Clearances
5. Measure distance between pinion and pinion re-
tainer.
PINION CLEARANCE
6.
If clearance is not within limits of .010-.160 in.
mm), it may indicate excessive wear
of solenoid linkage, shift lever yoke, or improper
assembly of shift lever mechanism. Replace
worn or defective parts, since no provision is
made for adjusting pinion clearance.
Pinion clearance must be checked after reassembly
of starter motor.
(0.25-4.00
1.
Disconnect brush lead from solenoid motor and
insulate it carefully.
a
b
a
c
74041
a - Brush Lead
2.
3.
Connect 12 volt battery positive (+) lead to bat-
tery terminal and negative (–) lead to frame.
72077
a - Pinion
b - Retainer
c - Feeler Gauge
Momentarily touchajumperleadfrombatteryter-
minal to switch terminal. This shifts pinion into
cranking position where it will remain until battery
is disconnected.
Installation
IMPORTANT: Install special mounting shim (if
equipped) between starter motor and engine
block.
1.
2.
Place starter motor in position and install mount-
ing bolts. Torque bolts to 30 lb. ft. (41 N·m).
Connect yellow/red wire to terminal S of sole-
noid. Connect orange wire, red wire, and battery
cable to large terminal of solenoid. Tighten fas-
teners securely. Coat terminals with Quicksilver
Liquid Neoprene. Install battery cable boot, if so
equipped.
3.
Connect battery cables to battery in the following
order. Connect positive (+) cable to positive (+)
battery terminal and tighten cable clamp. Then
connect negative (–) cable to negative (–) termi-
nal and tighten clamp.
72629
4.
Push pinion back toward commutator end to
eliminate slack.
Index
4A-38 - 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