Table of Contents
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Table of Contents
Precautions........................................................................4A-2
MerCruiser Color Wiring Diagrams....................................4A-4
Starter Identification...........................................................4A-2
Starter Specifications.........................................................4A-2
Torque Specifications........................................................4A-3
Lubricants, Sealants, and Adhesives.................................4A-3
Special Tools.....................................................................4A-3
Diagrams............................................................................4A-5
10-pin Starting System Electrical Diagram.................4A-5
14-pin Starting System Electrical Diagram.................4A-6
Positive Current Flow.........................................................4A-3
Battery Cable Size for MerCruiser Models.........................4A-6
Starter................................................................................4A-7
90-864260200 AUGUST 2009
Electrical System
Section 4A - Starting System
Starting System Tests......................................................4A-10
Standard Starter Slave Solenoid......................................4A-11
Starter Removal..........................................................4A-7
Inspection...................................................................4A-8
Starter Solenoid Removal...........................................4A-8
Installation...................................................................4A-8
Voltage Drop Test.....................................................4A-10
Low Voltage Test......................................................4A-10
Water and Corrosion Inspection...............................4A-10
Removal....................................................................4A-11
Testing......................................................................4A-11
Installation.................................................................4A-11
Starting System
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Page 4A-1
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Table of Contents
Summary of Contents for Delco PG260G1
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Page 1: Table Of Contents
Starting System Electrical System Section 4A - Starting System Table of Contents Precautions................4A-2 Starter Removal............4A-7 MerCruiser Color Wiring Diagrams........4A-4 Inspection..............4A-8 Starter Identification............4A-2 Starter Solenoid Removal...........4A-8 Starter Specifications............4A-2 Installation..............4A-8 Torque Specifications............4A-3 Starting System Tests............4A-10 Lubricants, Sealants, and Adhesives.........4A-3 Voltage Drop Test.............4A-10 Special Tools..............4A-3 Low Voltage Test............4A-10 Diagrams................4A-5... -
Page 2: Precautions
• Do not splice wires into the harness. • Do not attempt diagnostics without the proper, approved service tools. Starter Identification Delco starter identification PG 260G1 PG 260L 29184 Starter Specifications The Permanent Magnet Gear Reduction starter motors features small permanent magnets mounted inside the field frame (NOTE: The actual configuration of these magnets differs between the PG200, PG250 and PG260;... -
Page 3: Torque Specifications
Starting System Delco PG260G1 starter specifications No load test Delco ID Engine Maximum Volts Minimum amp draw Minimum RPM Maximum RPM number rotation amp draw 9000884 12.0 2550 4150 Delco PG260L starter specifications No load test Delco ID Engine Maximum... -
Page 4: Special Tools
Starting System Special Tools DMT 2004 Digital Multimeter 91‑892647A01 Measures RPM on spark ignition (SI) engines, ohms, amperes, AC and DC voltages; records maximums and minimums simultaneously, and accurately reads H z TEMP in high RFI environments. TEMP C O M 4516 MerCruiser Color Wiring Diagrams Large scale, oversized color wiring diagrams are available in the MerCruiser Diagram Binder. -
Page 5: Diagrams
Starting System Diagrams 10‑pin Starting System Electrical Diagram Starting system electrical diagram Ignition switch 20 amp fuse Slave solenoid Circuit breaker Neutral safety switch To the alternator Starter motor 90 amp fuse Engine ground 29187 90-864260200 AUGUST 2009 Page 4A-5... -
Page 6: 14-Pin Starting System Electrical Diagram
Starting System 14‑pin Starting System Electrical Diagram PNK/PUR YEL/RED RED/PUR RED/PUR 25316 Ignition switch Harness plug Starter solenoid Circuit breaker Starter motor Wire junction Neutral safety switch 90‑amp fuse Engine ground (–) This is a general description of the positive current flow from the battery through the starting system until the starter motor cranks. NOTE: Ensure that all connections are tight and have the required resistance. -
Page 7: Starter
Disconnect the battery cables from the battery. Disconnect the wires from the solenoid terminals. Remove the starter mounting bolts. Pull the starter assembly away from the flywheel and remove from the engine. 29188 PG260G1 PG260L 90-864260200 AUGUST 2009 Page 4A-7... -
Page 8: Inspection
Starting System Inspection The starter motor and the solenoid are completely enclosed in the drive housing to prevent contamination by moisture and dirt. Perform any required periodic inspection as follows: Inspect the terminals for corrosion and loose connections. Reseal any exposed electrical connections. Starter electrical connections Starter solenoid Positive (RED) cable... - Page 9 Starting System Connect the YELLOW/RED wire to the switch "S" terminal. Tighten the terminal nut to specification. Starter electrical connections Switch terminal, (S) Positive battery terminal (+) Resistor terminal (R) 29217 Description lb‑in. lb‑ft Switch terminal (S) nut – Connect the positive (+) battery cable and the 90 amp fuse to the battery terminal. Tighten the terminal nuts to specification. Description lb‑in.
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Page 10: Starting System Tests
Starting System Starting System Tests Voltage Drop Test Low power supply voltage and water contamination are the primary causes of most starter motor failures. Low power supply voltage causes excessive heat to build up in the starter motor. It can also cause starter motor solenoid contact problems. IMPORTANT: Perform these tests with a digital voltmeter before removing the starter from the engine. -
Page 11: Standard Starter Slave Solenoid
Starting System Standard Starter Slave Solenoid Removal Remove and retain the starter solenoid insulator. Remove and retain the starter solenoid top terminal nuts and lockwashers. Mark the position of the engine harness wires on the starter solenoid top terminals, and remove the wires from the starter solenoid. - Page 12 Starting System Notes: Page 4A-12 90-864260200 AUGUST 2009...
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