1993 1997 Mercury-MerCruiser GM V8 454 CID 7.4L and 502 CID 8.2L Marine Engines Service Manual Number 16

Table of Contents
Page
Page
Standard Starter Slave Solenoid  . . . . . . . . . . 4A-15
Testing/Replacement . . . . . . . . . . . . . . . . . . 4A-15
Starting System Components  . . . . . . . . . . . . . 4A-16
Positive Current Flow  . . . . . . . . . . . . . . . . . . . . 4A-17
Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-17
PG 200 and PG 250 Starter Motor
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
Replacement Parts Warning  . . . . . . . . . . . . . . . 4A-1
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
Battery Cable Recommendations  . . . . . . . . 4A-1
Torque Specifications  . . . . . . . . . . . . . . . . . . . . . 4A-1
Lubricants/Sealants  . . . . . . . . . . . . . . . . . . . . . . 4A-1
Direct Drive Starter Motor  . . . . . . . . . . . . . . . . . 4A-2
Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Torque Specifications  . . . . . . . . . . . . . . . . . . . . . 4A-2
Lubricants/Sealants  . . . . . . . . . . . . . . . . . . . . . . 4A-2
Positive Current Flow  . . . . . . . . . . . . . . . . . . . . . 4A-2
Starting System Components  . . . . . . . . . . . . . . 4A-3
Starter Motor (Exploded View)  . . . . . . . . . . . . . 4A-4
Periodic Inspection  . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Starter Motor Repair . . . . . . . . . . . . . . . . . . . . . . 4A-5
Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Solenoid Switch  . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Starter Motor Disassembly . . . . . . . . . . . . . . 4A-7
Cleaning and Inspection  . . . . . . . . . . . . . . . . 4A-8
Armature Tests  . . . . . . . . . . . . . . . . . . . . . . . . 4A-8
Field Coil Tests . . . . . . . . . . . . . . . . . . . . . . . . 4A-9
Loose Electrical Connections . . . . . . . . . . . . 4A-9
Turning the Commutator . . . . . . . . . . . . . . . . 4A-9
Reassembly  . . . . . . . . . . . . . . . . . . . . . . . . . 4A-10
Clearances  . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-12
Permanent Magnet Gear Reduction (PG200,
(Exploded View)  . . . . . . . . . . . . . . . . . . . . . . . . 4A-18
Solenoid Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4A-19
Periodic Inspection  . . . . . . . . . . . . . . . . . . . . . . 4A-19
PG 200 and PG 250 Starter Motor Repair  . . 4A-19
Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-19
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . 4A-20
Cleaning and Inspection  . . . . . . . . . . . . . . . 4A-22
Armature Tests  . . . . . . . . . . . . . . . . . . . . . . . 4A-22
Armature Bearing (Commutator End) . . . . 4A-23
Gear Bearing   . . . . . . . . . . . . . . . . . . . . . . . . 4A-23
Shaft Assembly Bearing  . . . . . . . . . . . . . . . 4A-24
Drive End Housing Bearing  . . . . . . . . . . . . 4A-24
Brushes and Brush Holder  . . . . . . . . . . . . . 4A-24
Reassembly  . . . . . . . . . . . . . . . . . . . . . . . . . 4A-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-27
PG 260 Starter Motor   . . . . . . . . . . . . . . . . . . . 4A-28
Exploded View  . . . . . . . . . . . . . . . . . . . . . . . 4A-28
Solenoid Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4A-29
Periodic Inspection  . . . . . . . . . . . . . . . . . . . . . . 4A-29
PG 260 Starter Motor Repair . . . . . . . . . . . . . . 4A-29
Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-29
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . 4A-30
Cleaning and Inspection  . . . . . . . . . . . . . . . 4A-32
Armature Tests  . . . . . . . . . . . . . . . . . . . . . . . 4A-33
Brushes and Brush Holder  . . . . . . . . . . . . . 4A-33
Reassembly  . . . . . . . . . . . . . . . . . . . . . . . . . 4A-35
Clearances  . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-38
PG250 and PG260) Starter Motor  . . . . . . . . . 4A-13
Specifications  . . . . . . . . . . . . . . . . . . . . . . . . 4A-13
Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . 4A-14
Testing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-14
Storage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-14
NOTICE
For information  and procedures  on trouble-
shooting, refer to Section 1C.
Index
44A-0A   S-TSTARTINGARTING SYSYSTEMSTEM
90-823224--2  796
Product Specification
CategoriesMercury MerCruiser Manuals
Tags,
Model Year1993, 1994, 1995, 1996, 1997
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(4 votes, average: 4.5 out of 5)
Marine readers have rated 1993 1997 Mercury-MerCruiser GM V8 454 CID 7.4L and 502 CID 8.2L Marine Engines Service Manual Number 16 4.5 out of 5.0 based on 4 product reviews.
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1993 1997 Mercury-MerCruiser GM V8 454 CID 7.4L and 502 CID 8.2L Marine Engines Service Manual Number 16 SKU UPC Model
Nick on Aug 13, 2018. Exactly what I was looking for!

Hugely helpful service manual! Perfect. Thank you!
Sonthaya Traipug on May 04, 2018. Freelance Yachts Service

Manuals are all Important for Technician
Glenn on Dec 02, 2015. Nice

This book is invaluable if you do your own repairs. Great book.
Joseph on Oct 04, 2015. 1997 7.4l Bravo

Could not find a copy until a search brought me here.
Excellent print.
Thank you

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