Evinrude E-NATION, for those dedicated to water, power, fishing and fun
Posts: 1
Registered: ‎04-27-2019

2004 Etec 40hp starting issue

Let's start with the electric starter. First cold start of the day is an absolute nightmare. Push the start button and motor turns over once then stops. Push again and then you hear a single click. This will happen over and over. If you let sit a for a few minutes you will get one or two turnovers and then stop. Takes about 10 to 12 cycles of this before it fires. Tried 3 different, GOOD batteries, same issue. After you get it running, it will fire right up after you push the button. Good all day, next morning, start whole process over again....what gives...?
Posts: 938
Registered: ‎08-20-2017

Re: 2004 Etec 40hp starting issue

The starter draws more current on a cold start. The click you hear are the relay contacts being pulled together. Most likely you have a starter relay that is failing. You can carefully put a screwdriver across the two large posts on the relay to bypass the points to verify the problem.
Posts: 9,447
Registered: ‎07-14-2011

Re: 2004 Etec 40hp starting issue

It may be a good idea to have the starter looked at by a reputable starter-alternator shop as many can refurbish small engine starters. Some dealers may also service starter motors, though some just want to sell you a new one. Rebuilt starters are available also.


With yours being 15 years old, it could be needing new brushes, the commutator machined, and the bushings replaced or lubed as needed. 




"There is never just one thing wrong with a boat";
                    -- Travis McGee, main character in a book series by John D. McDonald 



The factory recommends that a properly trained technician service your Johnson or Evinrude outboard motor. Should you elect to perform repairs yourself, use caution, common sense, and observe safety procedures in the vicinity of flammable liquids, around moving parts, near high-temperature components, and working with electrical or ignition systems.

The information offered here is only general in nature and should not be construed as complete factory approved procedures, techniques, or specifications. Always use the proper service manual for your motor, up-to-date service literature, the correct tools, and have an understanding of how to proceed with troubleshooting and repair methods. If you are unsure or uncomfortable with a procedure, a situation, or a technique, enlist the services of a factory trained technician.