Installation - MerCruiser GM4 Service Manual

4. Connect 12 volt battery positive (+) lead to sole-
noid switch terminal and negative (–) lead to sole-
noid frame.
5. Momentarily touch a jumper lead from solenoid
motor to starter motor frame. This shifts pinion
into cranking position where it will remain until
battery is disconnected.
6. Push pinion back toward commutator end to elim-
inate slack.
7. Measure distance between pinion and pinion re-
tainer.
8. If clearance is not within limits of .010-.160 in.
(0.25-4.00 mm), it may indicate excessive wear of
solenoid linkage, shift lever yoke, or improper as-
sembly of shift lever mechanism. Replace worn or
defective parts, since no provision is made for ad-
justing pinion clearance.
a - Pinion
b - Retainer
c - Feeler Gauge
Index
90-816462 2-695
72629
a
b
c
72077

Installation

IMPORTANT: Install special mounting shim (if
equipped) between starter motor and engine
block.
1. Place starter motor in position and install mount-
ing bolts. Torque bolts to 30 lb. ft. (41 N·m).
2. Connect YELLOW/RED wire to terminal S of so-
lenoid. Connect ORANGE wire, RED wire, and
battery cable to large terminal of solenoid. Tight-
en fasteners securely. Coat terminals with Quick-
silver 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.
STARTING SYSTEM - 4A - 31