Hot Stud; Starter; Inspection - Mercury MerCruiser Service Manual

Starting System
Circuit Length and Cable Size
Less than or equal to 2.7 m (9 ft)
NOTE: Consider the following information before choosing your cables:
1. Two numbers are provided for minimum cable size. The second number (in parentheses) is the American Wire Gauge
(AWG) cable recommended by MerCruiser for the indicated cranking circuit length. The first number is an approximate
cross‑sectional area equivalent to the AWG number, expressed in square millimeters (mm
used as the minimum cable size when selecting cables not denoted in gauge, such as ISO sizes. Always round up.
2.
All listed cables are sized for engine cranking only .

Hot Stud

The hot stud is located at the rear of the engine. It is normally covered by a protective boot. It is also located next to the 90‑amp
fuse. The hot stud provides a ready connection point for the positive battery cable. A second thick gauge cable is used to
connect the hot stud to the starter. Both the cable from the battery to the hot stud and the cable from the hot stud to the starter
are considered battery cables, and must be included in the total length used to calculate wire gauge.
a

Starter

Inspection

The starter motor and the solenoid are completely enclosed in the drive housing to prevent contamination by moisture and dirt.
Periodically:
1. Inspect the terminals for corrosion and loose connections. Reseal any exposed electrical connections with Liquid
Neoprene.
Tube Ref No.
Liquid Neoprene
25
2. Inspect the wiring for frayed or worn insulation.
3. Ensure that the starter mounting bolts are tight.
Page 4A-8
Circuit Length
2.7–4.6 m (9–15 ft)
4.6–7.6 m (15–25 ft)
7.6–9.5 m (25–31 ft)
9.5–11.9 m (31–39 ft)
11.9–15.2 m (39–50 ft)
15.2–19.2 m (50–63 ft)
19.2–24.4 m (63–80 ft)
b
55252
Description
© 2016 Mercury Marine
Shown with protective boot removed
a - 90‑amp fuse
b - Hot stud
Where Used
Electrical connections
Minimum Cable Size
(see notes)
2
13.3 mm (6 AWG)
2
21.2 mm (4 AWG)
2
33.6 mm (2 AWG)
2
42.4 mm (1 AWG)
2
53.5 mm (0 AWG)
2
67.7 mm (00 AWG)
2
85.2 mm (000 AWG)
2
107 mm (0000 AWG)
2
). This equivalent is to be
90-8M0099748 eng DECEMBER 2015
Part No.
92- 25711 3