Starting System

Electrical System
Section 4A - Starting System
Table of Contents
Finding Other Diagrams.....................................................4A-2 Periodic Inspection..................................................... 4A-2
Starter Motor...................................................................... 4A-2 Starter Removal..........................................................4A-3
Identification................................................................4A-2 Installation...................................................................4A-4
Starter Specifications..................................................4A-2

4
A

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Starting System

Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
25 Liquid Neoprene Starter terminals 92- 25711 3

Finding Other Diagrams

NOTICE
Refer to the appropriate Mercury MerCruiser Diagram Binder for wiring diagrams or other diagrams not found in this manual.

Starter Motor
Identification

19724

Starter Specifications
Delco I.D. Number MerCruiser part number
9000821 50‑806964

Starter Specifications

No Load Test Brush Spring

Engine
Tension
Rotation Volts . Amps Max Amps Min. RPM Max. RPM Grams (Oz.)
2352–2948
LH 10.6 60 95 2750 3250
(83–104)
Pinion Clearance 0.025–4.06 mm (0.010–0.160 in.)
Bearing Depth (gear) 0.038 mm (0.014 in.) Maximum
Bearing Depth (housing) 0.4 mm (0.017 in.) Maximum

Periodic Inspection
The starter motor and solenoid are completely enclosed in the drive housing to prevent entrance of moisture and dirt. However,
periodic inspection is required as follows:
1. Inspect the terminals for corrosion and loose connections.
2. Inspect the wiring for frayed and worn insulation.
3. Tighten the starter mounting bolts to specification.

Description Nm lb. in. lb. ft.

Starter mounting bolt 41 – 30

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 Starting System

Starter Removal
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.

1. Disconnect the battery cables from the battery.

2. Remove and retain the nuts and washers from the solenoid terminals.

a b a - Nut and washer on large terminal

b - Nut and washer on small terminal

49555
3. Remove and retain the wires from the solenoid terminals.

b c a - ORANGE wire, RED wire, and fuse

b - Hot stud wire (RED power)
c - YELLOW/RED wire

49553
4. Support the starter while removing the starter mounting bolts.

a a - Starter
b - Starter mounting bolt (2)
c - Flywheel

c
49552
a
b
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Starting System

5. Pull the starter assembly away from the flywheel and remove it from the engine.

Installation
1. Place the starter motor in position and install the mounting bolts.
2. Tighten the bolts to specification.

a a - Starter
b - Starter mounting bolt (2)
c - Flywheel

c
49552
a
b

Description Nm lb. in. lb. ft.

Starter mounting bolts 41 – 30
3. Connect the YELLOW/RED wire from the harness assembly to the upper solenoid terminal.

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4. Connect the hot stud cable to the large terminal.

a b
d
b
a
c 49558

a- Hot stud cable

b- YELLOW/RED wire
c- ORANGE wire, RED wire, and fuse
d- Starter solenoid

5. Connect the ORANGE wire, RED wire, and fuse from the harness assembly to the large terminal over the hot stud wire.

b c a - ORANGE wire, RED wire, and fuse

b - Hot stud wire (RED power)
c - YELLOW/RED wire

49553

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6. Install washers and nuts on the large and small terminals to secure the wires. Tighten the nuts to specification.

a b a - Nut and washer on large terminal

b - Nut and washer on small terminal

49555

Description Nm lb‑in. lb‑ft

Starter solenoid small terminal nut 2 20 –
Starter solenoid large terminal nut 7 50 –
7. Apply sealant to the starter terminals.

Tube Ref No. Description Where Used Part No.

25 Liquid Neoprene Starter terminals 92- 25711 3
8. Connect the battery cables to the battery in the following order:
a. Connect the positive (+) battery cable to the positive (+) battery terminal and tighten the cable clamp.
b. Connect the negative (–) battery cable to the negative (–) battery terminal and tighten the clamp.

19726

Typical

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