Starter Circuit Troubleshooting - Mercury 200 OptiMax Jet Drive Service Manual

5. Attach the black cable with the yellow sleeve to the starter solenoid with a M8 nut. Tighten the nut to the specified torque.
Cover the nut with the red boot.
b
c
d
e
f
Description
Mounting bolts (0.312‑18)
Nut (M5)
Nut (M8)
6. Connect the battery cables to the battery.

Starter Circuit Troubleshooting

Before troubleshooting the starter circuit, verify the following conditions:
• The battery is fully charged
• The remote control lever or tiller handle shift control is in neutral
• All power and ground terminal connections are tight and free of corrosion
• Check all cables and wiring for frayed or worn insulation
• Check all of the fuses related to the operation of the engine
Use the DMT 2004 digital multimeter or an equivalent auto range digital meter for all of the tests.
DMT 2004 Digital Multimeter
Some of the tests require the battery voltage be removed from the starter solenoid to prevent unexpected engine cranking.
The following starter circuit troubleshooting chart will assist in locating any malfunction in the starting circuitry. Do not skip any of
the testing sequence procedures unless advised to do so.
90-8M0050731 MAY 2011
a
j
i
h
g
45198
Charging and Starting System
a - Upper mounting bolts (0.312‑18 x 1.50)
b - Bracket
c - Starter motor
d - Cover
e - Lower mounting bolts (0.312‑18 x 2.00)
f - Ground cable
g - Positive cable (black cable with yellow sleeve, M8 nut)
h - Yellow/red wire
i - Starter solenoid
j - Starter ground cable
Nm
24
2.5
9
91‑892647A01
lb‑in. lb‑ft
17.7
22
80
Page 2B-25