I have a 2002 Honda 225 with very low hours. In the past two days it has begun to have instances where it will not turn over when key switch is turned to start. Sometimes if you move the switch and hold it for a second or two it will catch and then start normally. It seems obvious there is an electrical glitch somewhere but I would like to know where to go next.
I have done the following:
=Jumped power to S terminal on solenoid, solenoid engages and engine starts fine.
=tested S terminal with key switch turned to start when nothing happens, no voltage reading at the terminal.
=Swapped key switch panel harness with my other engine to see if problem is in panel switch, same symptoms with other harness. Other engine starts instantly on that harness. Cannot stretch wires from switch harness on bad start motor to other motor to test in reverse.
Currently I was able to get six good instant starts after a period with no luck and then intermittent luck.
When the starting is in the intermittent phase, the solenoid seems to chatter when power finally reaches it so it seems there is some interruption in the voltage. It almost sounds like a solenoid when voltage is low but I have good voltage to power post on solenoid and good heavy cables with new ends.
Any suggestions would be welcome.