Reassembly
e. Assemble thrust collar on shaft with shoulder
next to snap ring.
After all parts are thoroughly tested and inspected
and worn or damaged parts replaced, reassemble
starter as follows:
f.
Place thrust collar and retainer next to snap
ring and using two pliers squeeze both until
snap ring is forced into retainer.
1.
Assemble brushes and related parts to field
frame as follows:
3.
4.
Place 4 or 5 drops of light engine oil in drive hous-
ing bushing. Slide armature and clutch assembly
into place while engaging shift lever with clutch.
a. Assemble brushes to brush holders. Attach
ground wire to grounded brush and field lead
wire to insulated brush.
Position field frame over armature and apply
Quicksilver Liquid Neoprene between frame
against drive housing, observing caution to pre-
vent damage to brushes.
b. Assemble insulated and grounded brush
holders together with V-spring. Position as a
unit and install support pin. Push holders and
spring to bottom of support and rotate spring
toengagecenterofV-springinslotinsupport.
5.
Place 4 to 5 drops of light engine oil in bushing in
commutator end frame. Place brake washer and
commutator end frame onto shaft.
2.
Assemble over-running clutch assembly to arma-
ture shaft as follows:
a. Lubricate drive end of armature shaft with
SAE 10W oil.
6. Install solenoid return spring on plunger.
b. Slide assist spring and clutch assembly onto
armature shaft with pinion outward.
7. Position solenoid assembly to starter motor end
frame and turn solenoid to engage flange in slot.
c. Slide retainer onto shaft with cupped surface
facing end of shaft (away from pinion).
8.
9.
Install (and tighten securely) screws which hold
solenoid assembly to end frame.
d. Drive snap ring onto shaft and slide down into
groove.
Secure starter motor connector strap terminal
with screw and washer.
Clearances
PINION CLEARANCE
Pinion clearance must be checked as follows after
reassembly of motor to insure proper adjustment.
a
b
72073
a - Snap Ring
b - Groove
Index
4A-10 - STARTING SYSTEM
90-823224--2 796
| Categories | Mercury MerCruiser Manuals |
|---|---|
| Tags | Mercury MerCruiser 454 CID, Mercury MerCruiser 502 CID |
| Model Year | 1993, 1994, 1995, 1996, 1997 |
| Download File |
|
| Document File Type | |
| Copyright | Attribution Non-commercial |
(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. Hugely helpful service manual! Perfect. Thank you!
Manuals are all Important for Technician
This book is invaluable if you do your own repairs. Great book.
Could not find a copy until a search brought me here.
Excellent print.
Thank you