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Starting System  

Page 4A-4

90-864260200   AUGUST  2009

Special Tools

DMT 2004 Digital Multimeter

91‑892647A01

C O M 

m A 

H z 

mV

H z  TEMP

m A 

IG

IP

OFF

H z 

TEMP

4516

Measures RPM on spark ignition (SI) engines, ohms, amperes, AC and DC

voltages; records maximums and minimums simultaneously, and accurately reads

in high RFI environments.

MerCruiser Color Wiring Diagrams

Large scale, oversized color wiring diagrams are available in the MerCruiser Diagram Binder. The initial distribution of the

MerCruiser Diagram Binder was delivered to MerCruiser authorized repair facilities in June and July of 2007. As new diagrams

are developed they will be distributed along with a revised, comprehensive index for addition to an existing binder.
The MerCruiser Diagram Binder features:

An index that identifies the diagrams by harness number, by engine group and drive, and by engine size and type

The diagrams are printed on an extremely durable, coated synthetic paper and can be wiped clean of grease and oil after

use.

The larger diagrams are easier to read. The diagrams will come in two sizes, depending on the complexity of the related

harness.

Removable pages are easier to reference and allow the technician to take only the required diagram to a repair site instead

of a complete service manual.

Dry erase markers can be used directly on the diagrams for tracing circuits or for training. They wipe clean after use.

Harness number headings make the drawings easy to find. The accompanying MerCruiser Diagram Binder Index speeds

lookup when the harness number is not known.

For information about ordering additional copies of the MerCruiser Diagram Binder or binder updates contact:

MerCruiser Authorized Dealers, Repair Centers, or OEMs can order service literature on MercNET.

Consumers can order service literature through the Mercury Dock Store (www.mercurydockstore.com), contacting Mercury

MerCruiser publications at 920‑929‑5110 or by contacting their local MerCruiser Authorized Dealer or Repair Center.

Summary of Contents for PG260G1

Page 1: ...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...

Page 2: ...ter the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation IMPORTANT Refer to the following precaution...

Page 3: ...ositive current flow following ignition switch activation includes Battery to the starter mounted solenoid switch RED battery cable Solenoid switch to the circuit breaker RED Circuit breaker to the wi...

Page 4: ...printed on an extremely durable coated synthetic paper and can be wiped clean of grease and oil after use The larger diagrams are easier to read The diagrams will come in two sizes depending on the co...

Page 5: ...10 pin Starting System Electrical Diagram Starting system electrical diagram a Ignition switch b 20 amp fuse c Slave solenoid d Circuit breaker e Neutral safety switch f To the alternator g Starter m...

Page 6: ...tight and have the required resistance Battery to the solenoid switch on the starter RED battery cable Solenoid switch to the circuit breaker RED Circuit breaker to the wire junction RED PPL Wire jun...

Page 7: ...se corrosion and a subsequent failure Average Cable Length Cable Size Gauge Up to 1 1 m 3 5 ft 25 mm 4 1 1 1 8 m 3 5 6 ft 35 mm 2 1 8 2 3 m 6 7 5 ft 50 mm 1 2 3 2 9 m 7 5 9 5 ft 50 mm 0 2 9 3 7 m 9 5...

Page 8: ...be Ref No Description Where Used Part No 25 Liquid Neoprene Electrical connections 92 25711 3 2 Inspect the wiring for frayed or worn insulation 3 Ensure that the starter mounting bolts are tight Star...

Page 9: ...hten terminal nut securely a Starter terminal b Insulator c Positive battery connection NOTE The back of the fuse is an insulator NOTE The PURPLE YELLOW wire is the 12 volt battery positive to the ele...

Page 10: ...e voltmeter negative lead to the battery cable itself which is inside the crimped battery cable ring terminal 5 Continue to test each battery cable connection back to the battery positive post If a ba...

Page 11: ...r 2 d Battery terminals e Side terminals Testing 1 Connect continuity meter test leads of to each of the two solenoid battery terminals 2 Connect positive 12 volt battery power with jumper leads to on...

Page 12: ...Starting System Notes Page 4A 12 90 864260200 AUGUST 2009...

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