Commutator End Frame Gap; Installation - Mercury MerCruiser MCM 454 Mag MPI Service Manual

STARTING SYSTEM
6. If clearance is not within limits of .010-.140 in. (0.25-3.5 mm), it may indicate excessive
wear of solenoid linkage shift lever yoke buttons or improper assembly of shift lever
mechanism. Check for proper assembly, and recheck gap. If still excessive, replace
worn or defective parts, since no provision is made for adjusting pinion clearance.

Commutator End Frame Gap

To keep the ignition-proof and safety requirement, the gap between the commutator end
frame and field coil housing must be checked. See specifications. If the gap exceeds mea-
surement when checked with a feeler gauge, the end frame should be checked for proper
seating on the field coil housing. If properly seated and still found to have excessive gap,
the end frame must be replaced.

Installation

1. Place starter motor and solenoid assembly in position and install mounting bolts. Torque
bolts to 50 lb-ft (68 Nm).
2. Fasten wires as outlined in wiring diagram.
3. Coat solenoid terminal connections with Quicksilver Liquid Neoprene.
4. Place rubber boot over positive battery cable connection.
Index
Page 4A-12
Downloaded from https://needmanual.com/
a - Pinion
b - Retainer
c - Feeler Gauge
c
d
a - Positive (+) Battery Cable
b - Rubber Boot
c - Orange Wire and Red Wire
d - Yellow/Red Wire
SERVICE MANUAL NUMBER 23
a
b
c
a
0
0
b
72077
72637
90-861326--1 MARCH 1999