454 Crusader XL Starting/Starter Issue

[390Express]

Port motor starts and runs great, lights gauges etc. barely flicker when I push the start button. Everything seems normal there. Starboard motor, however, really draws a ton of current. It will stall the port motor completely if it doesn't start right away, the lights dim like an exorcism, even when it's hooked up to the charger, and the gauges go wonky (ping and bottom out completely). I thought I may have got a crappy starter from DB Electric, causing the current draw, but I swapped starters and same issue with the stbd motor, no issue with the port motor. Seems like it has to be a wiring issue with the ground or main power supply to the starter. Is the only engine ground the thin 8-10 gauge green wire? Anyone have any success with running a dedicated ground right to the negative battery cable?

The stbd relay triggers nice, and the solenoid does it's job, (still draws a ton of current jumping the solenoid) but it seems the main power cable or ground is weak or corroded. I'm torn between running a new ground, and/or tracing back the thick red power wire that runs to the starter. I see that the main power supply runs from the starter, across the port motor, and up the sidewall, likely to the Perko on/off switch that I can access from the cockpit. Does the Perko switch come apart for cleaning, or should it just be replaced if it's the issue?

[bud37]

The green wire is the boats bonding system ground.....there should be a large black cable on each engine grounding them to the batteries and to each other.. If the engine is trying to run 250 amps thru that green wire then there is your problem.

[throwback2]

Check all the ground connections and make sure they are clean and tight.

[390Express]

Qr Bbpost The green wire is the boats bonding system ground.....there should be a large black cable on each engine grounding them to the batteries and to each other.. If the engine is trying to run 250 amps thru that green wire then there is your problem.

Where would the thick black wire be Bud? Any ideas?

[bud37]

Check the other engine and compare ....large black battery cable going from a bolt or stud on the engine block to the negative battery terminal or a negative terminal block that then goes back to the batteries,..... take your time to look with a nice bright light......can't say for sure cause I am not there and who knows what has been done before but obviously the other engine has this as it starts and runs fine.....a lack of proper ground can produce many damaging problems with ECU based engines.

[390Express]

Gah, turns out, 10pm isn’t the best tome to look for a black wire. Stbd motor has a nice, proper, 2 gauge ground. The ground wires follow the black fuel lines and connect at the bellhousing. Ground is nice and clean. Stbd motor has two grounds, one that goes to the port motor, and one that goes to bank 2 of the batteries. I did have the 2nd ground disconnected. It went to my generator battery, and I have that out rn. I hooked it up to the other battery in bank 2 and no difference.

I’m going to pull all the grounds tomorrow and hit them with some sandpaper and no-ox/dielectric grease. Any additional advice?

[tomschauer]

Does the starboard motor start and run? Hopefully not the case but I believe you posted some issues with overheating etc. If so, if its hydro locked (water in the cylinders) it would exhibit the same symptoms. This could be caused by bad manifolds or risers, or simply a bad riser gasket. Pull the plugs and see if she spins and pumps water out of the cylinders. Don't keep trying to crank it, 'cause believe it or not you can bend a rod or two with the torque of the starter.

If it does start and run disregard.

[390Express]

Qr Bbpost Does the starboard motor start and run? Hopefully not the case but I believe you posted some issues with overheating etc. If so, if its hydro locked (water in the cylinders) it would exhibit the same symptoms. This could be caused by bad manifolds or risers, or simply a bad riser gasket. Pull the plugs and see if she spins and pumps water out of the cylinders. Don't keep trying to crank it, 'cause believe it or not you can bend a rod or two with the torque of the starter.

If it does start and run disregard.

Starboard motor never had an over heating issue. Port motor used to get hot at idle, and would cool back down over 1500 rpm. There were two broken impeller lobes in the oil cooler. New impeller and flush this year, should be back to good. Port motor never really over heated, it just puked coolant twice and would go past 180 if it idled for more than 15-20 min.

Starboard motor has started a few times this year. I've also pulled the plugs and did a compression check, which checked out fine on all cylinders. I don't think it's anything mechanical. Also swapped the starter from one side to the other. Seems like it's definitely wiring at this point, but it's maddening. The main power to the starters for both motors really kind of come from the same place, same with the ground. Ground actually ties in a couple places, including with the port motor.

[mjk1040]

I'm thinking Perko battery switch change and all cables to that engine need to be replaced. Corroded contacts or corroded cables.

[km1125]

Does the Perko battery switch feed both engines? If so, you can rule that out. I'd definitely check/clean the negative cables from engine to engine and from BOTH engines to battery. It's possible you have an issue with the port negative cable that's using the stbd connection when IT starts (OK) but when the stbd engine is trying to start the voltage drop on that cable affects the port motor.