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Testing Starter Motors

This document provides instructions for testing starter motors on MerCruiser gas engines and determining whether a starter motor should be covered under warranty. It outlines steps to check for low voltage or water damage, which are the most common causes of premature starter motor failure. Any starter motor returned for warranty that tests properly or shows signs of water damage will have the warranty claim rejected.

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54 views

Testing Starter Motors

This document provides instructions for testing starter motors on MerCruiser gas engines and determining whether a starter motor should be covered under warranty. It outlines steps to check for low voltage or water damage, which are the most common causes of premature starter motor failure. Any starter motor returned for warranty that tests properly or shows signs of water damage will have the warranty claim rejected.

Uploaded by

litieuduy
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 4

No.

2001-11

WARRANTY INFORMATION SERVICE INFORMATION

This Service Bulletin replaces Service Bulletin 99-1 and 95-20.

Testing Starter Motors

Models
All MerCruiser gas engines.

No Trouble Found or Water in Starter Motors


We receive starter motors returned for warranty that function properly when tested. The first
test that should be done on an engine with a starter motor problem is to check the condition
of the engine’s cranking battery. If the fault is not with the battery, test the starter motor volt-
age as outlined in this bulletin.
We also have found either water or corrosion inside starter motors returned for warranty.
Condensation will not cause the amount of damage found. Inspect all starter motor failures
for signs of water damage before sending it in for warranty.

Testing the Starter Motor with a Voltmeter


Other than water damage, low voltage is the number one cause of shortening the expected
life of a starter motor. Low voltage causes excessive heat to build up in the starter motor.
It can also cause starter motor solenoid contact problems. Perform these tests before re-
moving starter from the engine.
1. An analog or digital voltmeter can be used, but the digital meter is best.
NOTE: Be sure to ‘0’ meter before making the test and that the boat’s battery is fully charged.
2. Remove the coil wire from distributor cap and ground it so engine does not start.
3. Connect voltmeter positive (+) lead directly to the large, threaded starter motor terminal
that the battery positive (+) cable is connected to.
4. Connect voltmeter negative (–) lead directly to an unpainted metal surface on starter
housing.
5. Crank engine over with key switch for about 10-15 seconds and watch the voltmeter.

2001-11 AUGUST 2001 Printed in U.S.A. -  2001, Mercury Marine Page 1 of 4


TESTING STARTER MOTORS

6. A voltmeter reading of 9.5 volts or more indicates that there is sufficient voltage being
supplied to the starter to operate properly.
a. If the starter does not function like it should, there could be a problem with the starter
or the engine. Remove the spark plugs and try turning the engine over by hand to
rule out the engine itself.
7. A meter reading below 9.5v indicate voltage loss between the starter motor and the bat-
tery. Example: Voltage measured at the battery posts indicates 12.5v. You measure 9v
at the starter. That means there is a 3.5v drop between the battery posts and the starter.
Corroded battery cables, loose or dirty connections, loose battery cable terminal crimps,
under size battery cable gauge for length used in boat, painted surfaces or battery
switches could be the cause for this voltage drop.
Look for cause of low voltage by using the following test.
8. Test the battery positive (+) cable first. Connect voltmeter (+) lead directly to the battery
(+) post, not the battery cable ring terminal. Connect voltmeter (–) lead directly to the
large, threaded starter motor terminal that the battery (+) cable is connected to.
NOTE: Remove one voltmeter lead before starter motor is turned off or voltmeter damage
may occur. The starter may produce a voltage spike that can damage a voltmeter.
a. Crank engine over while looking at the voltmeter.
The maximum allowed drop is 0.25v.
b. To find the point where the resistance is highest, leave the voltmeter (+) lead on the
battery post and move the voltmeter (–) lead to the battery (+) cable ring terminal,
that is on the threaded starter terminal.
c. Next, move voltmeter (–) lead to the battery cable itself that is inside the crimped
battery cable ring terminal.
d. Test each battery cable connection in this manner all the way back to the battery (+)
post. If a battery switch is used, check between the battery cable ring terminal and
the switch’s terminal.
9. Check for voltage drop on battery negative (–) cable. Connect voltmeter (–) lead directly
to the battery (–) post, not the battery cable ring terminal. Connect voltmeter (+) lead to
an unpainted surface of the starter housing.
NOTE: Remove one voltmeter lead before starter motor is turned off or voltmeter damage
may occur. The starter may produce a voltage spike that can damage a voltmeter.
a. Crank engine over while looking at the voltmeter.
The maximum allowed drop is 0.25v.
b. To find the point where the resistance is highest, leave voltmeter (–) lead on battery
(–) post and move voltmeter (+) lead to the ground stud where the battery (–) cable
is connected.
c. Then move the voltmeter (+) lead to the battery (–) cable ring terminal, that is on the
ground stud.
d. Next, move voltmeter (+) lead to the battery cable itself that is inside the crimped
battery cable ring terminal.
e. Test each battery cable connection in this manner all the way back to the battery
post.
10. After testing to ensure that the starter motor is getting at least 9.5v, test the starter motor
solenoid to see if it is getting at least 9.5v from the slave solenoid during cranking. Low
voltage at the starter solenoid can cause intermittent operation of the solenoid contacts
and shorten the life of it.
Page 2 of 4 AUGUST 2001 2001-11
TESTING STARTER MOTORS

a. Connect the voltmeter (+) lead to the terminal on the starter solenoid that has the
YEL/RED wire from the slave solenoid connected to it. Connect the voltmeter (–)
lead to unpainted surface of the starter housing.
b. Crank engine over and watch the voltmeter. If the starter solenoid is not getting 9.5v,
the YEL/RED wire or the slave solenoid could be the cause of the low voltage.

Water or Corrosion Inspection


1. Delco PG260 models only, remove the 2 short screws from the end cap and look at the
threads.
a. If they are clean and gold in color, the starter motor did not have water inside of it.
b. If they are dirty and black or gray in color, the starter motor may have had water on
the inside of it, go to step 2.
2. Remove the 2 long bolts to disassemble and inspect the inside of the starter motor.
a. Heavy rust and corrosion inside the starter motor indicates water damage.
b. If starter motor has little or no signs of rust or corrosion on the inside, go to step 3.
3. Remove starter solenoid. Look at condition of solenoid plunger grease.
a. Brown or red rust colored grease or if the plunger is rusty, solenoid has been under
water.
4. If no signs of rust or corrosion is found after steps 1-3, place all loose parts in a sealed
plastic bag. Return starter motor and bagged parts with warranty claim.

a
74041

All Delco Starter Motors


a - Short Screws, PG260 Models Only
b - Long Screws

2001-11 AUGUST 2001 Page 3 of 4


TESTING STARTER MOTORS

Replacing Starter Motors


When a starter motor is replaced, retest the voltage at the starter motor to ensure that it is
getting a minimum of 9.5 volts.
If a complete starter motor is needed for warranty replacement, it must be ordered from Mer-
cury Parts. The use of any other company’s starter motor as a warranty replacement is not
allowed.

Warranty
Any starter motor returned for warranty that has either a “no trouble found condition” or signs
of water being on the inside of it, will have the warranty claim rejected and the part returned
to the dealer.

Page 4 of 4 AUGUST 2001 2001-11

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