Isuzu Intermittent Starting Problems

[Jay Knoll]

Hi Everyone

I've been having intermittent starting problems with my Isuzu 155 hp. It will start flawlessly and then all of a sudden decide to do nothing. I've had the starter rebuilt, there's a new (last year) isolated starting battery, we ran new wires from the ignition switch to the starter, the entire battery system was upgraded and all connections cleaned/renewed. There is an Blue Sea ACR in the system preventing the starting battery from being run down.

If it doesn't start with the switch I use a little jumper cable from the post on the starter to the 12 volt post, bam! starts every time at the slightest touch.

So I've decided that the problem is the ignition switch. I pumped some contact cleaner into it, no change.

I can't determine the manufacturer of the switch. It has 6 terminal posts on the back, and a round key. The only identifying information I can see on the body of the switch are two series of numbers 504SS-112 and 545

Here's a pic of the back of the switch any idea who manufacturers it so I can find a replacement?

Thanks for the help

Jay

switch back.JPG

[denchen]

That looks like one of those switches you can take to bits and clean the contacts.........

[don123]

I would jump the proper wires on the back of the switch and see if it starts reliably doing that. If not, you have a wiring problem somewhere. If it does start every time, carefully disassemble the switch and clean the contacts and put it back together. That *should* solve your problem

Don

[coolchange]

Hey same problem ...and same results..still intermittent...happened on a long trip so I started "jumping" the solinoid (sp) with spare jumper cables...then upgraded to a 10ga wire (pair) wired to a small battery switch in the glove box...I am changing to an intermittent on switch which I will put on the dash (just need to find one with a cover to lift to protect against accidental start).

I did get a new ignition switch and it helped reduce the problem...I think it is one wire that can't carry the load ..but I'm done chasing it.

[Jay Knoll]

Got tired of opening the hatch to jump start the engine, I wired a push switch parallel with the key circuit now if I turn the key and it doesn't start I just reach for the push switch, hit it and off we go. This should do me until we find a proper replacement switch

Hey Cool, what switch did you get? Source? Thanks

Jay

[sulli]

I am having the same problem with my 1988 27 Sport. I would love to replace the ignition switch, but I have no idea where to find one.

My switch is so old and corroded I can't remove the key.

If anyone knows of a replacement or new switch I would very much like to replace mine.

Thanks,

Mike

[Jay Knoll]

I'm having some work done on my engine and asked the yard to find a replacement I'll let you know what they found

Jay

[don123]

My Kubota powered diesel gen set came with this switch

http://www.ebay.com/itm/1-NEW-GENUINE-K ... 2a54b783a1

Preheat, On and Off - Pretty high quality switch which should last you a long time

Don

[sulli]

Thanks Jay and Don.

The Kubota looks like the closest thing I have seen yet.

Jay if you find the part please let me know. I have searched the internet and marine supply houses and I can't find it.

Thanks again,

Mike

[Jay Knoll]

Hi guys

Sorry for the delay, life happens

This is what the marina finally settled on

http://products.pollakaftermarket.com/v ... 4-position

So far, so good, fires up every time

Jay

[Jay Knoll]

Well the intermittent problem cropped up again and I finally found someone who had a solution. He installed a second solenoid in the system. The new solenoid is activated by the ignition key and feeds power to the starter solenoid this really seems to have solved the problem. She starts instantly

[Beta Don]

He installed a second solenoid in the system. The new solenoid is activated by the ignition key and feeds power to the starter solenoid this really seems to have solved the problem.

FWIW, my Yanmar came set up that way from the factory - The key switch engages a relay mounted on the block just under the starter and that relay provides the 12 volts to the starter solenoid

Don