Eletril System Strting System Tle of Contents Setion 4A - Strting System Preutions...4A-2 MerCruiser Color Wiring Digrms...4A-4 Strter Identifition...4A-2 Strter Speifitions...4A-2 Torque Speifitions...4A-3 Lurints, Selnts, nd Adhesives...4A-3 Speil Tools...4A-3 Digrms...4A-5 10 pin Strting System Eletril Digrm...4A-5 14 pin Strting System Eletril Digrm...4A-6 Positive Current Flow...4A-3 Bttery Cle Size for MerCruiser Models...4A-6 Strter...4A-7 Strter Removl...4A-7 Inspetion...4A-8 Strter Solenoid Removl...4A-8 Instlltion...4A-8 Strting System Tests...4A-10 Voltge Drop Test...4A-10 Low Voltge Test...4A-10 Wter nd Corrosion Inspetion...4A-10 Stndrd Strter Slve Solenoid...4A-11 Removl...4A-11 Testing...4A-11 Instlltion...4A-11 4 A 90-864260200 AUGUST 2009 Pge 4A-1
Strting System Preutions! WARNING Avoid fire or explosion hzrd. Eletril, ignition, nd fuel system omponents on Merury Mrine produts omply with federl nd interntionl stndrds to minimize risk of fire or explosion. Do not use replement eletril or fuel system omponents tht do not omply with these stndrds. When serviing the eletril nd fuel systems, properly instll nd tighten ll omponents.! WARNING Neglet or improper mintenne, repirs, or inspetions of the power pkge n result in produt dmge or serious injury or deth. Perform ll proedures s desried in this mnul. If you re not fmilir with proper mintenne or servie proedures, onsign the work to n uthorized Merury Mrine deler.! WARNING Performing servie or mintenne without first disonneting the ttery n use produt dmge, personl injury, or deth due to fire, explosion, eletril shok, or unexpeted engine strting. Alwys disonnet the ttery les from the ttery efore mintining, serviing, instlling, or removing engine or drive omponents. NOTICE Without suffiient ooling wter, the engine, the wter pump, nd other omponents will overhet nd suffer dmge. Provide suffiient supply of wter to the wter inlets during opertion. IMPORTANT: Refer to the following preutions when working on or round the eletril hrness, or when dding other eletril essories, to void dmge to the eletril system. Do not tp essories into the engine hrness. Do not punture wires for testing (proing). Do not reverse the ttery leds. Do not splie wires into the hrness. Do not ttempt dignostis without the proper, pproved servie tools. Strter Identifition Delo strter identifition - PG 260G1 - PG 260L Strter Speifitions The Permnent Mgnet Ger Redution strter motors fetures smll permnent mgnets mounted inside the field frme (NOTE: The tul onfigurtion of these mgnets differs etween the PG200, PG250 nd PG260; the field frmes with permnent mgnets re not interhngele. Otherwise, the units re similr.) These mgnets tke the ple of urrent rrying field oils mounted on iron pole piees. A 4:1 rtio Internl ger redution results in rmture speeds in the 7000 RPM rnge. The rmture nd drive shft re mounted on roller or ll erings in the ple of ushings. The solenoid swith, plunger, return spring, nd shift lever re permnently mounted in the drive housing. 29184 Pge 4A-2 90-864260200 AUGUST 2009
Strting System Delo ID numer Engine rottion Volts Delo PG260G1 strter speifitions Minimum mp drw No lod test Mximum mp drw Minimum RPM Mximum RPM 9000884 LH 12.0 35 85 2550 4150 Delo ID numer Engine rottion Volts Delo PG260L strter speifitions Minimum mp drw No lod test Mximum mp drw Minimum RPM Mximum RPM 9000888 LH 12.0 35 85 2550 4150 Torque Speifitions PG260F1 nd PG260L Desription Nm l in. l ft Strter mounting olts 40.5 30 Bttery terminl nut 9 84 Swith terminl nut 2 20 Resistor terminl nut 2 20 Lurints, Selnts, nd Adhesives Tue Ref No. Desription Where Used Prt No. 25 Liquid Neoprene Eletril terminls 92-25711 3 Speil Tools DMT 2004 Digitl Multimeter 91 892647A01 Positive Current Flow NOTE: Ensure tht ll onnetions re tight nd hve the required resistne. Positive urrent flow following ignition swith tivtion inludes: Bttery to the strter mounted solenoid swith (RED ttery le). Solenoid swith to the iruit reker (RED). Ciruit reker to the wire juntion (RED/PUR). Wire juntion to the wiring hrness plug (RED/PUR) terminl 6. Wiring hrness plug to the 20 mp fuse (RED/PUR). 20 mp fuse to the ignition swith terminl I (RED/PUR); ignition swith is in the "START" position. Ignition swith terminl I to terminl C. Ignition swith terminl C to the neutrl strt swith (YEL/RED); the neutrl strt swith muh e in the neutrl position. Neutrl strt swith to the wiring hrness plug terminl 7 (YEL/RED). Wiring hrness plug to the strter solenoid (smll terminl) (YEL/RED). The lk (smll terminl) wire is ground. Strter solenoid is now losed, ompleting the iruit etween the lrge terminl (RED/PUR) nd the other lrge terminl (YEL/RED), using the strter motor to rnk. Lurints, Selnts, Adhesives Tue Ref No. Desription Where Used Prt No. 25 Liquid Neoprene Eletril terminls Eletril onnetions 92-25711 3 90-864260200 AUGUST 2009 Pge 4A-3
V H z mv OFF A H z TEMP m A A IG IP TEMP m A C O M V H z Strting System Speil Tools DMT 2004 Digitl Multimeter 91 892647A01 Mesures RPM on sprk ignition (SI) engines, ohms, mperes, AC nd DC voltges; reords mximums nd minimums simultneously, nd urtely reds in high RFI environments. 4516 MerCruiser Color Wiring Digrms Lrge sle, oversized olor wiring digrms re ville in the MerCruiser Digrm Binder. The initil distriution of the MerCruiser Digrm Binder ws delivered to MerCruiser uthorized repir filities in June nd July of 2007. As new digrms re developed they will e distriuted long with revised, omprehensive index for ddition to n existing inder. The MerCruiser Digrm Binder fetures: An index tht identifies the digrms y hrness numer, y engine group nd drive, nd y engine size nd type The digrms re printed on n extremely durle, oted syntheti pper nd n e wiped len of grese nd oil fter use. The lrger digrms re esier to red. The digrms will ome in two sizes, depending on the omplexity of the relted hrness. Removle pges re esier to referene nd llow the tehniin to tke only the required digrm to repir site insted of omplete servie mnul. Dry erse mrkers n e used diretly on the digrms for tring iruits or for trining. They wipe len fter use. Hrness numer hedings mke the drwings esy to find. The ompnying MerCruiser Digrm Binder Index speeds lookup when the hrness numer is not known. For informtion out ordering dditionl opies of the MerCruiser Digrm Binder or inder updtes ontt: MerCruiser Authorized Delers, Repir Centers, or OEMs n order servie literture on MerNET. Consumers n order servie literture through the Merury Dok Store (www.merurydokstore.om), ontting Merury MerCruiser pulitions t 920 929 5110 or y ontting their lol MerCruiser Authorized Deler or Repir Center. Pge 4A-4 90-864260200 AUGUST 2009
Digrms 10 pin Strting System Eletril Digrm Strting System e d Strting system eletril digrm - Ignition swith - 20 mp fuse - Slve solenoid d - Ciruit reker e - Neutrl sfety swith f - To the lterntor g - Strter motor h - 90 mp fuse i - Engine ground f h g i 29187 90-864260200 AUGUST 2009 Pge 4A-5
Strting System 14 pin Strting System Eletril Digrm PNK/PUR YEL/RED B S I YEL/RED YEL/RED YEL/RED RED/PUR RED/PUR f d RED YEL/BLK YEL/RED g e i BLK BLK RED h 25316 - Ignition swith - Hrness plug - Strter solenoid d - Ciruit reker e - Strter motor f - Wire juntion g - Neutrl sfety swith h - 90 mp fuse i - Engine ground ( ) This is generl desription of the positive urrent flow from the ttery through the strting system until the strter motor rnks. NOTE: Ensure tht ll onnetions re tight nd hve the required resistne. Bttery to the solenoid swith on the strter (RED ttery le). Solenoid swith to the iruit reker (RED). Ciruit reker to the wire juntion (RED/PPL). Wire juntion to the wiring hrness plug terminl 6 (RED/PPL). Ignition swith terminl "C" to the neutrl strt swith (YEL/RED). Neutrl strt swith must e t neutrl position. Bttery Cle Size for MerCruiser Models IMPORTANT: Only use opper ttery les. Do not use luminum les for ny mrine instlltions. Pge 4A-6 90-864260200 AUGUST 2009
If longer ttery les re required, the le guge size must inrese. See hrt following for orret wire size. Strting System - Wire size y ross setionl re (guge) - Bttery le length NOTE: Engine strting tteries should e loted s lose to engine s possile. To selet proper size positive (+) nd negtive ( ) ttery les using the following proedure nd hrt: 1. Add the positive nd negtive le lengths together. 2. Divide y 2 to otin the verge le length. IMPORTANT: Terminls must e soldered to le ends to ensure good eletril ontt. Use eletril grde (rosin flux) solder only. Do not use id flux solder, s it my use orrosion nd susequent filure. Averge Cle Length Cle Size (Guge) Up to 1.1 m (3.5 ft.) 25 mm² (4) 1.1 1.8 m (3.5 6 ft.) 35 mm² (2) 1.8 2.3 m (6 7.5 ft.) 50 mm² (1) 2.3 2.9 m (7.5 9.5 ft.) 50 mm² (0) 2.9 3.7 m (9.5 12 ft.) 70 mm² (00) 3.7 4.6 m (12 15 ft.) 95 mm² (000) 4.6 5.8 m (15 19 ft.) 120 mm² (0000) Strter Strter Removl! WARNING Performing servie or mintenne without first disonneting the ttery n use produt dmge, personl injury, or deth due to fire, explosion, eletril shok, or unexpeted engine strting. Alwys disonnet the ttery les from the ttery efore mintining, serviing, instlling, or removing engine or drive omponents. 1. Disonnet the ttery les from the ttery. 2. Disonnet the wires from the solenoid terminls. 3. Remove the strter mounting olts. 4. Pull the strter ssemly wy from the flywheel nd remove from the engine. 2758 29188 - PG260G1 - PG260L 90-864260200 AUGUST 2009 Pge 4A-7
Strting System Inspetion The strter motor nd the solenoid re ompletely enlosed in the drive housing to prevent ontmintion y moisture nd dirt. Perform ny required periodi inspetion s follows: 1. Inspet the terminls for orrosion nd loose onnetions. Resel ny exposed eletril onnetions. Strter eletril onnetions - Strter solenoid - Positive (RED) le - 90 mp fuse (not serviele) d - Negtive (BLK) le e - Ruer oot e d 29190 Tue Ref No. Desription Where Used Prt No. 25 Liquid Neoprene Eletril onnetions 92-25711 3 2. Inspet the wiring for fryed or worn insultion. 3. Ensure tht the strter mounting olts re tight. Strter Solenoid Removl 1. Remove the srews retining the solenoid to the strter - Strter solenoid - Strter motor - Srews (3). 2. Remove the solenoid from the drive housing. Instlltion 29189 IMPORTANT: The speil mounting shim (if equipped) instlled etween the strter motor nd the engine lok must e reused. 1. Ple the strter motor into position nd instll the mounting olts. Torque the olts. Desription Nm l in. l ft Strter mounting olts 40.5 30 Pge 4A-8 90-864260200 AUGUST 2009
Strting System 2. Connet the YELLOW/RED wire to the swith "S" terminl. Tighten the terminl nut to speifition. Strter eletril onnetions - Swith terminl, (S) - Positive ttery terminl (+) - Resistor terminl (R) 29217 Desription Nm l in. l ft Swith terminl (S) nut 2 18 3. Connet the positive (+) ttery le nd the 90 mp fuse to the ttery terminl. Tighten the terminl nuts to speifition. Desription Nm l in. l ft Bttery terminl nut 9.5 84 4. Connet the ORANGE wire nd the RED wire to the post on the 90 mp fuse tht is instlled to the strter positive (+) ttery terminl. Tighten terminl nut seurely. - Strter terminl - Insultor - Positive (+) ttery onnetion NOTE: The k of the fuse is n insultor. NOTE: The PURPLE/YELLOW wire is the 12 volt ttery positive (+) to the eletroni fuel pump while the engine is in strting mode. 5. Crureted Models: Connet the PURPLE/YELLOW wire to the resistor "R" terminl. Tighten the terminl nut to speifition. Desription Nm l in. l ft Resistor (R) terminl nut 2 18 6. Cot ll terminl with selnt. Tue Ref No. Desription Where Used Prt No. 25 Liquid Neoprene Eletril onnetions 92-25711 3 7. Instll the ttery le oot, if equipped. 8. Connet the positive (+) ttery le to the positive (+) ttery terminl nd tighten the le lmp. 9. Connet the negtive ( ) ttery le to the negtive ( ) ttery terminl nd tighten the lmp. 29218 90-864260200 AUGUST 2009 Pge 4A-9
Strting System Strting System Tests Voltge Drop Test Low power supply voltge nd wter ontmintion re the primry uses of most strter motor filures. Low power supply voltge uses exessive het to uild up in the strter motor. It n lso use strter motor solenoid ontt prolems. IMPORTANT: Perform these tests with digitl voltmeter efore removing the strter from the engine. 1. Set the digitl voltmeter to 0 efore testing. 2. Ensure tht the ttery is fully hrged. 3. Remove the oil wire from the distriutor p nd ground it to prevent the engine from strting. 4. Connet the voltmeter positive (+) led diretly to the lrge, threded terminl. 5. Connet the voltmeter negtive ( ) led diretly to n unpinted metl surfe on the strter housing. 6. Crnk the engine over with the key swith for 10 15 seonds while oserving the voltmeter. A voltmeter reding of 9.5 volts or more indites tht the ttery is supplying suffiient voltge to the strter to operte properly. If the strter does not funtion properly, the strter or the engine re mlfuntioning. Remove the sprk plugs nd try turning the engine over y hnd to rule out n engine prolem. A voltmeter reding elow 9.5 volts indites voltge loss etween the strter motor nd the ttery. Chek ll omponents etween the strter motor nd the ttery for dmge, wer, nd proper pplition. Low Voltge Test 1. Test the ttery positive (+) le first. Connet the voltmeter positive (+) led diretly to the positive (+) post of the ttery. Do not use the ttery le terminl. Connet the voltmeter negtive ( ) led diretly to the lrge, threded strter motor positive (+) terminl to whih the ttery positive (+) le is onneted. NOTE: Remove one voltmeter led efore strter motor is turned off or voltmeter dmge my our. The strter my produe voltge spike tht n dmge voltmeter. 2. Crnk the engine over while oserving the voltmeter. The mximum llowed drop is 0.25 volts. 3. To find the point where the resistne is highest, leve the voltmeter positive (+) led on the ttery post nd move the voltmeter negtive ( ) led to the ttery positive (+) le ring terminl, whih is on the threded strter terminl. 4. Move voltmeter negtive ( ) led to the ttery le itself, whih is inside the rimped ttery le ring terminl. 5. Continue to test eh ttery le onnetion k to the ttery positive (+) post. If ttery swith is used, hek etween the ttery le ring terminl nd the swith's terminl. 6. Chek for voltge drop on the ttery negtive ( ) le. Connet voltmeter negtive ( ) led diretly to the ttery negtive ( ) post, not the ttery le ring terminl. Connet voltmeter positive (+) led to n unpinted surfe of the strter housing. NOTE: Remove one voltmeter led efore strter motor is turned off or voltmeter dmge my our. The strter my produe voltge spike tht n dmge voltmeter. 7. Crnk the engine over while oserving the voltmeter. IMPORTANT: The mximum llowed drop is 0.25 volts. 8. To find the point where the resistne is highest, leve voltmeter negtive ( ) led on ttery negtive ( ) post nd move voltmeter positive (+) led to the ground stud where the ttery negtive ( ) le is onneted. 9. Move the voltmeter negtive ( ) led to the ttery negtive ( ) le ring terminl tht is on the ground stud. 10. Move the voltmeter positive (+) led to the ttery le itself, whih is inside the rimped ttery le ring terminl. 11. Test eh ttery le onnetion in this mnner k to the ttery post. 12. After testing to ensure tht the strter motor is getting t lest 9.5 volts, test the strter motor solenoid for t lest 9.5 volts from the slve solenoid during rnking. Low voltge t the strter solenoid n use intermittent opertion of the solenoid ontts nd shorten the life of the solenoid. 13. Connet the voltmeter positive (+) led to the terminl on the strter solenoid with the YEL/RED wire from the slve solenoid onneted to it. 14. Connet the voltmeter negtive ( ) led to unpinted surfe of the strter housing. 15. Crnk the engine over nd oserve the voltmeter. If the strter solenoid is not getting 9.5 volts, the YEL/RED wire or the slve solenoid ould e the use of the low voltge. Wter nd Corrosion Inspetion 1. Remove the 2 short srews from the strter motor end p nd inspet the threds. 2. If they re len nd gold in olor, the strter motor hs not hd wter inside of it. 3. If they re dirty nd disolored the strter motor my hve wter ontmintion nd should e repled. IMPORTANT: Strter dmge used y wter ontmintion is not overed y the Merury MerCruiser wrrnty. Pge 4A-10 90-864260200 AUGUST 2009
Stndrd Strter Slve Solenoid Removl 1. Remove nd retin the strter solenoid insultor. 2. Remove nd retin the strter solenoid top terminl nuts nd lokwshers. Strting System 3. Mrk the position of the engine hrness wires on the strter solenoid top terminls, nd remove the wires from the strter solenoid. 4. Mrk the position of the engine hrness oot onnetors on the strter solenoid side terminls. Remove the onnetors from the strter solenoid. 5. Remove nd retin the solenoid retining srews. 6. Remove the strter solenoid. - Insultor - Nut (2) - Lokwsher (2) d - Bttery terminls e - Side terminls e d Testing 1. Connet ontinuity meter test leds of to eh of the two solenoid ttery terminls. 2. Connet positive (+) 12 volt ttery power with jumper leds to one of the solenoid side terminls. 3. Atute the solenoid y supplying negtive ( ) 12 volt ttery power to the other solenoid side terminl. 4. If no meter movement ours, reple the solenoid. Instlltion 29219 1. Ple the strter solenoid on the mounting rket nd seure with the strter solenoid retining srews. 2. Connet the engine hrness oot onnetors to the strter solenoid side terminls. 3. Connet the engine hrness wires to the strter solenoid top terminls, with the lokwshers nd nuts. Tighten seurely. 4. Instll the strter solenoid insultor onto the strter solenoid top terminls. 90-864260200 AUGUST 2009 Pge 4A-11
Strting System Notes: Pge 4A-12 90-864260200 AUGUST 2009