires and a large black canister. This looks like a bigger job than expected. Thanks for the advice Davidr. If you or anyone else has any other suggestions please let me know.

[Sbt3]

RE: How to replace the starter relay

Flcerik,
I think you are actually refering to the starter solenoid. It is a bitch to change. It took me about 1-1/2 hours to change it out. On my old boat it took about 10 minutes. I don't have any other advice for changing it other than if you do get it changed and it doesn't work there is a second solenoid on the starter itself. After I changed mine I had to change the starter because it was the problem. I figured I would try the $20 part first though. If it is the starter the cheapest I found it was also at Skidim and it was around $200. Just make sure when you are changing the part you have you pay close attention to where the wires go. It is easy to get them messed up.

[davidr]

RE: How to replace the starter relay

Sbt3, don't take this the wrong way, but "starter relay" is the more accurate term I believe.

A relay is an electrically operated switch, a solenoid is an electromagnet.

The relay and the starter each have a solenoid but the solenoids do different things - the solenoid in the relay closes the switch, whereas the solenoid in the starter moves the starter motor drive gear into engagement with the gear teeth on the engine flywheel.

Not a big deal, but using "solenoid" instead of "relay" gets confusing since there is more than one solenoid.

I agree with you about the wires connecting to the relay - it is easy to get them messed up if one does not pay careful attention.

[Sbt3]

RE: How to replace the starter relay

davidr,
I guess I was wrong about the terminology on that one. I have always called it a solenoid. When I went to the parts store that is what I asked for. I looked on Skidim and they use the term relay. No worries learn something new everyday. But it is still a pain to change that much I know.

[FLCERIK]

RE: How to replace the starter relay

Well guys I gave it a try and had no luck. That fricking starter relay is buried so deep in wires and brackets I finally gave up. I was worried if I started taking other parts out to get to the relay I would break something. The large bracket has 3 bolts 2 of which are easy to take out and the third is impossible to get to. The actual relay has 2 bolts and one is difficult to get to the other is impossible. When I take the boat in to the CC dewaler to have its next service I will pay to have it done. Thanks for the help. I give the guys who have replaced these on a GT-40 v-drive a lot of credit.