Has anyone had this problem. I turn it over and sometimes it starts right up and other times it just clicks as if the clutch is engaged or the battery is dead. You turn it over 5 more times it will start. I thought it was my starter and solenoid. I just had the starter completely cleaned and re-worked and replaced the solenoid and it is still doing the same thing. Let me know if anybody has any thoughts. Thx.

Just to be clear, the battery is not dead, the clutch is not engaged, and the kill switch is in place. Thx for any input!

Ground wire to the battrey .... ??? Mite be loose or not a good contact ...

Yeah, check your wiring really well. Make sure all your connections are solid, maybe look into replacing the wiring...

Both good thoughts- I was thinking the same thing. I thought I had read somewhere about this being a common problem with PD's, but i couldn't find it. I may just have to re-wire the starter connections and see how this goes... Thx for the input!

I just found the links I was looking for- I was searching on my phone and came up empty. It sounds like for CC models the wire coming out of the starter is not big enough to carry the current to the starter. I will replace this line and see what happens. Any ideas thought from the guys who have CC models and have had this problem though would be useful! Thx again.

I had the exact same problem with mine. I did as Peck recommended and doubled up the wire from the key switch to the started and I also cleaned up the ground connections to the motor frame from the battery and it seems to have cured the problem. I just ran another 12-14 gauge wire parallel to the one previously installed to the starter.

Thx Man- I appreciate the info. I am going to do the same. I will post what I find out. I wish I read these posts before I bought a new solenoid and had my starter taken apart and cleaned!!

I replaced the entire line from the starter to the engine with a 10 ga. No problems anymore. Save yourself the money and learn from this thread if you have this problem with a CC. It is not your solenoid and starter! Just change the wiring to a larger ga. I could have saved a lot of money. Just a heads up. Thx for the input from the guys who contributed!

What line was it? Batt to starter? Or switch to starter? If it was the batt cable, I didn't even know they were that small, both ours have 4ga. Either way, glad your back in business!

it had to have been switch to starter

Yea- Switch to starter. I actually emailed the shop who did the work the posts from this site! They were pulling out there hair trying to figure it out. They were sure it was the starter and the solenoid, so thank you!

thats actually kinda strange b/c a solenoid is basically a relay- takes a small amount of power to switch a large load. wouldnt think it would take that much current to activate it

autogateman- I think the solenoid turned out to be fine (even though I replaced it). The problem as I understand it, was the 14 ga wire wasn't enough to activate the starter itself.

yeah thats what im sayin, the solenoid itself is what activates the starter, not the keyswitch. a solenoid doesnt take alot of current to activate (usually)

A regular Bosch relay needs only 200 milliamps to open. I guess the starter solenoid needs considerably more current. It is a pretty heavy duty relay.

I was curious too, 10ga sounded overkill to open the solenoid. But hey, its working that's all that matters.

I wonder if the stock wiring is breaking inside the shielding. I would think it's plenty big to carry the current, but who knows. I know I had a circuit tester at work that had been giving me fits. Had taken it apart a couple times and the connections on the board were good, but it would only work if i held the wire in a specific position. Finally peeled back the shielding and one of the wires was cut in two. When bending the wire back and forth it would make just enough contact to work. Shielding was in perfect shape though.

There was a small voltage drop from my key switch to the starter when I metered mine. I wouldn't have thought it would have been enough to matter but apparently it was. I'm guessing mine was right at the lower limit as to get the starter to kick over and that's why it sometimes worked and sometimes didn't. It could have been from corrosion on some of the contacts or it could have been that the battery was just a hair weaker than when it was new . Or it could have just been that the wire degraded over time and it was causing to much resistance so the voltage drops at the starter.

PD knows about it but are they the ones that rigged yours up to begin with? They aren't the ones who rigged mine up so I can't blame them for it, Peck just happened to be the one that I talked to on the phone who helped diagnose the problem for me. I would bet they rig them up with a little heavier wire now. I haven't talked to the dealer who did mine but I would bet PD has passed on the info to them to wire heavier.

I would assume you are right.

I spoke to the guy today who was working on my boat, and just as an FYI there was a 16 gauge wire running from the Starter to the switch, and then out of the switch to the solenoid. Not sure if this is how it is supposed to be rigged or not, but this is how mine was rigged. No wonder the 16 ga wire was having trouble keeping up. I replaced both lines with a 10 ga.