background image

  Starting System

90-864260200   AUGUST  2009

Page 4A-7

If longer battery cables are required, the cable gauge size must increase. See chart following for correct wire size.

a -

Wire size by cross‑sectional

area (gauge)

b -

Battery cable length

NOTE: Engine starting batteries should be located as close to engine as possible.

To select proper size positive (+) and negative (–) battery cables using the following procedure and chart:
1. Add the positive and negative cable lengths together.
2. Divide by 2 to obtain the average cable length.
IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical contact. Use electrical grade (rosin flux) solder

only. Do not use acid flux solder, as it may cause corrosion and a subsequent failure.

Average Cable Length

Cable Size (Gauge)

Up to 1.1 m   (3.5 ft.)

25 mm²  (4)

1.1 ‑ 1.8 m  (3.5 ‑ 6 ft.)

35 mm²  (2)

1.8 ‑ 2.3 m  (6 ‑ 7.5 ft.)

50 mm²  (1)

2.3 ‑ 2.9 m  (7.5 ‑ 9.5 ft.)

50 mm²  (0)

2.9 ‑ 3.7 m  (9.5 ‑ 12 ft.)

70 mm²  (00)

3.7 ‑ 4.6 m  (12 ‑ 15 ft.)

95 mm²  (000)

4.6 ‑ 5.8 m  (15 ‑ 19 ft.)

120 mm²  (0000)

Starter

Starter Removal

!

 WARNING

Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death

due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery

before maintaining, servicing, installing, or removing engine or drive components.

1. Disconnect the battery cables from the battery.
2. Disconnect the wires from the solenoid terminals.
3. Remove the starter mounting bolts.
4. Pull the starter assembly away from the flywheel and remove from the engine.

a -

PG260G1

b -

PG260L

2758

a

b

29188

a

b

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...

Reviews: