Grateful for any advice on an intermittent starter problem with a year 2000 Johnson 40HP outboard model BJ40PLSSM please!
90% of the time starting is asbsolutely normal without problem, but occassionally starting displays all the signs of a dead battery; the starter motor engages properly, spins engine a bit but then lugs to a stop, as if the battery is dead. The engine will start immediately with a pull cord and subsequently everything is fine till the next time!
- The 85AH battery is fully charged and discharge rate has been checked as 100% by the battery shop.
- When working, the starter motor will spin the engine vigorously and I have tested it for extended periods (20 seconds or so) with the plugs disconnected, so I don't think the starter motor is the problem.
- The battery terminals and all connections to the starter motor and solenoid have been cleaned and are sound.
The only breaks in the high current starter circuit are the battery master switch, which appears fine, and the starter solenoid. Obviously there must be a high resistance in the circuit restricting the current flow when this problem occurs and the only thing I can't check are the internal solenoid contacts. Do solenoids burn out or play up, is this the likely problem or what?
Grateful for any advice please.