arco marine electronics & navigation catalog · from arco starting & charging. every effort...
TRANSCRIPT
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isafullservicesupplierofnewandremanufacturedelectricalproductsforthe startingandchargingofmarineengines.LocatedintheUnitedStates,hasoperatedinPensacola,Floridasince1960.
sellsonlyoriginalequipmentqualityitems!Allnewandremanufacturedunitsareassembledunderthestrictestqualitycontrolstandards.Eachandeveryunitistestedontheassemblylinetoensureoriginalequipmentreliability.
productsaredistributedtothousandsofdealersthroughanetworkof180nationalandinternationalwarehousedistributorsworldwide.
stocksthousandsofcompleteunitsandreplacementpartstoserviceeverythingfrombassboatstobattleships.
servicesallD.C.voltagesystems,includingclockwiseandcounterclockwiserotationstartingmotors.
catalogsonlytheitemsmostfrequentlyrequestedbyourcustomersworldwide.
alsosuppliesreplacementpartsformany“hard-to-find”and“obsolete”unitsfromourconstantlyexpandinginventory.
TablE of ConTEnTs
Policies .................................2
Warranty Information .............................3
Part number Quick Reference ............... 4-9
outboard starters ......................... 14-26
Inboard starters .............................. 30-36
Tilt/Trim Motors & Repair Kits ............ 40-47
Inboard alternators ......................... 51-58
Inboard battery Isolators ................... 60-61
solenoids ..................................... 68-71
outboard Rectifiers ............................. 72
Relays ............................................. 73
Voltage Regulators .............................. 74
Miscellaneous Items ........................ 74-76
Computerized Testing Equipment ............. 10
battery facts ................................. 11-12
Corrosion Protection ........................... 13
starter failure ................................... 27
How to Determine starter Rotation ........... 28
Drive Gear facts ................................ 29
Tilt Trim Motor Tips ......................... 37-39
Charging systems ................................ 48
alternator Tips ............................... 49-50
battery Isolator Circuits ........................ 59
Recommended Wire sizes .................. 62-64
solenoid Types, Circuits & Testing ....... 65-67
noTE:All rights reserved.Nopartof thisbookmaybe reproducedor transmitted inany formorby anymeans, electronicorotherwise,withoutpriorwrittenpermissionfromARCOStarting&Charging.Everyefforthasbeenmade tomakeall informationascompleteandasaccurateaspossible.Productdescriptions, typographic,price,orphotographicerrorsareunintentionalandsubjecttocorrection.
TECH TIPs
InDEx
also
catalogs
services
stocks
products
sells
is
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PolICIEs
all returns must be pre-approved and are subject to a 15% handling charge or an offsetting order of twice the equivalent value. Merchandise must be returned freightprepaid in original packaging and in saleablecondition. Dirty or damaged packaging will be replaced and charged to the customer’s account.
WaRRanTY RETURns:all returns must be pre-approved and returned fREIGHT PREPaID. Warranty
returns must include a complete explanation. .
sToCK aDjUsTMEnT:
our warranty is limited to the repair or replacement
of defective units only.
labor or any other expenses are noT covered.
all warranty returns must have a RETURn GooDs
aUTHoRIzaTIon nUMbER and include a complete
explanation of malfunction.
noteWarranty
our warranty is limited to repair or replacement of the defective unit.
It does not cover labor or any other expense.
losT oR DaMaGED GooDs: our responsibility ceases when the transportation company signs the bill of lading signifying yourmerchandise has been picked up in good condition. If part of your shipment is lost or damaged, do not accept shipment until the freight agent makes a notation on your freight bill.
THoRoUGHlY InsPECT YoUR sHIPMEnT as soon as IT Is RECEIVED.Ifanyconcealedlossordamageisdiscovered,itisabsolutelynecessaryforyoutorequestaninspectionbyyourfreightagent.Wearewillingtogiveourassistanceincollectingclaimsforlossordamage;however,wecannotberesponsibleforclaimscollectionorreplacementofdamagedgoods.
returnS
PaCKaGInG:Allreturneditemsmustbepackagedwithduecareintheoriginalbox(es).Acopyoftheoriginal invoiceandthereturningcompany’spacking listmustbeincluded. The packing list should showthe part number(s) returned. all warranty returns must include a complete explanation of the problem.
products,when properly installed, arewarrantedbyagainstdefectsinmaterialsandworkmanshipforaperiodof12 MonTHs foR lEIsURE UsE.Productsusedincommercialorracingapplicationsarewarrantedforaperiodof90days.
Thiswarrantyextendstotheapplicationundernormaluseandserviceanddoes not apply to rust, corrosion, submersions, cut wires, deliberate abuse, broken drive gears or housings.
Improper installation, careless handling, tampering or dismantling of units makes this warranty null and void.
Thiswarrantybeingexpresslyinlieuofallotherobligationsorliabilitiesand neitherassumesnorauthorizesanyotherpersonorfirmtoassumeforitanyotherliabilityinconnectionwiththesaleofitsproductsormerchandise.
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Cuttingaunit’swiresordismantlingaunitimmediatelyvoidsthemanufacturer’swarranty.Inaddition,takingamotoroffthereservoirandtryingtoinstallitonanoldreservoirusuallydamagesthebrushesandsealsinthemotor.Disassembledpartsarenot covered by warranty.
Abrokenflangeistypicallycausedbyimproperinstallation.Themountingholesmaylookevenlyspacedinatriangularpattern,buttheyarenot—oneholeisslightlyoffset.Forcingamountingbolt intotheoffsetholemaycausetheflangetobreak.Thismayalsooccurifthemountingboltsarenottightenedevenly.Abrokenshaftiscausedbyamalfunctioninthegearbox.Thesebreaksarenotmaterialdefects,andtheyarenot covered by warranty.
Thistypeoffailureisalwaysblamedonabadcasting.Infact,itiscausedwhenastarter,spinningatahighrateofrpm,comestoanabruptstop.Thiscanoccurwhenanenginebackfiresormomentarilyreleasingthestartswitchandre-engagingthestarterbeforeithasspundown.Itmayalsohappenwhenacylindersuffersawaterhydrauliclock.Ineithercase,thedamageisnotduetoadefectiveunit,andisnot covered by warranty.
Thesolenoidwasnotbrokenwhenthestarterwaspackagedtobeshipped.Wehavespecialboxesmadeforthestarters,andweusespecialpackingmaterialstoensuretheitemwillarrivetothecustomersafely.Some-times,though,thepackagesaremishandledbythecarrier(i.e.,droppedorthrown)andthesolenoidbecomesdamaged.Thisisthecarrier’sresponsibility.Itisnotamaterialdefect;thereforeitisnot covered by warranty.
part boxes are not shipping boxes. Ifyouareshippingaparttoacustomerorsendingawarrantyreturn,thepartmustbepackagedinawaytopreventpossibledamage.Placeextrapackingmaterialaroundthepart,placeitbackinthepartboxandthenintoawellpacked,sturdyshippingcontainer.
Topreventdamage,properlypackallpartsbeforereshipment.
treatseverycomponentwithaspecialrustandcorrosionresistantcoatingtopreventwaterdamage.However,itisimpossibletoprotecttheunitfromdirectcontactwithwater.Therefore,afailuredirectlycausedbyrust,corrosionorsubmersionisnot covered by warranty.
fREIGHT DaMaGE
bRoKEn solEnoIDs
RUsT, CoRRosIon oR sUbMERsIons
bRoKEn MoUnTInG flanGEs oR sHafTs
CUT WIREs oR DIsManTlED UnITs
bRoKEn nosE HoUsInGs
WaRRanTYInfoRMaTIon
an aRCo Warranty Protects You from Defects in Materials or Workmanship…
The Warranty DoEs noT cover such things as:
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The next time you install an part you can have confidence that the part will perform to o.E.M. specifications.
Wehaveinvestedoveramilliondollarsinfullyautomatedcomputerizedtestingequipmentforourinboardstarters,outboardstartersandtilt/trimmotors.Eachandeveryunitistestedforperformancebeyonditsnormaloperatingcondition.Thetesterspicturedabovearespecificallydesignedfortestinginboardandoutboardstartersandarejustthreeoffivedifferenttesterswe have in use today. We also have one designed for testing tilt/trim motors and another for testing hydraulic pumpassemblies.
Mostmanufacturersonlyperformspottestsorafreerunonlytest.Itisimpossibletoknowthateveryunitisperformingtospecificationwithoutperforminganextensiveloadtestoneveryunit.Itisveryexpensivetotesteachandeveryunit,however,ourgoalistosupplyyouwiththehighestqualityunitpossibleatareasonableprice.
Aftercompletionofathoroughtestprocedure,detailedtestresultsaredisplayed.Thetestsaresocompletethateventheresistanceofthesolenoidcontactsareshownonthereport.Armaturerippleisalsoshownalongwithaperformancecurve.Ifaunitfailstoperformtospecificationitisrejectedandissenttoourqualityassurancedepartmentforinspection.
sTaTE-of-THE-aRT, CoMPUTERIzED TEsTInG EQUIPMEnT
You have a better chance at winning a lottery than you have of receiving an unit that doesn’t perform!
EVERY unit is load tested with state-of-the-art testing equipment.
DID YOU KNOW…
TECH TIPs
The next time you install an part you can have confidence that the part will perform to
We call this ValUE!
unit is load tested
than you have of receiving an unit
The next time you install an part
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loosE baTTERY TERMInal EnDs Can DEsTRoY a baTTERYLooseorcorrodedbatterycablelugscancauseallsortsofproblems.Whenthestarterisengagedthelooseorcorrodedconnectioncancauseaheavyarcwhichwillmeltthepostrightoutofthebattery.Ifthebatteryisgassing,thearccancausethebatterytoexplode.Neverusethetemporarytypebatteryends.Theseareonlygoodforemergencyuseandwillbecomecorrodedinashortperiodoftime.always use a crimped and sealed battery cable end or replace the battery cable.
baTTERIEs WIll sElf DIsCHaRGE WHEn sToRED
Asabatterybecomesdischargedthepercentageofsulfuricacidintheelectrolytebecomesless.Thesulfuricacidcombineswiththeleadplatesproducingleadsulfate.Asthishappensthe electrolyte solution becomes pure water.Adischargedbatterywillfreezeincoldclimates,whichwilldestroytheinsulatorsandplatesinsideit.
ElECTRolYTE bECoMEs WaTER In a DIsCHaRGED baTTERY
Manysmallbatteriesaresuppliedwiththeelectrolyteinaseparatecontainer.Ifyouhavetofillanewbatterywithelectrolyte, YoU MUsT PlaCE THE baTTERY on a QUICK CHaRGER. Thechargingsystemwillneverbringthebatterytoafullychargedstate.THE baTTERY CaPaCITY WIll nEVER bE aboVE 80%.Pullingthebatteryoutlaterandtryingtochargeitwillnotwork.THE baTTERY’s CaPaCITY Has bEEn PERManEnTlY CUT bY 20% anD THERE Is noTHInG YoU Can Do aboUT IT.
Batterieswillselfdischargewhenstoredforlongperiodsoftime.Thisisanormalprocesswithallleadacidbatteries.always charge the battery to full charge before storing.Alsodisconnectthenegativebatterycable.Thiswillkeepthesmallsystemdrainsfromacceleratingthedischargeprocess.Thebestwaytoavoidshortenedbatterylifeisuse a sMaRT CHaRGER (not a trickle charger)onthebatterywhenit’snotbeingused.Asmartchargerisachargingdevicethatwillmaintainthebatteryatafullstateofchargebyonlychargingthebatterywhenthevoltagedropstoaspecifiedlevelwithoutovercharging.
IMPoRTanT baTTERY faCTs
DRY CHaRGED baTTERIEs MUsT bE CHaRGED bEfoRE UsInG
Makesurethereisagapbetweentheendsoftheterminalwhentight.
PoInTs To REMEMbERThe battery is the heart of the electrical systemalways start troubleshooting at the battery never store a battery in a discharged statenever add anything except distilled water to a battery
aaaa
Agoodbatterycanprovidefourorfiveyearsofworry-freeservicewiththerightkindofcare.
TECH TIPs
ManyfillTheCitTHERE
RGED DRY CHaRGED
Assulfuricsolution becomes pure water.the
oMEElECTRolYTE olYTE ol bECoElECTRolYTE olYTE ol bECo
bigger is better!Thebatteryyouarereplacingdoesnothavetobethesamesizeastheoriginal.IT Is alWaYs bETTER To HaVE ExTRa baTTERY CaPaCITY.
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WaRnInG! batteries give off hydrogen gas constantly. Hydrogen gas is highly explosive.always wear safety glasses or goggles and use caution when working with batteries.
oPEn CIRCUIT VolTaGE TEsT before you can properly test any battery it must be at fUll CHaRGE. Youcanverifythestateofchargewiththeuseofadigital multimeter.Connectthedigitalmultimetertothebatteryterminals.Afullycharged12voltbatterywillreadatleast12.6volts(2.1voltspercell)onthemultimeter.If your reading is 12.4 oR bEloW you must recharge the battery before testing.
baTTERY TEsTInG PRoCEDUREs
before you can properly test any battery it must be at fUll CHaRGE. Theonlywayyoucanthoroughlytestabatteryistoplaceahighamperageloadacrossthebatteryterminals.
starter motors have very high amperage requirements which can exceed 300 amps on certain engine applications. Ifthebatteryhastoberechargedyoumustfirstremovethesurfacecharge.Thiscanbedonebyusingthestarter.Disabletheignitionspark(consultmanufacturer’smethodtoavoidelectronicignition)andcranktheenginefor10-15seconds.Onceyouhaveremovedthesurfacecharge,disconnectthebatterycablesandconnectthebatteryloadtestertothebatteryposts.
Adjustcurrentdrawontheloadtesterto50%oftheCCArating.Continuethisfor15secondswhileviewingthevoltagereadingonthebatterytester.Thevoltageshouldstayabovethespecifiedreading(seechartbelow)withoutfallingoff.Ifthevoltageremainsatthespecifiedlevelorabove,thebatterywouldbeconsideredgood.Ifthevoltagereadingdropsbelowthespecifiedlevel,replacethebattery.
loaD TEsTInG THE baTTERY
Determine the cold cranking amperage rating of the battery you are testing. If the cold cranking amp rating (CCa) is not known, use 450 CCa for four cylinder engines,
550 CCa for six cylinder engines and 650 CCa for V-8 engines.
Open Circuit Volts Percent of Charge11.7voltsorless 0%12.0 25%12.2 50%12.4 75%12.6ormore 100%
Minimum Voltage Temperature (degrees)9.6 70F 21Candabove9.5 60F 16C9.4 50F 10C9.3 40F -1C9.1 30F -7C8.9 20F -12C8.7 10F -18C8.5 0F -18C
Load Test Chart
TECH TIPs
12voltbattery
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TECH TIPs
Moistureisthenumberone“killer”ofmarinestarters.Thatiswhy,fromstarttofinish,wedesignandmanufactureourstarterswithcorrosionprotectioninmind.Infact,overthreemilliondollarshasbeeninvestedintotallycomputerizedproductionandtestingmachinery.Followalongasweshowyouhowwenotonlygotowaragainstcorrosion,butbuildqualityintoeachandeverypart.
First,westartwithnickel-platedarmatureshaftsandsiliconsteellaminationstacks.Addalayerofpowdercoating,thebestinsulationandcorrosionpreventativeavailable,andyouareaheadinthebattle.
Next,thecommutatorisattached,computer-woundcopperwindingsareadded,andagroundfaulttestismadeoneacharmature.Strategictestingduringtheearlystagesofassemblyisanessentialmaneuverforuncoveringandcorrectingpotentialweaknesses.Thecommutatortabsarethencrimpedandhotstaked.Onthelathe,thecommutatorfaceissmoothedandpolishedensuringthebrushesrunasfriction-freeaspossible.Acomputerized18pointarmaturecheckismadeatthistime.
Nowthearmaturegoesontoourautomated,state-of-the-artassemblyline.Thefirststopisthepolyestertricklevarnish“carousel”.Thevarnishnotonlyassistsinholdingthewindingsinplaceduringpeakperformance,butalsodissipatesheat—anotherofthestarter’senemies.Movingalong,thearmaturesarenowinsertedintotheepoxycoatedshell.Theshellshavebeenpreviouslypreparedwithhighperformancemagnetsbondedtotheinterior.Nuts,bolts,gaskets,aspring,drivegear,brushkitandendcapareaddedtocompletetheassemblyofthestarter.Thehighperformancemagnetsarenowfullycharged.Last,butnotleast,acomputerizedfullloadperformancetestisconductedoneachandeverystarter.Onlybypassingthisfinalinspectionisanstartercertifiedasreadyforbattle.
The best offense …is a great defense
Rust, Corrosion or Submersions are NOT COVERED BY WARRANTY
TECH TIP
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REPlaCEMEnToUTboaRD sTaRTERs
DV510*9-tooth drive gear
3420 (nEW) fITs: YaMaHa25-40HP,2 strokeMaRInER20-40HP,2 strokeReplaces:HitachiS108-80,S108-80A,S108-80B11-tooth drive gear
*Will fit These starters only:3420,HitachiS108-80B,Yamaha689-81800-13
sR420*brush holder assembly
DV520*11-tooth drive gear
3421 (nEW)fITs: YaMaHa 1984-19979.9-15HP1988-199825HPReplaces:HitachiS106-07B,S106-07E,S106-07F10-tooth drive gear
3412 (nEW)fITs: sUzUKI, ToHaTsU, nIssan30-40HP,2 strokeReplaces:HitachiS108-94,S108-112,S108-1209-tooth drive gear
*Will fit These starters only:3412,HitachiS108-120,Tohatsu3C8-76010-100
sR412*brush holder assembly
DV512*9-tooth drive gear
3410 (nEW)fITs: ToHaTsU 45-140HP,2 strokeReplaces:HitatchiS114-415A,S114-415,S114-571A,S114-6679-tooth drive gear
*Will fit These starters only:3410,HitachiS114-667,TohatsuFM5900
sR410*brush holderassembly
3422 (nEW)fITs: YaMaHa 1984-UP70HP1991-UP60HP,2 strokeReplaces:HitachiS108-97A9-tooth drive gear
*Will fit These starters only:3422,HitachiS108-97A,Yamaha6H3-81800-11
sR422*brush holder assembly
DV522*9-tooth drive gear
sR423*brush holder assembly
DV523*11-tooth drive gear
*Will fit These starters only:3423,HitachiS108-87A,Yamaha6F5-81800-11
3423 (nEW)fITs: YaMaHa1987-Up30HP1989-Up40-50HPReplaces:HitachiS108-87A11-tooth drive gear
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*Will fit These starters only:3426,HitachiS114-323C,Yamaha6E5-81800-12
3426 (nEW) fITs: YaMaHa 1984-1996115-200HP,2 stroke1995-200040-50HP,4 strokeReplaces:HitachiS114-3239-tooth drive gear
DV528*9-tooth drive gear
3429 (nEW)fITs: YaMaHa 1998-UPV200;1994-UP225HP1990-UP250HPReplaces:HitachiS114-559B9-tooth drive gear
*Will fit These starters only:3429,HitachiS114-559B,Yamaha61A-81800-01
sR429*brush holder assembly
DV529*9-tooth drive gear
3424 (nEW) fITs: YaMaHa, MaRInER 55-60HP2-Cyl,2 strokeEnginesReplaces:HitachiS114-2219-tooth drive gear
sR424*brush holder assembly
DV524*9-tooth drive gear
*Will fit These starters only:3424,HitachiS114-221J,Yamaha697-81800-13
*Will fit These starters only:3425,HitachiS108-99B,Yamaha6H4-81800-12
3425 (nEW)fITs: YaMaHa 1984-198840-50HPReplaces:HitachiS108-99B9-tooth drive gear
DV525*9-tooth drive gear
sR425*brush holder assembly
3428 (nEW) fITs: YaMaHa115-225HP,2StrokeReplaces:HitachiS114-552,S114-6609-tooth drive gear
*Will fit These starters only:3428,HitachiS114-660B,Yamaha6N7-81800-10
sR428*brush holder assembly
3427 (nEW)fITs: YaMaHa 1994-1999 75HP; 1991-1996 85HP; 1984-UP90HPReplaces:HitachiS114-263B,9-tooth drive gear
*Will fit These starters only:3427,HitachiS114-263B,Yamaha688-81800-12
DV527*9-tooth drive gear
sR427*brush holder assembly
sR426*brush holder assembly
DV526*9-tooth drive gear
REPlaCEMEnToUTboaRD sTaRTERs
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3430 (nEW)fITs: YaMaHa 1999-Up80HP,4 stroke1999-Up100HP,4 stroke MERCURY/MaRInER90HP,4 strokeReplaces:HitachiS114-828B13-tooth drive gear
3432 (nEW)fITs: YaMaHa 2000-UpF115,4 stroke2000-UpLF115,4 strokeReplaces:HitachiS114-838A13-tooth drive gear
3431 (nEW)fITs: YaMaHa 2000-Up LZ150-175HP2000-UpVZ150-175HP2000-UpZ150-175HP2000-UpLZ200-Z200HPReplaces:HitachiS114-836A13-tooth drive gear
3442 (nEW) fITs: sUzUKI90/100,150-225HP,2 strokeReplaces:HitachiS114-551,S114-6748-tooth drive gear
*Will fit These starters only:3442,HitachiS114-674,Suzuki31100-92E00
DV542*8-tooth drive gear
sR442*brush holder assembly
3444 (nEW)fITs: sUzUKI 115-140HP,2 strokeReplaces:HitachiS114-437,S114-6739-tooth drive gear
DV544*9-tooth drive gear
*Will fit These starters only:3444,HitachiS114-673,Suzuki31100-94610
sR444*brush holder assembly
3440 (nEW)fITs: sUzUKI75/85HP,1988-2000 2 strokeReplaces:HitachiS114-5559-tooth drive gear
sR440*brush holder assembly
DV540*9-tooth drive gear
*Will fit These starters only:3440,HitachiS114-555,Suzuki31100-95601
3433 (nEW)fITs: YaMaHa 2004-Up150HP,4 stroke2005-Up250HP,4 stroke2006-Up225HP,4 strokeReplaces:HitachiS114-86713-tooth drive gear
REPlaCEMEnToUTboaRD sTaRTERs
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The o/b starter Drives are Rubber Cushioned Drives. If any oil gets between the compression
nut and the rubber grip surface, drive failure will result.
“Do noT”sPRaY oIl oR oTHER lUbRICanTs on o/b sTaRTER DRIVEs
“Do”
always remove the drive assembly before applying lube to the shaft. only apply a thin film of water
resistant grease to the shaft. Make sure to wipe off any excess.
REMoVE THE DRIVE assEMblY WHEn aPPlYInG lUbE To THE sHafT
5359 (neW) fITs: MERCURY/MaRInER 8,9.9,13.5,15HP4 stroke9-tooth drive gear
DV3599-tooth drive gear
sR359brush holder assembly
5361 (neW) fITs: o.M.C.1993-UP9.9-15HPsmall 10-tooth drive gear2”casing
DV361small 10-tooth drive gear
sR361brush holder assembly
5360 (neW) fITs: MERCURY 2001-UP40,50,60HP4-cyl, 4 stroke9-tooth drive gear
DV3609-tooth drive gear
sR360brush holder assembly
5358 (neW)fITs: EVInRUDE40,50,75,90HPE-TecModels9-tooth drive gear
DV3589-tooth drive gear
sR358brush holder assembly
3446 (nEW)fITs: HonDa40 HP,4 strokeReplaces:HitachiS114-677,S114-561;Honda31200-ZV5-0130,31200-ZV6A-01309-tooth drive gearCW Rotation
sR446*brush holder assembly
*Will fit These starters only:3446,HitachiS114-677,Honda31200-ZV6A-0130
REPlaCEMEnToUTboaRD sTaRTERs
• Excess oil or grease may cause drive failure. • Be sure to follow the lubrication directions shown below.TECH TIP
3447 (nEW)fITs: HonDa2002 - UP115&130HPReplaces:MitsubishiMOT60381;Honda:31200-ZW5-00313-tooth drive gear
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• Excess oil or grease may cause drive failure. • Be sure to follow the lubrication directions shown on page 17.TECH TIP
5364 (nEW)fITs: MERCURY 1998-Up25HP,4 strokeYamaha25HP,4 stroke 9-tooth drive gear
• Be sure to follow the lubrication directions shown on page 17.
NOTEWhen ordering drive
assemblies for B.R.P./O.M.C.
starters, be aware that some
B.R.P./O.M.C. outboard starters
use a 2-piece drive assembly;
older B.R.P./O.M.C. starters use
a 1-piece drive assembly.
ORdER ThE
CORRECT dRiVE.
ThEy aRE NOT
iNTERChaNgEaBLE!
5362 (neW) fITs: MERCURY 40-50HP 1997-UP 4-stroke9-tooth metric drive gear
DV3629-tooth metric drive gear
5366 (nEW)fITs: MERCURY35-50HP9-tooth drive gear
DV3669-tooth drive gear
sR366brush holder assembly
DV3659-tooth drive gear
sR365brush holder assembly
5365 (nEW)fITs: MERCURY 30/40/50/60HP1999-Up 3-cyl, 4 stroke2000-UP Yamaha40HP,4 stroke9-tooth drive gear
DV3649-tooth drive gear
sR364brush holder assembly
sR363brush holder assembly
jsa518jack shaft assembly/10-tooth drive gearfits johnson Evinrude direct injection engines
jsa517jack shaft assembly/9-tooth drive gearfits johnson Evinrude carbureted engines
DV5179-tooth drive gear
DV51810-tooth drive gear
sR362brush holder assembly
5363 (nEW)fITs: o.M.C. 1991-Up150-175HPV6Eagle-Series1997-UpV4andV6200375/90/115HP2003-UP90/105/11560oEngine2004-UP100-175HPDirectInjection
REPlaCEMEnToUTboaRD sTaRTERs
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• Excess oil or grease may cause drive failure. • Be sure to follow the lubrication directions shown on page 17.TECH TIP
5367 (nEW)fITs: MERCURY/MaRInER 1986-19966-15HP1980-200318-25HP10-tooth drive gear2½”motorcasing
5368 (nEW)fITs: o.M.C.1997-2000 9.9/15HP,4-stroke10-tooth drive gear
5369 (nEW)fITs: o.M.C. 8/9.9-11HP1997-1998 4 stroke1977-19929.9-15HP10-tooth drive gear2”motorcasing
DV36910-toothdrive gear
sR369brush holder assembly
DV36710-tooth drive gear
sR367brush holder assembly
see page 75
(3) Remove Tool leaving brushes loaded for assembly
Save Time With sR107 - bRUsH loaDInG Tool
(1) Depress brushes and slide End Cap In Tool
(2) Insert armature
one Tool fits all These Caps!
Makes brush loading as simple as 1-2-3The “perfect tool” for loading outboard starter brushes.strong stainless steel construction.
DVK68*2-pc drive kit*see noTE
sR368brush holder assembly
REPlaCEMEnToUTboaRD sTaRTERs
• Be sure to follow the lubrication directions shown on page 17.
NOTEWhen ordering drive
assemblies for B.R.P./O.M.C.
starters, be aware that some
B.R.P./O.M.C. outboard starters
use a 2-piece drive assembly;
older B.R.P./O.M.C. starters use
a 1-piece drive assembly.
ORdER ThE
CORRECT dRiVE.
ThEy aRE NOT
iNTERChaNgEaBLE!
�0
DV370*9-tooth drive gear*see noTE
5370 (nEW)fITs: o.M.C. 55-75HP3-cyl9-tooth drive gear
sR370brush holder assembly
5371 (nEW)fITs: o.M.C. 50-60HP2-cyl9-tooth drive gear
DV371*9-tooth drive gear*see noTE
sR371brush holder assembly
DVK71*2-pc drive kit*see noTE
5373 (nEW)fITs: o.M.C.150-235HPV68-tooth drive gear
sR373brush holder assembly
5372x (nEW)fITs: o.M.C. 1969-197085-115HP1971-197285-125HPlarge 10-tooth drive gear
DV372x large10-tooth drive gear
sR372brush holder assembly
5372 (nEW)fITs: o.M.C.85-140HP;Late-modelV4small 10-tooth drive gear
DV372*small 10-tooth drive gear*see noTE
sR372brush holder assembly
DVK72*2-pc drive kit*see noTE
DVK70*2-pc drive kit*see noTE
DV3738-tooth drive gear
REPlaCEMEnToUTboaRD sTaRTERs
NOTEWhen ordering drive
assemblies for B.R.P./O.M.C.
starters, be aware that some
B.R.P./O.M.C. outboard starters
use a 2-piece drive assembly;
older B.R.P./O.M.C. starters use
a 1-piece drive assembly.
ORdER ThE
CORRECT dRiVE.
ThEy aRE NOT
iNTERChaNgEaBLE!
• Excess oil or grease may cause drive failure. • Be sure to follow the lubrication directions shown on page 17.TECH TIP
��
TECH TIP
5374x (nEW)fITs: MERCURY 1956-195725-30HP195755HP195830-55HP195935&55HPlarge 10-tooth drive gear
DV374xlarge10-toothdrive gear
sR374brush holder assembly
5377 (nEW) fITs: MERCURY/MaRInER90-175HPInline150HPV610-tooth drive gear
DV377 10-tooth drive gear
sR377brush holder assembly
5376 (nEW) fITs: o.M.C. 18-40HP11-tooth drive gear
DV376*11-toothdrive gear*see noTE
sR376brush holder assembly
DVK76*2-pc drive gear kit*see noTE
5375 (nEW)fITs: MERCURY/MaRInER50-90HP/65HPJet10-tooth drive gear
DV375 10-toothdrive gear
sR375brush holder assembly
5374 (nEW)fITs: MERCURY65-85HP4-cyl10-tooth drive gear
DV37410-tooth drive gear
sR374brush holder assembly
REPlaCEMEnToUTboaRD sTaRTERs
NOTEWhen ordering drive
assemblies for B.R.P./O.M.C.
starters, be aware that some
B.R.P./O.M.C. outboard starters
use a 2-piece drive assembly;
older B.R.P./O.M.C. starters use
a 1-piece drive assembly.
ORdER ThE
CORRECT dRiVE.
ThEy aRE NOT
iNTERChaNgEaBLE!
• Excess oil or grease may cause drive failure. • Be sure to follow the lubrication directions shown on page 17.TECH TIP
��
5380 (nEW) fITs: MERCURY/MaRInER 135-200HPV6105HPJet8-tooth drive gear
DV380 8-toothdrive gear
sR380brush holder assembly
5379 (nEW)fITs: MERCURY/MaRInER 40-50HP10-tooth drive gear
DV379 10-toothdrive gear
sR379brush holder assembly
5378x (nEW)fITs: MERCURY/MaRInER V150HP,V175HPlarge 10-tooth drive gear
DV378x large10-toothdrive gear
sR380brush holder assembly
5381x (nEW)fITs: MERCURY/MaRInER 150-225HP9-tooth drive gear
5381 (nEW)fITs: MERCURY 1999-UP2.5DFI1996-1999200HP V6DFI1998-Up 225HPV6DFI1999-Up3.OL V69-tooth drive gear
DV3819-toothdrive gear
DV3819-toothdrive gear
sR380brush holder assembly
sR381brush holder assembly
REPlaCEMEnToUTboaRD sTaRTERs
NOTEWhen ordering drive
assemblies for B.R.P./O.M.C.
starters, be aware that some
B.R.P./O.M.C. outboard starters
use a 2-piece drive assembly;
older B.R.P./O.M.C. starters use
a 1-piece drive assembly.
ORdER ThE
CORRECT dRiVE.
ThEy aRE NOT
iNTERChaNgEaBLE!
• Excess oil or grease may cause drive failure. • Be sure to follow the lubrication directions shown on page 17.TECH TIP
��
5382 (nEW)fITs: CHRYslER/foRCE 35-50HP11-tooth drive gear
DV38211-toothdrive gear
sR382brush holder assembly
5386 (nEW)fITs: o.M.C. 1985-Up 120-140HPV410-tooth drive gear
DV386*10-toothdrive gear*see noTE
DVK86*2-pc drive kit*see noTE
5387 (nEW)fITs: o.M.C. V6,V8loop10-tooth drive gear
DV38710-toothdrive gear
5385 (nEW)fITs: MERCURY35-40HP,2-cyl10-tooth drive gear
DV38510-toothdrive gear
5384 (nEW)fITs: MERCURY/MaRInER 2.0L, 2.4L,2.5LV6, CoUnTER-RoTaTInG, RaCInG oUTboaRDs10-tooth drive gear
sR384brush holder assembly
sR387brush holder assembly
sR385brush holder assembly
sR386brush holder assembly
DV38410-toothdrive gear
REPlaCEMEnToUTboaRD sTaRTERs
NOTEWhen ordering drive
assemblies for B.R.P./O.M.C.
starters, be aware that some
B.R.P./O.M.C. outboard starters
use a 2-piece drive assembly;
older B.R.P./O.M.C. starters use
a 1-piece drive assembly.
ORdER ThE
CORRECT dRiVE.
ThEy aRE NOT
iNTERChaNgEaBLE!
• Excess oil or grease may cause drive failure. • Be sure to follow the lubrication directions shown on page 17.TECH TIP
��
5390 (nEW)fITs: o.M.C. 1987-199320-35HP;2-cyl9-tooth drive gear
5388 (nEW)fITs: MERCURY50-60HP,3-cyl,1991-199645HPJet10-tooth drive gear
DV38810-toothdrive gear
5389 (nEW)fITs: o.M.C. 1989-Up25,40,50HP;2-cyl1990-Up48-50HP9-tooth drive gear
DV389*9-tooth drive gear*see noTE
DVK89*2-pc drive kit*see noTE
5393 (nEW)fITs: CHRYslER/foRCE 70-150HP9-tooth drive gear
5392 (nEW)fITs: MERCURY/MaRInER100-125HPInline4-cyl;80HPJet8-tooth drive gear
DV3928-toothdrive gear
DV3939-toothdrive gear
sR388brush holder assembly sR392
brush holder assembly
sR390brush holder assembly
sR393brush holder assembly
sR389brush holder assembly
DV390*9-tooth drive gear*see noTE
DVK90*2-pc drive kit*see noTE
REPlaCEMEnToUTboaRD sTaRTERs
NOTEWhen ordering drive
assemblies for B.R.P./O.M.C.
starters, be aware that some
B.R.P./O.M.C. outboard starters
use a 2-piece drive assembly;
older B.R.P./O.M.C. starters use
a 1-piece drive assembly.
ORdER ThE
CORRECT dRiVE.
ThEy aRE NOT
iNTERChaNgEaBLE!
• Excess oil or grease may cause drive failure. • Be sure to follow the lubrication directions shown on page 17.TECH TIP
��
5394 (nEW)Determine location of the battery stud on starter being replaced before ordering - see 5397 fITs: foRCE 1996-199940-50HP13-tooth drive gear
Batterystudexits
boTToM ofstarter
sR394brush holder assembly
DV39413-tooth drive gear
5396 (nEW)fITs: MERCURY1994-199630-40HP,2-cyl,55-60HP1997-Up45HPJet10-tooth drive gear
sR396brush holder assembly
DV39610-toothdrive gear
5395 (nEW)fITs: MERCURY/MaRInER 1994-Up225HP8-tooth drive gear
sR395 brush holder assembly
DV3958-tooth drive gear
5397 (nEW)Determine location of the batterystud on starter being replaced before ordering - see 5394 fITs: foRCE 1992-199540HP1992-199550HP13-tooth drive gear Batterystud
exitssIDE
ofstarter
DV39713-tooth drive gear
sR397brush holder assembly
5398 (nEW)fITs: o.M.C. 1997-199925-35HP3-cyl10-tooth drive gear
sR398 brush holder assembly
DVK98*2-pc 10-tooth drive gear*see note
REPlaCEMEnToUTboaRD sTaRTERs
NOTEWhen ordering drive
assemblies for B.R.P./O.M.C.
starters, be aware that some
B.R.P./O.M.C. outboard starters
use a 2-piece drive assembly;
older B.R.P./O.M.C. starters use
a 1-piece drive assembly.
ORdER ThE
CORRECT dRiVE.
ThEy aRE NOT
iNTERChaNgEaBLE!
• Excess oil or grease may cause drive failure. • Be sure to follow the lubrication directions shown on page 17.TECH TIP
��
5400 (nEW)fITs: MERCURY2001-UP135-250HP200-250SportJet2005-UP VERaDo 4 sTRoKE200-275HP14-tooth drive gear
sR399brush holder assembly
5399 (nEW)MoToR onlYfITs: o.M.C. 90-115HP1997-UP60oV41998-200080HP1998-2000100HP
sR551brush holder assembly
DV551 large 10-tooth drive gear
5551 (nEW)fITs: CHRYslER25-35HPlarge 10-tooth drive gear
DV325 9-tooth drive gear
7325 (nEW)fITs: MERCURY/foRCE90-120HPSportJet9-tooth drive gear
sR325 brush holder assembly
DV326 8-tooth drive gear
7326 (nEW)fITs: MERCURY 1996-UPV6SportJet8-tooth drive gear
sR326brush holder assembly
jsa517jack shaft assembly/9-tooth drive gearfits johnson Evinrude carbureted engines
DV5179-tooth drive gear
sW463Replacement solenoid
REPlaCEMEnToUTboaRD sTaRTERs
NOTEWhen ordering drive
assemblies for B.R.P./O.M.C.
starters, be aware that some
B.R.P./O.M.C. outboard starters
use a 2-piece drive assembly;
older B.R.P./O.M.C. starters use
a 1-piece drive assembly.
ORdER ThE
CORRECT dRiVE.
ThEy aRE NOT
iNTERChaNgEaBLE!
• Excess oil or grease may cause drive failure. • Be sure to follow the lubrication directions shown on page 17.TECH TIP
��
TECH TIPs
We could tell you why your starter failed, but we thought you might like to see for yourself.
WaTER InTRUsIon Is THE #1 CaUsE of sTaRTER faIlURE.Ifwatergetspumpedintothemotorportionofthestarterfromtheflywheel,itwillnotdrainout.Asyoucansee,rustandcorrosionwilldestroytheinsidecomponentsofthestarter.
THE #2 CaUsE of sTaRTER faIlURE Is WaTER InGEsTIon InToTHE EnGInE.Leakingexhaustmanifolds,gasketsandrisersareoftenthesource.Damagetothemountingpads,asshownabove,indicatethestarterhasbeenlooseontheengine;possiblycausedbywateringestionintothecylinder.Althoughtheenginemaynotexperienceacompletehydrolock,ifenoughwaterisontopofthepistontoraisethecompressiontoahighlevel,thestarterboltsandmountingpadswillbestressedbeyondnormalloadconditions.
Don’T bE foolED bY oUTWaRD aPPEaRanCEs.Asshownhere,theoutsideconditionofthestarterappearstobefine,butbyremovingandinspectingthelowerstartercasebolt,itisobviouswaterhasgotteninsidethestarter.
Althoughtheoutsideofthestarter(atbottomright)looksfine,theflywheelpickedupwaterfromthebilgeandpumpeditinsidethestartercausingthecorrosionshownhere.
Shownherearedamagedstartermountingpads.Wateringestedintotheenginestressesthemountingboltsbeyondnormalconditions.Theboltsstretchandcausethestartertobecomeloose.Thiscouldeventuallyleadtodamagetotheringgear,startercastingandpossiblytheentireengineblock.
If left unchecked, these problems will result in prematurestarter failure REGARDLESS of the STARTER MANUFACTURER.
These problems are not the fault of the starter.Simply replacing the starter without first locating andcorrecting the source of water intrusion will onlyresult in more starter failures.
Questions?In need of a replacement starter?
Give us a call.These types of damage are
NOT COVERED BY WARRANTY
TECH TIP
��
Engine Rotation Viewed from The flywheel End
This is not very common ontoday’s marine engines. Thisis the opposite rotation ofautomotiveengines.
This is the most commonengine rotation found ontoday’s marine engines.This is the same rotation asautomotiveengines.Usethesechartstodeterminethecorrectstarterrotationneeded.
Anotherwaytodeterminethestarterrotationistoinspectthechamferonthestarterdrivegear.Thebevelwillalwaysbeonthetrailingedge.
Clockwise Rotation
How To Determine The Correct starter Rotation
Worn out battery Batteriescausemoretroublethananyothercomponentinamarineelectricalsystem.
loose Connections Besuretocheckalltheterminalsandconnectionsandmakesuretheyarecleanandtight.
Incorrect Wiring Incorrectwiringcancauseburnouts.Alwaystagthewireswhenremovinganelectricalcomponent.
High Resistance This is a very common problemfound in marine electrical systems.Corrosion, undersized wire, or badconnectionswillcauselowvoltagetotheelectricalcomponents.Lowvoltagecauses high heat and will destroyelectrical devices. Be sure to checkforvoltagedrops.
loose battery Clamps Cable terminalsmustbe tight. If theendsoftheclampstouchatthetop,disconnectthecableclampsandshavetheendsoftheclampjawswithafilesothereisagap.
Important Check Points
Important Check Points
Counter Clockwise Rotation
Right Hand Engine Rotation
always make sure the battery is completely charged and load testedbefore replacing other components.
left Hand Engine Rotation
TECH TIPs
��
TheFolo-Thrutypedrivecurrentlyusedonmanystartingmotorshasbroughtaboutdifficultyduetoamisunderstandingofoperatingandlackofinformationonproperservicing.Thisfacthasbeenreflectedbythenumberofdrivesreturnedforwarrantywhicharefullyoperative.
TheFolo-Thrudriveisdesignedtolockandremainintheextendedorengagedpositionuntiltheenginestartsandreachesapproximately400to500RPM.Thedrivetoflywheelrotationisfifteentoone.Whentheengineisturningat400RPM,thestarterdrivegearisturning6,000RPM.Ifthedriveislockedintheextendedpositionithastobereinstalledontheengineandtheenginestartedorthedrivemustbeturnedinexcessof6,000RPMbyawirewheelmountedonanelectricbenchgrindertomakeitdisengage.
Thereasonthepinionlocksintheengagedpositionistoassurethestartercontinuestocrankuntiltheenginehasstarted,thuspreventingfalsestarts.Thisisaccomplishedbyusingaspringloadedpinwhichridesononeofthepinionscrewthreadsanddropsintoaholewhenthepinionisinthefullyengagedposition.Thislocksthepinionintheengagedposition.Whentheenginestarts,theflywheeloftheenginedrivesthestarterpinion.AclutchmechanismisbuiltintothepiniontoprotectthestarterfromexcessiveRPM.
Theclutchallowsthepiniontoturnfasteroroverrunthearmatureshaft.Whentheenginereaches400-500RPM,thepinionspinsfastenoughtocreatetheneededcentrifugalforcetothrowthespringloadedpinoutoftheholeintheshaftandallowthepiniontodisengage.
Do not condemn a drive until it has been tried in actual operation and proven faulty.
TECH TIPs
Asshownhere,spinningthedrivewithawirewheelinthedirectionitclickswilldisengagethelocks.
InERTIa DRIVEs GEaRs
DRIVE GEaRs
Centerofshaftislocatedfartherawayfromtheringgear.
Centerofshaftislocatedclosertotheringgear.
Distanceisgreaterforthe11-toothgear.
Distanceislessforthe9-toothgear.
11-tooth Drive Gear startero.E.M. 9-tooth
Drive Gear starter30470DID YoU KnoW…
Did you know the gear profile for the 9-tooth o.E.M. gear reduction starter and the 11-tooth High Performance gear reduction starter are the same?The only difference is the diameter of the drive gear.Since the 11-tooth drive gear has two more teeth it isnaturallylargerindiameter.Tocompensateforitssmallerdiameter, the center of the 9-tooth drive gear is locatedcloser to the flywheel. Both starters are thus completelyinterchangeable. These are powerful starters and we areable to take advantage of a better gear ratio using this11-toothgear.
�0
REPlaCEMEnT InboaRD sTaRTERs
Rust, Corrosion or Submersions are NOT COVERED BY WARRANTYTECH TIP
treats every component with special rust and corrosion resistant coatings to prevent water damage. However, it is impossible to protect the unit from direct contact with water. Therefore, a failure directly caused by rust, corrosion or submersion is not covered by warranty.
30119HEaVY-DUTYfITs: MERCRUIsER, o.M.C., VolVo PEnTa, ETC.w/standardsolenoid12Volt,CW Rotation
sW975Replacementsolenoid
nEW H/D REPlaCEMEnT aVaIlablE! CW Rotation: order #30460
30124 HEaVY-DUTYfITs: MERCRUIsER, o.M.C. CobRa,YaMaHa, VolVo PEnTaw/metricsolenoid12Volt,CW Rotation
sW984Replacementsolenoid
nEW H/D REPlaCEMEnT aVaIlablE! CW Rotation: order #30460
30433 (nEW) ValUE PRICED!sTanDaRD DUTYDirect o.E.M. replacementgear reduction starter.fITs: all GM EnGInEswith14”flywheelusingastaggeredboltpattern.Recommendedforlatemodel3.0Literwith14”flywheelusingtailbracket.
Canalsobeusedinplaceof10MTwithtwolongboltstaggeredpatternor30470!MountingboltkitMBK450requiredifreplacing10MT*MountingboltkitMBK450requiredifreplacing10MT.
sW463ReplacementSolenoid
Motor
30457 (nEW) HIGH-PERfoRManCE fITs: MERCRUIsER, CRUsaDER, MaRInE PoWER, PlEasURECRafT, anD oTHERs.14MT,CCW Rotation
30456 (nEW) HIGH-PERfoRManCE fITs: MERCRUIsER, CRUsaDER, MaRInE PoWER, PlEasURECRafT, anD oTHERs.14MT,CW Rotation
sW45614MTReplacementSolenoid4Post,3-BoltMount
DV456 CW RotationReplacementDrivefits: Delco14MT, 30456starter
DV457CCW Rotation ReplacementDriveReplaces: Mercury 850402fits: Delco14MT,30457starter
Willalsoreplace 30120
Three-bolt MountBattery
SWR
four Post
Replaces this 10 MT style starter
��
30470 (nEW)HIGH-PERfoRManCEPermanent magnet gear reduction starter fITs: VolVo PEnTa, MERCRUIsER, MaRInE PoWER, ETC.Twolongboltstaggeredpattern14”flywheel,CW RotationWill also replace 9-tooth oEM version.
DV450Replacement11-tooth drive gear
sW450Replacementsolenoidfor 30460, & 30470 only!Does not include plunger; see below.order plungers separately.
Pa450s1¾”PlungerforSW450
Pa450l2¼”PlungerforSW450
MbK450MoUnTInG bolT KIT REQUIRED if replacing 10MT style starters.
30462 (nEW)fITs: 6.0l GM EnGInEsPermanent magnet gear reduction starterwithtwolongboltslightoffsetboltpattern
sW463 ReplacementSolenoid
30459 (nEW)HIGH-PERfoRManCE fITs: MERCRUIsER, CRUsaDER, MaRInE PoWER, anD oTHERs.Light weightandcompact;permanentmagnetgearreduction.CCW Rotation
sW463ReplacementSolenoid
DV460Replacement9 tooth drive gearfits 30460 only!
30460 Will Replace all CW Rotating 10MT starters with one long and one short bolt straight across Pattern.
30460 (nEW) HIGH-PERfoRManCEPermanent magnet gear reduction starter fITs: MERCRUIsER, CobRa, YaMaHa, VolVo PEnTaCW Rotation12¾”flywheel
IncludesMounting bolts & Gasket
sW450Replacementsolenoidfor 30460 & 30470 only!Does not include plunger; see below.order plungers separately.
Pa450s1¾”PlungerforSW450
Pa450l2¼”PlungerforSW450
30470 Will Replace all CW Rotating 10MT starters with Two long bolt staggered Pattern. DoEs noT include mounting bolt kit - see below.
REPlaCEMEnT InboaRD sTaRTERs
Rust, Corrosion or Submersions are NOT COVERED BY WARRANTYTECH TIP
treats every component with special rust and corrosion resistant coatings to prevent water damage. However, it is impossible to protect the unit from direct contact with water. Therefore, a failure directly caused by rust, corrosion or submersion is not covered by warranty.
Replaces this10 MT style starter
Replaces this10 MT style starter
��
50109HEaVY-DUTYfITs: CHRYslER318MarineV8Two-bolt mount, 1 threaded hole12Volt,CW rotation
5011012 Volt,CCW Rotation
50137HEaVY-DUTYfITs: CHRIs CRafT anD oTHERsThree-bolt mount, (two3/8”holes,one5/16”threadedhole)12 Volt,CW Rotation
5013812 Volt,CCW rotation
50143HEaVY-DUTYfITs: MERCRUIsER 470Threadedmountingstudincase12Volt,CW rotation
50141HEaVY-DUTY12Volt,CCW rotation
50142HEaVY-DUTYfITs: CHRIs CRafT, VolVo PEnTa V8Two-bolt mount12Volt,CW rotation
50160HEaVY-DUTYfITs: CHRIs CRafTThree-bolt housing12Volt,CW rotation
50161HEaVY-DUTYfITs: CHRIs CRafT12Volt,CCW rotation
REPlaCEMEnT InboaRD sTaRTERs
Rust, Corrosion or Submersions are NOT COVERED BY WARRANTYTECH TIP
treats every component with special rust and corrosion resistant coatings to prevent water damage. However, it is impossible to protect the unit from direct contact with water. Therefore, a failure directly caused by rust, corrosion or submersion is not covered by warranty.
50134HEaVY-DUTYfITs: CHRIs CRafT, HaRMan MaRInEThree-bolt mount (two3/8”holes,one5/16”threadedhole)12Volt,CW Rotation
5013512 Volt,CCW rotation
��
70106fITs: CRUsaDER anD oTHERs W/foRD EnGInEsnose extends 2” into flywheelTwo-bolt mount12Volt,CW rotationside battery terminal
sW394Replacementsolenoid
To be discontinued when present stock is exhausted.
50169HEaVY-DUTYfITs: MERCRUIsER888, 302, 351 foRDsTwo-bolt mount12Volt,CW rotation
sW394Replacementsolenoid
70108fITs: 460 foRDsHeavy Duty12Volt,CW rotation
70117fITs: ManY laTE MoDEl foRDsModllstyle;4 ½” diameter casenose extends �⅜” into flywheelTwo-bolt mount12Volt,CW rotationRear battery terminal
To be discontinued when present stock is exhausted.
To be discontinued when present stock is exhausted.
70125 (nEW)Permanent magnet Gear-reduction starterfITs: ManY laTE MoDEl 5.0l, 5.8l foRDs12Volt,CW rotation
sW125Replacementsolenoid
Electrical Technical ManualPublished by Mechanics for Mechanics
Order YourCopy Today!
REPlaCEMEnT InboaRD sTaRTERs
TM001Electrical Technical Manual
Rust, Corrosion or Submersions are NOT COVERED BY WARRANTYTECH TIP
treats every component with special rust and corrosion resistant coatings to prevent water damage. However, it is impossible to protect the unit from direct contact with water. Therefore, a failure directly caused by rust, corrosion or submersion is not covered by warranty.
��
70200 (nEW)HIGH PERfoRManCEPermanent magnetGear-reduction starterfITs: 302, 351 foRDs12 Volt,CW rotationKit includes wiring harness to replace conventional starter.
70201 (nEW)HIGH PERfoRManCECCW RoTaTIonSameasaboveexceptCCW rotation.
sW125Replacementsolenoid
70212 (nEW)HIGH PERfoRManCEPermanent magnet Gear-reduction starterfITs: 460 foRD EnGInEsReplaces: o.M.C.98801312 Volt,CW rotationTwo-bolt mount with 3/8” x 18threaded mounting ear. Kit includes wiring harness to replace conventional starter.
sW125Replacementsolenoid
Will also replaceconventional style starter
90105 (nEW)fITs: REnaUlT & MERCRUIsER70,80,90series,PaRIs RHonEThree-bolt mount12Volt,CW rotation
90110 (nEW)fITs: bUKH & RUGGERInI DV8,RD80,180,181,RF140seriesReplaces: PaRIs RHonE D9E50Two-bolt mount12Volt,CCW rotation
70216 (nEW)HIGH PERfoRManCEPermanent magnet Gear-reduction starterfITs: 2.3l foRD EnGInEsReplaces: o.M.C.98801212Volt,CW rotationThree-bolt mount.Kit includes wiring harness to replace conventional starter.
sW125Replacementsolenoid
REPlaCEMEnT InboaRD sTaRTERs
Rust, Corrosion or Submersions are NOT COVERED BY WARRANTYTECH TIP
treats every component with special rust and corrosion resistant coatings to prevent water damage. However, it is impossible to protect the unit from direct contact with water. Therefore, a failure directly caused by rust, corrosion or submersion is not covered by warranty.
Will also replaceconventional style starter
Will also replaceconventional style starter
��
90120 (nEW) fITs: PERKIns, REnaUlT MaRInE, VolVo PEnTaReplaces: PaRIs RHonED11E119TThree-bolt mount12Volt,CW rotation
sW814Replacementsolenoid
90125 (nEW)24 Volt, CW rotationfITs: PERKIns, REnaUlT MaRInE, VolVo PEnTaReplaces: PaRIs RHonE D11E122TThree-bolt mount
95949 (nEW)fITs: REnaUlT MaRInE, VolVo PEnTaReplaces: PaRIs RHonED11E126,D11E156Three-bolt mount12Volt,CW rotation
sW814 Replacementsolenoid
97225 (nEW) Gear-reduction starterfITs: VolVo PEnTaTMD40,TMD41,KAD42andothers.Replaces: PaRIs RHonE/ValEoD9R116,D9R144,Three-bolt mount,12Volt,CW rotation
sW225Replacementsolenoid
DV225Replacementdrivegear
98170lucas M45G starterfITs: PERKIns 4-108Vapropulsion13-tooth drive gear12volt,CW rotation
98175Mitsubishi gear reduction starterfITs: WEsTERbEKE9-tooth drive gear12volt,CW rotation
97308 (nEW)bosch style starterfits: TaMD120a, TaMD120b,VolVo PEnTa 24Volt, 11-Tooth Drive GearCW rotation
To be discontinued when present stock is exhausted.
REPlaCEMEnT InboaRD sTaRTERs
Rust, Corrosion or Submersions are NOT COVERED BY WARRANTYTECH TIP
treats every component with special rust and corrosion resistant coatings to prevent water damage. However, it is impossible to protect the unit from direct contact with water. Therefore, a failure directly caused by rust, corrosion or submersion is not covered by warranty.
��
12100fITs: ManY sMall PERKIns DIEsEls10-tooth gear12 Volt,CW rotation
1210110-tooth gear12 Volt,CCW rotation
12200fITs: ManY MID-sIzE PERKIns DIEsEls 4cyl10-tooth drive gear12Volt,CW rotation
10113 (neW)Gear-reduction starterfITs: VolVo PEnTa4cyl,6cylgasAluminumpinionhousingw/2threadedmountingholesPermanent magnet,12volt,CW rotation
98185 (neW)fITs: YanMaR4JH,QM20,2QM20,&2TenginesReplaces: HITaCHIS114-483,S114-815
12205fITs: CUMMIns MaRInE 6.9L, PEnInsUlaR 6.2L,379T,ETC.10-tooth drive gear12Volt,CW rotation
1220612Volt,CCW rotation
12202fITs: ManY MID sIzE PERKIns DIEsEls12-tooth drive gear12Volt,CW rotation
12213 (nEW)fITs: CUMMIns 6bT, PEnInsUlaR, 6.2L DIEsEl, ETC.10-tooth drive gear12Volt,CW rotation
98180 (neW)fITs: YanMaRGM,GM2,GM3,GM10,GM20/2-20F,GM30,GMF,1GM,2GM,3GMReplaces: HITaCHIS114-303,S114-303A
REPlaCEMEnT InboaRD sTaRTERs
Rust, Corrosion or Submersions are NOT COVERED BY WARRANTYTECH TIP
treats every component with special rust and corrosion resistant coatings to prevent water damage. However, it is impossible to protect the unit from direct contact with water. Therefore, a failure directly caused by rust, corrosion or submersion is not covered by warranty.
37
ReveRsable TilT-TRim moToRsToday’s tilt-trim motors use wire wound or permanent magnet fields. befoRe you can accuRaTely TesT The moToR you musT know whaT Type iT is.
Wire wound field motors will normally have three wires and will usually have four screws placed around the perimeter of the motor case. If the motor has only two wires; it is usually a permanent magnet field motor. However, some older Mercury Marine wire wound field motors have only two wires and use an external ground that is attached to the motor housing. Since wire wound field motors have a higher current draw, solenoids are used to relay battery current to the motor. Permanent magnet field motors draw much less current and miniature relays are used to relay the battery current.
RemembeR - blue sky (up) wiRe To posiTive makes The moToR Run in The up DiRecTionGReen GRass (Down) wiRe To posiTive makes The moToR Run in The Down DiRecTion
wire wound field motor
Connecting the blue lead to battery positive and the green lead to battery negative will make the motor run in the up direction. This will raise the outdrive or outboard motor.
Connecting the green lead to battery positive and the blue lead to battery negative will make the motor run in the down direction. This will lower the outdrive or outboard motor.
permanent magnet field motor
Tech Tips
Connecting the blue lead to battery positive and the black lead to battery negative will make the motor run in the up direction and will raise the outdrive or outboard motor.
Connecting the green wire to battery positive and the black wire to batterynegative will make the motor run in the down direction. This will lower the outdrive or outboard motor.
38
motor Running in The Down Direction
TilT-TRim moToR ReveRsinG Relays
peRmanenT maGneT fielD moToRs
motor Running in The up DirectionWhen the tilt-trim switch is moved to the up position, relay #2 activates supplying positive voltage to the blue wire by connecting terminal #87 to terminal #30.
Relay #1 remains in the off position. Terminal #87a and #30 are connected when the relay is in the off position. This allows the green wire to be connected to battery negative.
When the tilt-trim switch is moved to the down position, relay #1 activates supplying positive voltage to the green wire by connecting terminal #87 to terminal #30.
Relay #2 remains in the off position. Terminal #87a and #30 are connected when the relay is in the off position. This allows the blue wire to be connected to battery negative.
Tech Tips
39
TilT-TRim moToR solenoiDs
motor Running in The Down Direction
When the tilt-trim switch is in the down position,solenoid #1 is energized and battery positive voltage is supplied to the green wire making the motor run in the down direction. This lowers the outdrive or outboard motor.
wiRe wounD fielD moToRs
motor Running in The up DirectionWhen the tilt-trim switch is in the up, position solenoid #2is energized and battery positive voltage is supplied to the blue wire making the motor run in the up direction. This raises the outdrive or outboard motor.
Tech Tips
40
Replacement tilt/tRim motoRs &
RepaiR Kits
cutting a unit’s wires or dismantling a unit immediately voids the manufacturer’s warranty. Water can easily seep into the motor through cut wiring. in addition, taking a motor off the reservoir and trying to install it on an old reservoir usually damages the brushes in the motor. Disassembled parts are not covered by warranty.
Do not cut WiRes oR Dismantle units
6204 (neW) Fits: o.m.c. 3-wire connection 2-bolt mount
tR204 Repair kit
6206 (neW) Fits: o.m.c. 3-wire connection 3-bolt mount
tR206 Repair kit
6208 (neW)(motoR/ReseRvoiR only) Fits: o.m.c. 3-wire connection
tR208 Repair kit
6209 (neW) Fits: o.m.c. 2-wire connection
tR209 Repair kit
6211 (neW) Fits: o.m.c.stern-drive 1979-1985 2.5L, 3.0L 3-wire connection Ring Terminal Ends
tR211 Repair kit (cast aluminum)
tR210 Repair kit (stamped steel)
41
Replaces early square-style
motor
tR218Brush kit
6219Slow speed motor Fits Jack lift for racing outboards
Will also replace units with
this style shaft
Replacement tilt/tRim motoRs &
RepaiR Kits
6213 (neW) Fits: GooD automatic WinDlass Ring Terminal Ends
6217 (neW)(motoR/ReseRvoiR only) Fits: B.m.W., meRcRuiseR, volvo penta Includes: Screws, gasket & adapter Ring Terminal Ends
tR217 Repair kit
taK217 Screws, gasket, adapter
6214 (neW)motoR/ReseRvoiR only Fits: o.m.c. 1979-1985 3.8L, 4.3L, 5.0L, 5.7L Stern Drive Engines 2-wire connection
6218 (neW)(motoR only) Fits: meRcRuiseR i/o’s anD meRcuRy outBoaRDs W/oilDyne pump 12 Volt Ring Terminal Ends
6216 (neW)(motoR/ReseRvoiR only)Fits: chRysleR, o.m.c. 3-wire connection
42
Replaces this style prestolite pump
Fits oildyne pump only
m531 (neW)ReseRvoiR Kit Fits: 6227 Includes: Reservoir, cap, and o-ring
For new style 4 screw mount see m533 in
miscellaneous section
to be discontinued when present stock
is exhausted
Fits: o.m.c. pump no. 173946
tR228 Repair kit
Replacement tilt/tRim motoRs &
RepaiR Kits
6220 (neW) heavy-Duty Fits: o.m.c. 2-wire connection includes o-ring 3-bolt mount Male Spade Terminal Ends96” leads
R473 Relay available
6220X (neW) heavy-Duty, Fits: o.m.c. 2-wire connection, includes o-ring, 3-bolt mount Male Spade Terminal Ends62” leads
6227 (neW)(complete)Fits: volvo penta - thRu 1999 W/oilDyne pump
6232 (motoR only)
6223 (neW)heavy-DutyFits: volvo penta Female Spade Terminal Ends
6224 (neW)(complete)Fits: volvo penta Includes: Hydraulic valve body Ring Terminal Ends
6225 (neW)(motoR/ ReseRvoiR only)Fits: pRestolite
6228 (neW)heavy-Duty (motoR only) Fits: many small o.m.c. outBoaRDs Includes gasket
43
Replacement tilt/tRim motoRs &
RepaiR Kits
includes o-ring and adaptor to replace motors with hollow hex shafts
also Replaces oem motoRs With holloW heX shaFt
note:Distance between
mounting bolts: 2.3”Bolt size: 10x24 coarse thread
note:Distance between
mounting bolts: 2.5”Bolt size: 10x32 fine thread
6231 (neW) (motoR only)Fits: u.s. maRine W/oilDyne pump 2-wire connection Female Spade Terminal Ends
6239 (neW)heavy-DutyFits: honDa 1992-2002 35-50 HP 2-wire connectionincludes o-ring4-bolt mounthollow-hex shaftFemale SpadeTerminal Ends
6232 (neW)(motoR only)Fits: 6227, late moDelvolvo penta W/ oilDyne pump 2-wire connection
6233 (neW)Fits: late moDelvolvo penta sX moDels. Replaces Teleflex Motor and Volvo part number 3861575
6238 (neW)heavy-DutyFits: o.m.c. 1998-up 75 HP-250 HP FFIOutboard Engines 4-bolt mount, Female Sealed Terminal Ends includes o-ring
6240 (neW)heavy-Duty Fits: yamaha1997-up 115 HP 2000-up 115 HP 4-stroke 1997-2000 130 HP 1997-up 150-200 HP 1998-up 225 HP 2-wire connection 4-bolt mount, Ring Terminal Ends includes o-ring
6241 (neW)heavy-Duty Fits: o.m.c. 60, 70, 90, 115, 150, 175 HP 1991-up 200, 225 HP 1991-94 120, 140 HP 1995-up 50 HP 3-cyl, 60 HP, V4 130 HP1997-up 115-200 HP 1998-99 225 HP 2-wire connection4-bolt mountFlat-blade shaftFemale Spade Terminal Ends
R473 Relay available
44
Replacement tilt/tRim motoRs &
RepaiR Kits
this motor will not replace an early model mercury cartridge pump motor!
order part no. 6278
to be discontinued when present stock is exhausted
taK247mounting bolts, flat washers, o-ring and couplers
taK247mounting bolts, flat washers, o-ring and couplers
6242 (neW)heavy-DutyFits: o.m.c. 1992-up J-suffix 40, 48, 50 HP 2-wire connectionincludes o-ring, 4-bolt mounthollow-hex shaftFemale Spade Terminal Ends
R473 Relay available
6243 (neW)heavy-DutyFits: o.m.c. 1989-1992 M-suffix 40, 48, 50 HP2-wire connection;4-bolt mount, includes o-ringhollow-hex shaftMale Spade Terminal Ends
R473 Relay available
6244 (neW)heavy-DutyFits: o.m.c. 1993 V6 1993-up Commercial V8 2-wire connection;3-bolt mount, includes o-ring Flat-blade shaftFemale Spade Terminal Ends
R473 Relay available
6245 (neW)heavy-DutyFits: o.m.c. coBRa 1989-1993 Stern drives (all models)volvo 1994-up 3.0-8.2L2-wire connection;3 bolt mount, Flat-blade shaftincludes o-ringFlag Connector Terminal Ends
6247 (neW)heavy-DutyFits: evinRuDe etec 2005-2009 70-90 HP2007-2009 115 HP2009- 130 HP2-wire connection4-bolt mount, includes taK247 mounting kit, Flat-blade shaft
6248 (neW)heavy-DutyFits: evinRuDe etec 2005-2009 40-50 HP2006-2009 60 HP2009- 25-30 HP2-wire connection4-bolt mount, includes taK247 mounting kit, Flat-blade shaft
6250 (neW)heavy-DutyFits: late model meRcuRy 135, 150 XR6, Magnum lll, 175, 200, 225, 250 HP, 105-140 HP Jet2-wire connection, 2-bolt mountincludes o-ring ,Flat-blade shaftBullet Connector Terminal Ends
45
6261 (neW)heavy-DutyFits: yamaha 1999-2004 75, 80, 90 &100 HP 4 stroke O/B Engines2-wire connection 4-bolt mount, Ring Terminal Ends includes o-ring
Replacement tilt/tRim motoRs &
RepaiR Kits
6255 (neW) heavy-DutyFits: late modelmeRcuRy/FoRce 25-50 HP outboards 2-wire connection4-bolt mountFlat-blade shaftBullet Connector Terminal Ends
6259 (neW) heavy-DutyFits: yamaha2001-2004 50 HP 4 stroke2002-2004 60 HP 4 stroke2001-2006 40 HP 2 stroke (tlR)2003-2009 50 HP 2 stroke (tlR)2-wire connection 3-bolt mountincludes o-ringRing Terminal Ends
6260 (neW)heavy-DutyFits: yamaha 1992-2002 90 HP 1992-1995 50-90 HP 1994 40 HP; 1996 70-90 HP 1997-up 60, 70, 90 HP2-wire connection, 3-bolt mountincludes o-ringFlat-blade shaftRing Terminal Ends
6263 (neW)heavy-DutyFits: yamaha 2002-2009 200, 225, 250 HP 4 stroke2002-2009 200-300 HP2 stroke2-wire connection 3-bolt mountincludes o-ringRing Terminal Ends
6264 (neW) heavy-DutyFits: yamaha 1985-1992 40-50 HP 2-wire connection 4-bolt mount, includes o-ring Ring Terminal Ends
6265 (neW) heavy-DutyFits: yamaha 1987-1995 115-200 HP Outboards1990-1993 225 HP 2-wire connection3-bolt mountincludes o-ringFlat-blade shaftRing Terminal Ends
6258 (neW) heavy-DutyFits: yamaha2005-up 75 HP 4 stroke2005-up 90 HP 4 stroke2-wire connection 4-bolt mountincludes o-ringRing Terminal Ends
46
Replacement tilt/tRim motoRs &
RepaiR Kits
For new style 4 screw mount mercruiser 883166a2 see m532
in miscellaneous section
m525 (neW)Reservoir kitFits: 6275includes: Reservoir, cap, o-ring, mounting screw
6266 (neW)Fits: yamaha1995-up 40/50 HP2-wire connection 3-bolt mountincludes o-ringRing Terminal Ends
6267 (neW)Fits: yamaha Early 70, 90,115, 150-200 HP 3-wire connection3-bolt mountRing Terminal Ends 4-mm thick shaft blade with 68.3-mm mounting collar.includes o-ring
6268 (neW)Fits: suzuKi 1991-1997 DT90, 1991-2000 DT100, 1991-2003 DT150, 1991-1992 DT175, 1991-2000 DT200, 1991-2003 DT2252-wire connection3-bolt mountincludes o-ring and adaptor Ring Terminal Ends
6269 (neW)Fits: suzuKi DT 150/2003-wire connection3-bolt mountincludes o-ringRing Terminal Ends
6270 (neW) (complete)Fits: late model meRcuRy 225-275 HP Outboards w/Oildyne pumpRing Terminal Ends
6271 (neW)(complete)Slow speed unit used for racingapplications
6274 (neW)heavy-DutyFits: late modelmeRcuRy/maRineR& FoRce 75-125 HPoutboards w/singleram 3-wire connection;4-bolt mountHollow-hex shaft(Motor/Reservoir Only for TrimPump Assembly 824051) includes stainless steelmounting screws, shaft adaptor, o-ringand fill plug.Ring Terminal Ends
6275 (neW)(complete)Fits: late model meRcRuiseR w/Oildyne pumpRing Terminal Ends
6218 motoR only
47
siDe Fill ReseRvoiR
aFt Fill ReseRvoiR
Replaces this square motor
tR279 Repair kit
Replacement tilt/tRim motoRs &
RepaiR Kits
motor Will not replace original equipment. order part no. 6278
Will also replace these style units
tR277Repair kit
6276 (neW)heavy-DutyFits: late model meRcuRy/maRineR, FoRce40-125 HP outboards w/single ram2-wire connection4-bolt mount
Hollow-hex shaft(Motor/Reservoir Only) includes stainless steel mounting screws, shaft adaptor, o-ring and fill plug.Bullet Connector Terminal Ends
taK276mounting bolts, o-ring, fill cap andshaft adapters for tilt/trim motors
6277 (neW)heavy-Duty(motoR only)Fits: cartridge pump 6278 only!2-bolt mountRing Terminal Ends
6278 (neW)(complete) hiGh-peRFoRmanceCartridge pump w/replaceable motor Fits: meRcuRy/maRineR35-220 HP Outboards 2-bolt mountw/Design I, 3 ram, 3-wire tilt/trim units W/siDe Fill ReseRvoiRReplaces square-style Eaton, round-style Prestolite
tR277 Repair kit
6279 (neW)heavy-DutyFits: meRcuRy/maRineR outboards w/Design II3 ram, three-wire trim unitsHollow-hex shaftW/aFt Fill ReseRvoiR3-wire connection2-bolt mountshaft adaptor and o-ring included.Ring Terminal Ends
48
AlternatorPulley
CrankshaftPulley
for every 23 amps of alternator output about one horsepower is required.FOR EXAMPLE: A 12 volt, 115 AMP alternator requires 5 horsepower.(115 divided by 23 = 5 horsepower). A 24 volt unit requires twice the horsepower.
* enGine hoRsepoweR ReQuiReD foR alTeRnaToRs
A common practice with the old generator system was to disconnect the battery cable while the engine wasrunning to see if the generator was working. If this procedure is done on today’s transistorized alternatorsystems, severe damage to the internal components of the alternator usually will be the end result.This includes using a battery selector switch while the engine is running.
Alternators are designed to supply current for the accessory load and maintain the charge of the battery.most alternators can safely charge at only two-thirds of their maximum rated output. When trying torecharge a dead battery, the alternator will charge at maximum output for extended periods of time causingthe alternator to overheat. high heat destroys transistors, diodes and windings.
Just because the alternator looks like it’s turning, doesn’t mean it’s turning fast enough to charge. mostalternators do not start charging until they reach 1,000 Rpm alternator shaft speed. 5,000 RPM alternatorshaft speed is normally required to reach maximum output. If you’re not sure what the alternator shaftspeed is, you can determine this with the pulley ratio. Measure the diameter of the crank shaft or drivepulley and the alternator pulley. Divide the crank shaft pulley diameter by the alternator pulley diameter.This figure would be the engine-to-alternator RPM ratio. A normal ratio would be 2.5 to 1. For example,let’s say we have a 7 inch diameter crank shaft pulley and a 2.75 inch alternator pulley. We would divide 7inches by 2.75 which equals 2.54 to 1. If the engine was turning 1,000 RPM we would multiply 1,000 by2.54 which would give us 2,540 alternator RPM.
again, with today’s high amperage alternators, belt condition and tension are critical in properalternator performance.
One-wire alternators, sometimes referred to as self-exciting alternators, require battery voltage at the outputterminal in order to charge. Since battery isolators eliminate the battery voltage to the alternator, you mustuse a battery isolator with an ignition excite capability or modifications must be made to the alternator toallow ignition excitation.
* one-wiRe alTeRnaToRs can noT be useD wiTh baTTeRy isolaToRs
* alTeRnaToRs musT TuRn The pRopeR Rpm in oRDeR To funcTion
* neveR DisconnecT The baTTeRy cable when The alTeRnaToR is chaRGinG
* alTeRnaToRs will chaRGe when TuRninG in eiTheR DiRecTion
* alTeRnaToRs aRe noT baTTeRy chaRGeRs
chaRGinG sysTems
noTe: alTeRnaToRs aRe noT baTTeRy chaRGeRs
if you aRe able To TuRn The alTeRnaToR fan by hanD, you Do noT have The belT TiGhT enouGh.
Tech Tips
49
vaRious maRine appRoveD alTeRnaToR DesiGns
brush cover installed
Delco style alternators use flame arrestors instead of sealed brush compartments.
Alternators that are being installed on inboard gasoline engines must be certified to meet Coast Guard requirements for ignition protection. In order for the alternator to be certified, it must pass the testing procedure, Marine SAE J1171, laid-out by the Society of Automotive Engineers (SAE).
Brushes inside the alternator cause some sparking when the alternator is charging. This is normal for any alternator. When the alternator is exposed to a flammable atmosphere, such as an enclosed engine compartment on an inboard gasoline application with a fuel leak, the sparking from the brushes in the alternator may cause an explosion.
The Marine SAE J1171 testing procedure is as follows: A sparking device, similar to a spark plug, is installed in the brush area of the alternator. Another device is also installed in the brush area of the alternator to supply a specified mixture of propane gas and oxygen. The alternator is then placed in an explosion proof test chamber. The chamber and the alternator are then filled with the explosive gas mixture. A high-voltage coil supplies current to the sparking device in the brush area of the alternator, causing an explosion. An explosion must not occur in the test chamber while this test is being performed. This step is repeated nine times. Finally, a spark is supplied inside the test chamber causing an explosion to ensure that the explosive mixture was present during the testing operations.
alTeRnaToRs appRoveD foR maRine use
motorola style prestolite style
Delco style stainless steel 3-ply screens
brush cover installed
brush cover Removed
brush cover Removed
Tech Tips
50
common maRine alTeRnaToR ciRcuiTs
Many alternators require ignition voltage to initiate charging. You must verify that all required connections are connected to the proper terminal and have the correct voltage in order for the alternator to operate properly. Below you will find the most common alternator circuits used on marine applications.
alTeRnaToR ciRcuiTs
eaRly moToRola sTyle fiTs wesTeRbeke anD oTheRs
GROUND B-
IGNITION +
laTe manDo sTylefiTs meRcRuiseR anD oTheRs
B- GROUND
B+ OUTPUT
Delco sTyle fiTs meRcRuiseR & omc
ReD b+BATTERY SENSE
B+ OUTPUT
black GROUND B-
Delco self eXciTinG sTylefiTs meRcRuiseR anD omc
B- GROUND
B+BATTERY OUTPUT
BATTERY -GROUND
WTACHOMETER
TERMINAL
D+ OR 61INDICATOR LIGHT
B+BATTERY OUTPUT
valeo/paRis Rhone fiTs volvo penTa
ReDIGNITION +
AUX NOT USED
B- GROUND
B+ OUTPUT
eaRly pResToliTe sTyle fiTs omc
S
L2INDICATOR
LIGHT
PAC TAP
TACHOMETERTERMINAL
laTe moToRola/pResToliTe sTyle fiTs meRcRuiseR & omc
B+ OUTPUT
D+ INDICATOR LIGHT
(NOT USED)
GReenor yellow
FIELD
VOLTAGEREG
(SENSE)ReD b+BATTERY SENSE
(EXC) puRple or black IGNITION +
(EXC)puRple or black
WIRE IGNITION TERMINAL
puRple or black IGNITION +
ReDWIRE BATTERY
+SENSE
BBATTERY +
OUTPUT
laTe moToRola/pResToliTe sTyle fiTs u.s. maRine
B+BATTERYOUTPUT
(EXC)IGNITION +
AC TAPTACHOMETER TERMINAL
D+ INDICATOR
LIGHT
AC TAPTACHOMETER TERMINAL
(NOT USED)
B-GROUND
B-GROUND
E GROUNDB-
Tech Tips
51
for high-amp (12 volt, 105 amp) replacement alternator, see
60122 on page 57.
20500Universal-mount alternator12 volt, 70 amp Self excitingIgnition protection screens1-wire connectionsingle groove pulley included1-inch mounting footAdaptors available for 2” and 3” mounting configurations
20102 fiTs: meRcRuiseR, o.m.c.12 volt, 70 amp Self excitingIgnition protection screensInternal regulatorNegative ground1-wire connection2-inch mounting footsingle groove pulley included
for high-amp (12 volt, 105 amp)replacement alternator,see 60122 on page 57.
20100 fiTs: many Diesel enGines12 volt, 70 amp Self exciting internal regulator Negative ground1-wire connection2-inch mounting footsingle groove pulley included
20104 fiTs: meRcRuiseR, o.m.c.12 volt, 70 ampIgnition protection screensInternal regulator Negative ground2-wire plug2-inch mounting footsingle groove pulley included
20800 (new)fiTs: meRcRuiseR 4.3L - 8.2L 1998-up 12 volt, 70 amp Internal Fan65-mm multi-groove serpentine pulley included
ReplacemenT inboaRD
alTeRnaToRs
20810 (new)fiTs: meRcRuiseR 3.0l 1999-up 12 volt, 70 ampInternal Fansingle groove pulley included
20815 (new)fiTs: meRcRuiseR 4.3L-6.2L12 volt, 70 ampInternal Fan50-mm multi-groove serpentine pulley included
for high-amp (12 volt, 105 amp) replacement alternator, see 60122 on page 57.
20820 (new)fiTs: inDmaR, pleasuRecRafT, cRusaDeR, anD oTheRs12 volt, 70 ampInternal Fan2-inch mounting foot65-mm multi-groove serpentine pulley included
52
20825 (new)fiTs: inDmaR, pleasuRecRafT, cRusaDeR, anD oTheRs12 volt, 70 ampInternal Fan2-inch mounting footsingle groove pulley included
20826 (new)hiGh ampfiTs: pleasuRecRafT12 volt, 95 amp Internal Fan 2-inch mounting foot65-mm serpentine pulley included
95amp
20822 (new)fiTs: pleasuRecRafT12 volt, 70 ampInternal Fan2-inch mounting foot 65-mm serpentine pulley included
20821 (new)fiTs: pleasuRecRafT12 volt, 70 ampInternal Fan 2-inch mounting foot 50-mm serpentine pulley included
20830 (new)fiTs: maRine poweR12 volt, 70 ampInternal Fan2-inch mounting footDouble pulley included
20827 (new)
hiGh ampfiTs: inDmaR12 volt, 95 ampInternal Fan 2-inch mounting foot65-mm serpentine pulley included
20828 (new)
hiGh ampfiTs: maRine poweR12 volt, 95 ampInternal Fan 2-inch mounting footDouble pulley included
95amp
95amp
20840 (new)fiTs: 2.5l meRcuRy ouTboaRD12 volt, 50 ampInternal Fan2-inch mounting footmulti-groove serpentine pulley included
ReplacemenT inboaRD
alTeRnaToRs
53
40147 (new)fiTs: pleasuRecRafT, waukesha12 volt, 55 ampNegative ground2-inch mounting footsingle groove pulley included
vR406Replacement Regulator for Prestolite alternatornot required for replacement alternator.
40115 (new)fiTs: chRis cRafT12 volt, 55 ampNegative ground1-inch mounting footsingle groovepulley included
vR407 Replacement Regulator for Prestolite alternator not required for replacement alternator.
Replaces this style unit
Replaces this style unit
40112 fiTs: chRysleR maRine12 volt, 70 amp Internal regulatorNegative groundsingle groove pulley included
vR405Replacement Regulator for Prestolite alternatornot required for replacement alternator.
20850 (new)fiTs: 3.0l meRcuRy ouTboaRD12 volt, 50 ampInternal Fanmulti-groove serpentinepulley included
*will not replacemercury # 821663a-1
Replaces this style unit
40152 fiTs: o.m.c.12 volt, 70 ampInternal regulatorNegative groundsingle groove pulley included
vR404 Replacement Regulator for Prestolite alternator not required for replacement alternator.
Replaces this style unit
60050 (new)manDofiTs: laTe moDel meRcRuiseR12 volt, 55 ampInternal regulator2-inch mounting footsingle groove pulley included
m883Replacement Regulator
65050 (new)75 amp high-output also available
ReplacemenT inboaRD
alTeRnaToRs
54
60071 (new)manDo fiTs: laTe moDel volvo penTa12 volt, 65 ampInternal Regulator2-inch mounting footmulti-groove serpentine pulley included
60070 (new)manDofiTs: laTe moDel volvo penTa12 volt, 65 ampInternal Regulator2-inch mounting footsingle groove pulley included
60065 (new)manDofiTs: laTe moDel meRcRuiseR12 volt, 65 ampInternal regulator2-inch mounting footsingle groove pulley included
65050 (new)75 amp high-output also available
60060 (new)manDo fiTs: laTe moDelmeRcRuiseR12 volt, 65 amp Internal Regulator2-inch mounting footmulti-groove serpentine pulley included
65055 (new)75 amp high-output also available
60055 (new)manDo fiTs: laTe moDel meRcRuiseR12 volt, 55 ampInternal regulator 2-inch mounting footmulti-groove serpentine pulley included
m883Replacement Regulator
65055 (new)75 amp high-output also available
60072 (new)manDofiTs: laTe moDel volvo penTa12 volt, 65 ampmulti-grooveserpentine pulley included
ReplacemenT inboaRD
alTeRnaToRs
55
60125 (new)fiTs: o.m.c. cobRaReplaces: Prestolite/Motorola12 volt, 55 amp Internal regulatorNegative ground2-inch mounting footsingle groove pulley included
Replaces this style unit
60108 (new) fiTs: univeRsal anD oTheRs12 volt, 55 amp Internal regulator Negative ground2-inch mounting footsingle groove pulley included
65108 (new)75 amp high-output also available
Replaces this style unit
60104 (new)Replaces: moToRola12 volt, 55 ampInternal regulatorNegative ground1-inch mounting footsingle groove pulley included
Replaces this style unit
60075 (new) univeRsal alTeRnaToR w/ many applicaTionsfiTs: yamaha, maRine poweR, cRusaDeRReplaces Motorola 12 volt, 55 ampInternal regulator Includes:Tachometer terminal, indicatorlight terminal, remote batterysensing terminal1-inch mounting foot with 3-ear adjustmentsingle groove pulley included
m883Replacement Regulator
60073 (new)volvo penTafiTs: laTe moDel volvo penTa12 volt, 75 amp50-mm multi-groove serpentine pulley included
60074 (new)volvo penTafiTs: laTe moDel volvo penTa12 volt, 75 amp2-inch mounting footsingle groove pulley included
60076 (new)volvo penTafiTs: laTe moDel volvo penTa12 volt, 75 amp63-mm multi-groove serpentine pulley included
ReplacemenT inboaRD
alTeRnaToRs
50mm
63mm
56
12 volT, 105 amp - hiGh amp alTeRnaToRs Today’s increased electrical loads and more sophisticated electronics demand improved performance, greater reliability, and higher output from the electrical generating system. ’s creative engineering offers a 105 amp series as the means to a totally efficient electrical system. For comparison, just look at the Performance Chart at the bottom of the page!
60122 (new)hiGh-amp12 volt, 105 ampSelf exciting integral regulatorIsolated groundIncludes: Tachometerterminal.External voltage adjustment. 2-inch mounting foot, 3/8” holesingle groove pulley included
60126 (new)hiGh-ampfiTs: late model volvo penTa w/warning panel connection12 volt, 105 ampIntegral regulatorIsolated groundIncludes: Tachometer terminal2-inch mounting foot, 10mm holesingle groove pulley included
for applications wiThouT warning panel connection, use 60124
60121(new)hiGh-amp 12 volt, 105 ampSelf exciting Integral regulatorIsolated groundIncludes: Tachometer terminal. External voltage adjustment.1-inch mounting foot, 1/2” hole single groove pulley included
60124 (new)hiGh-ampfiTs: volvo penTa12 volt, 105 ampSelf excitingIntegral regulatorIsolated groundIncludes: Tachometer terminalExternal voltage adjustment2-inch mounting foot, 10mm holesingle groove pulley included
60498 (new)hiGh-ampfiTs: caTeRpillaR Diesel 6T139612 volt, 105 ampIntegral regulatorIsolated groundHeavy duty bearings1-inch mounting footpulley noT incluDeD
Compare the power
105amp105
amp
105amp
105amp
105amp
for applications wiTh warning panel connection, use 60126
ReplacemenT inboaRD
alTeRnaToRs
57
60175 (new)Prestolite/Motorola24 volt, 100 ampIntegral regulatorIsolated ground7” casingpulley noT incluDeD
60170 (new)Prestolite/Motorola24 volt, 175 ampIntegral regulatorIsolated ground7” casingpulley noT incluDeD
60160 (new) Prestolite/Motorola12 volt, 160 ampIntegral regulatorIsolated ground7” casingpulley noT incluDeD
60150 (new)Prestolite/Motorola24 volt, 75 ampIntegral regulator Isolated ground7” casingpulley noT incluDeD
60197 (new)fiTs: caTeRpillaR Diesel 6T139524 volt, 35 ampIntegral regulator. Isolated ground. Heavy duty bearings1-inch mounting footpulley noT incluDeD
To be discontinued when present stock
is exhausted
60195 (new)Prestolite/MotorolafiTs: cummins Diesel12 volt, 65 ampInternal regulator Negative ground2-inch mounting footpulley noT incluDeDpoly-v pulley available separately
60180 (new)Prestolite/Motorola32 volt, 100 ampIntegral regulatorIsolated ground7” casingpulley noT incluDeD
60198 (new)fiTs: caTeRpillaR Diesel 6T139612 volt, 51 ampintegral RegulatorIsolated groundHeavy duty bearings1-inch mounting footpulley noT incluDeD
for high-amp (12 volt, 105 amp)
replacement alternator see 60498 on page 57.
To be discontinued when present stock
is exhausted
ReplacemenT inboaRD
alTeRnaToRs
58
84135hiTachi maRinefiTs: yanmaR Diesel12 volt, 35 ampInternal regulatorsingle groove pulley included
86050fiTs: wesTeRbeke12 volt, 50 ampInternal regulatorsingle groove pulley included
84150hiTachi maRinefiTs: yanmaR Diesel12 volt, 50 ampInternal regulatorsingle groove pulley included
80108 (new)fiTs: laTe moDel volvo penTaDiesel enGines12 volt, 55 ampInternal regulator2-inch mounting footpulley noT incluDeD
for high-amp (12 volt, 105 amp)
replacement alternator see 60124/60126
on page 57.
83160 (new)fiTs: lehman, peRkins, eTc.12 volt, 75 ampwith regulatorsingle groove
80200 (new)paRis Rhone/valeo fiTs: bauDoin, bukh, volvo penTaDiesel enGines24 volt, 30 ampIntegral regulator2-inch mounting footpulley noT incluDeD
To be discontinued when present stock
is exhausted
ReplacemenT inboaRD
alTeRnaToRs
59
Typical baTTeRy isolaToR ciRcuiTs
The two alternator, two battery isolator allows both alternators to charge both batteries.
The one alternator, two battery isolator with a battery selector switch will allow both banks of batteries to be charged regardless of what position the battery selector switch is in.
in the event of one alternator failure, both batteries would be maintained
by the working alternator.
Remember, when batteries are connected in parallel, they become one large battery.
The most common battery isolator is the one alternator, two battery unit. It doesn’t matter how many batteries are connected in parallel to the battery 1 or 2 terminal.
Tech Tips
60
inboaRD/ouTboaRD baTTeRy isolaToRs
bi-0702-41 Alternator, 2 Batteries70 AMP maxIncludes: Regulator sensing terminal
bi-07031 Alternator, 3 Batteries70 AMP max
bi-12021 Alternator, 2 Batteries120 AMP max
bi-1202-3a1 Alternator, 2 Batteries120 AMP maxIncludes: Exciter Terminal
bi-12031 Alternator, 3 Batteries120 AMP max
bi-07021 Alternator, 2 Batteries70 AMP max
bi-1203-3a1 Alternator, 3 Batteries120 AMP maxIncludes Exciter Terminal
bi-16021 Alternator, 2 Batteries160 AMP max
Battery isolators are solid-state devices which allow electrical current to flow in one direction only, thus permitting the alternator to be connected directly to two batteries without fear of one higher charged battery discharging into the lower charged battery. Both batteries are always being charged automatically, in proportion, to their needs, whenever the engine is running. When battery isolators are used in conjunction with selector switches, it is not necessary to change the switch position to provide for charging of both batteries. Isolators provide proportioning of the output or charging current on the alternator to the batteries as required, regardless of switch position. Rated for use with 10 to 350 amp alternators on 12, 24, or 32 volt negative ground systems.
noTeBattery Isolators cannot be used on 12 volt charging systems with 24 volt trolling motors.
61
bi-27032 Alternators, 3 Batteries70 AMP max
bi-32022 Alternators, 2 Batteries120 AMP max
bi-16031 Alternator, 3 Batteries160 AMP max
bi-24021 Alternator, 2 Batteries240 AMP max
bi-27022 Alternators, 2 Batteries70 AMP max
bi-32032 Alternators, 3 Batteries120 AMP max
bi-2703-42 Alternators, 3 Batteries70 AMP maxIncludes: Regulator sensing terminal
inboaRD/ouTboaRD baTTeRy isolaToRs
noTeBattery Isolators cannot be used on 12 volt charging systems with 24 volt trolling motors.
62
When electrical systems are designed, the wire size is calculated for the specific requirements of the electrical components being used. when electrical components are added or upgraded, the wire size has to be upgraded also. for example, replacing a low torque starter with a high torque starter will normally require the battery cables and possibly the battery to be upgraded. when in DoubT, always use a biGGeR wiRe.
a word about wire gauge The size of a wire (gauge) is expressed in terms of a standard american wire Gauge (awG) measurement. The higher the awG number, the smaller the wire. for example, a 14 gauge wire is smaller than a 10 gauge wire. The smaller the wire, the greater its resistance to the flow of electrons and the greater the heat generated when the wire is conducting electricity. The heat can destroy insulation and even kindle a fire. The laRGeR The ampeRaGe of a ciRcuiT, The laRGeR The wiRe ThaT is neeDeD.
Think of wiring as a water hose.The electrical current is like water flowing through the hose. The source or supply of this water would be the battery and alternator. Look at the diagrams below. The first diagram shows a one inch diameter hose which allows one gallon per minute of flow. Since the load requires only a gallon per minute of flow, we can say that this hose (wire size) is of sufficient size to carry the supply of water (current) to the load. This all changes when we reduce the water hose (wire size) to one half inch as shown in the second diagram. The hose (wire) can only deliver half the current needed by the load— this hose (wire) is NOT of sufficient size to carry the needed supply of water (current) to the load.
wiRinG
biGGeR (ThickeR) is beTTeR!The higher the awG number, the thinner the wire.
The larger the amperage of a circuit, the thicker the gauge of the wire that is needed.
load requires 1 gallon per minute of flow at 12 volts. Since the load requirement is met we can determine the hose (wire) size is “OK.”
— source of flow alternator and battery 12 volt
adequate wire size (gauge) inadequate wire size (gauge)
load requires 1 gallon per minute of flow at12 volts, but only half that mount can be delivered. Therefore, the hose (wire) size is too small.
— source of flow alternator and battery 12 volt
1 inch diameter hose
1/2 inch diameter hose
Tech Tips
wiring is just as important as any other component in the starting and charging system. it must be capable of delivering the amount of current that the load is demanding.
63
volTaGe is much like waTeR pRessuRe. When calculating proper wire sizing, voltage plays a very important role. Voltage is much like water pressure. The higher the voltage, the faster the current flows.
a 24 volt system can move the same amount of current through a wire one half the size required for a 12 volt system. This is also shown in the charging cable size chart on the following page. Notice that the 24 volt cable size requirements are much less than that of the 12 volt.
wiRinG anD volTaGe
— source of flow alternator and battery 24 volt
1/2 inch diameter hose
Load requires 1 gallon per minute of flow. 1/2 inch diameter hose allows
1 gallon per minute of flow at 24 volts.
— source of flow alternator and battery 12 volt
Load requires 1 gallon per minute of flow. 1 inch diameter hose allows
1 gallon per minute of flow at 12 volts.
1 inch diameter hose
The higher the voltage, the faster the current flows.
Tech Tips
64
UP TO 75” 75” - 125” 125”-175” 175”-225” 225”-275” 275”-325” 325”-425”
4 2 1 0 2/0 3/0 4/0
4 - 6 - 8 cylinder Gasoline engine
minimum sTaRTinG cable GauGe sizefoR mosT inboaRD Gasoline enGine applicaTions
Total cranking circuit length in inches
minimum battery cable size
0-20 AMPS 14 GA. 12 GA. 12 GA. 10 GA. 10 GA. 8 GA. 8 GA. 8 GA.
20-35 AMPS 12 GA. 10 GA. 8 GA. 8 GA. 6 GA. 6 GA. 6 GA. 4 GA.
35-50 AMPS 10 GA. 8 GA. 8 GA. 6 GA. 6 GA. 4 GA. 4 GA. 4 GA.
50-65 AMPS 8 GA. 8 GA. 6 GA. 4 GA. 4 GA. 4 GA. 4 GA. 4 GA.
65-85 AMPS 6 GA. 6 GA. 4 GA. 4 GA. 2 GA. 2 GA. 2 GA. 0 GA.
85-105 AMPS 6 GA. 6 GA. 4 GA. 2 GA. 2 GA. 2 GA. 2 GA. 0 GA.
105-125 AMPS 4 GA. 4 GA. 4 GA. 2 GA. 2 GA. 0 GA. 0 GA. 0 GA.
125-150 AMPS 2 GA. 2 GA. 2 GA. 2 GA. 0 GA. 0 GA. 0 GA. 00 GA.
0-20 AMPS 14 GA. 14 GA. 14 GA. 12 GA. 12 GA. 12 GA. 10 GA. 10 GA.
20-35 AMPS 12 GA. 12 GA. 12 GA. 10 GA. 10 GA. 8 GA. 8 GA. 8 GA.
35-50 AMPS 10 GA. 10 GA. 10 GA. 10 GA. 6 GA. 6 GA. 6 GA. 6 GA.
50-65 AMPS 8 GA. 8 GA. 8 GA. 8 GA. 6 GA. 4 GA. 4 GA. 4 GA.
65-85 AMPS 6 GA. 6 GA. 6 GA. 6 GA. 6 GA. 6 GA. 4 GA. 4 GA.
85-105 AMPS 6 GA. 6 GA. 6 GA. 6 GA. 4 GA. 4 GA. 4 GA. 2 GA.
105-125 AMPS 4 GA. 4 GA. 4 GA. 4 GA. 4 GA. 4 GA. 2 GA. 2 GA.
125-150 AMPS 2 GA. 2 GA. 2 GA. 2 GA. 2 GA. 2 GA. 2 GA. 2 GA.
Type of ouTpuT UP TO 4 FT. TO 7 FT. TO 10 FT. TO 13 FT. TO 16 FT. TO 19 FT. TO 22 FT. TO sysTem in ampeRes 4 FT. 7 FT. 10 FT. 13 FT. 16 FT. 19 FT. 22 FT. 28 FT.
ToTal lenGTh incluDinG GRounD cable
12 volT
24 volT
minimum chaRGinG cable GauGe size
Below you will find the recommended wire sizes for charging and starting systems. iT is veRy impoRTanT To incluDe The GRounD cable when calculaTinG The ToTal lenGTh of The sysTem.
RecommenDeD wiRe sizes
The ground cable must carry the same amount of current as the positive cable.
when in DoubT - - - - biGGeR is beTTeR!
Tech Tips
65
solenoiD Types anD ciRcuiTs
Both ends of the coil in this unit are insulated. A separate ground must be connected and this type of solenoid can be mounted on any surface.
This type of solenoid is normally used for starting motors. Since conventional ignition coils operate on 7 volts, the relay terminal supplies 12 volts to the ignition coil during starting for easier starts. The base of this solenoid must be grounded.
solenoiDs eQuippeD wiTh Relay TeRminal
insulaTeD base solenoiDs
GRounDeD base solenoiDs
One end of the coil is grounded to the mounting base. This type so leno id must mount on a grounded surface or a ground must be attached to the base.
many of the remote mount solenoids look identical on the outside.However, they can be very different on the inside. Beside the different internal circuits, these can be rated for continuous duty or intermittent duty use.
continuous duty solenoids are wound with very fine wire and draw very little amperage. The contacts in continuous duty solenoids will usually have a lower amperage rating than that of the intermittent duty type. These are normally used as tilt trim relays. This type of solenoid can also be used for a variety of applications where a remote relay is needed to power a motor or other device.
intermittent duty solenoids are wound with much heavier wire and draw more amperage. The contacts have a very high amperage rating. If these stay energized for extended periods of time they heat up and eventually burn out the coil inside the solenoid. This type of solenoid is normally used as a starter motor relay.
Tech Tips
66
step 1: Check the voltage on the battery side of the solenoid as shown on the left. The reading should be the same as the battery reading (12.6V = Full Charged Battery).
step 2: With the voltmeter still connected, turn the key to the start position and read the voltage. The voltage should not drop below 10.0 volts on this terminal. If the voltage drops below 10.0 volts, The battery cable should be cleaned or replaced. If the reading is 10.0 volts or more move on to step 3.
step 3: Keep the negative voltmeter lead on the metal base of the solenoid and move the positive voltmeter lead to the terminal marked “S” on the solenoid. Turn the key to the start position and read the voltage. The Voltage could read a little lower than the previous reading but should never be below 10.0 volts. If the voltage is lower than 10.0 volts, You must troubleshoot the start circuit (ignition switch, voltage supply to the ignition switch, neutral safety switch).
step 4: Move the positive voltmeter lead to the battery terminal on the solenoid and the negative voltmeter lead to the terminal that the starter cable is attached. Turn the key to the start position and read the voltage. The voltage should read no more than .3 volts. If the reading is more than .3 volts the contacts have excessive resistance and the solenoid should be replaced.
step 5: Some solenoids use a relay terminal on the solenoid to power fuel pumps or supply full battery voltage to ignition coils when the starter is activated. This terminal is usually marked “I” or “R”. Connect the voltmeter a shown. Turn the key to the start position. You should read no more than 0.3 volts. If you have more than 0.3 volts the solenoid should be replaced.
simple solenoiD TesTinG: GRounDeD base RemoTe solenoiDsnoTe: before performing These Tests you must fully charge and load Test The battery to verify it is Good.
To Ignition Coil +or Fuel Pump Relay
To Battery +
To Battery +
To Starter
To Ignition Switch
To Battery +
Tech Tips
67
step 1: Check the voltage on the battery side of the solenoid as shown on the left. The reading should be the same as the battery reading (12.6V = Full Charged Battery).
step 2: With the voltmeter still connected, activate the switch and read the voltage. The voltage should not drop below 10.0 volts on this terminal. If the voltage drops below 10.0 volts, the battery cable should be cleaned or replaced. If the reading is 10.0 volts or more move on to step 3.
step 3: Keep the negative voltmeter lead on the ground terminal of the solenoid and move the positive voltmeter lead to the terminal marked “S” on the solenoid. Activate the switch and read the voltage. The Voltage could read a little lower than the previous reading but should never be below 10.0 volts. If the voltage is lower than 10.0 volts, you must troubleshoot the switch circuit (toggle switch, push button switch, or voltage supply to these switches).
step 4: Move the positive voltmeter lead to the battery terminal on the solenoid and the negative voltmeter lead to the terminal that the starter cable is attached. Activate the switch and read the voltage. The voltage should read no more than .3 volts. If the reading is more than .3 volts the contacts have excessive resistance and the solenoid be replaced.
simple solenoiD TesTinG: insulaTeD base RemoTe solenoiDsnoTe: before performing These Tests you must fully charge and load Test The battery to verify it is Good.
To Battery +
To Load or Device
To Switch +
To Ground -
To Battery +
To Ground -
To Ground -
To Battery +
Tech Tips
68
Replacement SolenoidS
High Temp Housingfor Less Distortion
One PieceMoving Corewith SolidBrass Stem
Heavy DutyHigh TempCoil Assembly
Solid CopperMoving ContactCovers StudContacts for MoreContact Area
Studs are Molded in the Housing for More Precise Contacting
SW058 OEM StylEcOil & cOntact aSSEMbly
SW058HD cOil & cOntact aSSEMbly
SW054FitS: meRcRuiSeR, meRcuRyIsolated base12 Volt
SW058StandaRd-duty FitS: meRcRuiSeR, meRcuRyIsolated base12 Volt
SW058HdHeaVy-dutyFitS: meRcRuiSeR, meRcuRyIsolated base12 Volt
SW064FitS: meRcRuiSeR, meRcuRyIsolated base12 VoltWhite housing
SW081FitS: many applicationS; o.m.c. Isolated base12 Volt
SW097FitS: meRcRuiSeR, meRcuRyIsolated base12 VoltWhite housing
SW099FitS: meRcRuiSeR, meRcuRyIsolated base12 Volt
SW109FitS: meRcuRy/FoRceIsolated base12 Volt
69
pa450l2 1/4” Plunger for SW450
pa450S1 3/4” Plunger for SW450
Fits late model 30470.
Will also fit early model 30450 & all 30460.
Replacement SolenoidS
SW125 HeaVy-dutyFitS: FoRd 70125, 70200, 70201, 70212, 70216 gear reduction starters on late model 5.0L, 5.8L
SW295FitS: cHRySleR Isolated base12 Volt
SW340FitS: o.m.c. Isolated base12 Volt
SW225 HeaVy-dutyFitS: VolVo penta,Valeo gear reduction
SW268FitS: o.m.c. Grounded base12 Volt
SW394FitS: meRcRuiSeR & o.m.c. Grounded base12 Volt
SW275FitS: meRcuRy Isolated base12 Volt
SW450FitS: 30460, 304704 terminals 12 Voltplungers to fit these units muSt Be oRdeRed SepaRately-See BeloW
SW288FitS: o.m.c. Isolated base12 Volt
70
Replacement SolenoidS
SW456FitS: 14 mt 30456, 304574 Post, 3-Bolt Mount
SW590Starter SolenoidFitS: late model eVinRude e-tec engineSIsolated base
SW463 HeaVy-dutyFitS: o.e. delco pg 260, meRcRuiSeR, omc, VolVo pentathis solenoid will not fit 30460, 30470!
SW622FitS o.m.c. Isolated base12 Volt
SW486FitS: many HitacHi StaRteRS on yanmaR diesels12 Volt
SW661FitS: meRcuRy Isolated base12 Volt
SW565FitS: VolVo penta Isolated base12 Volt
SW730FitS: o.m.c. Grounded base12 Volt
SW580FitS o.m.c. 1993-up, 9.9 -15 HP OutboardIsolated base12 Volt
SW595FitS eVinRude e-tec 2010-up 15 HP-300 HP
71
Replacement SolenoidS
SW774FitS: cHRySleR, o.m.c. Replaces Chrysler 177917Grounded base12 Volt
SW814FitS: paRiS RHone d11e167t, etc.12 Volt
SW941FitS: yamaHaSolenoid
SW865HeaVy-duty12 Volt, 1000 ampParallel/solenoidIsolated ground
SW86624 Volt, 1000 amp
SW945FitS: yamaHa 2 & 4 StRoKe,meRcuRy 4 StRoKeStarter solenoid
SW950FitS: yamaHaSolenoid
SW924FitS: FoRce outBoaRdSChoke solenoidOrder plunger (below) separately
pa924Plunger to fit SW924
SW975FitS: delcoStandard solenoid12 Volt
SW925FitS: meRcuRy outBoaRdSChoke solenoid
SW926FitS: 75 Hp-V200 Hp meRcuRy outBoaRdSChoke solenoid
SW981FitS: meRcuRy Grounded base12 Volt
SW984FitS: delcoMetric solenoid12 Volt
72
outBoaRdRectiFieRS & Replacement
RelayS
aR351HeaVy-duty FitS: meRcuRy3-post Rectifier
aR103FitS: o.m.c.3-lead Rectifier
aR104FitS: o.m.c.4-lead Rectifier
R151FitS: meRcuRy &maRineR outBoaRdS12 Volt, 30 Amp
R177FitS: VolVo penta 12 Volt, 30 Amp
R202FitS: meRcRuiSeR12 Volt, 30 Amp
R211FitS: meRcuRy 12 Volt, 30 Amp
R012 continuous duty relay;12 Volt, 85 Amp
R024 24 Volt, 85 Amp
R036 32-36 Volt, 85 Amp
R473FitS: o.m.c. 12 Volt, 30 AmpR038
S.P.D.T. normally closed, continuous duty relay used w/many winch motorsIsolated ground, 12 Volt, 85 Amp
R040FitS: VolVo penta 12 Volt, 30 Amp
R509FitS: meRcuRy, maRineR & FoRce,outBoaRdS12 Volt, 30 Amp
73
Replacement RelayS & Voltage
RegulatoRS
R670FitS: VolVo penta 12 Volt, 30 Amp
R952FitS: VolVo penta 12 Volt, 30 Amp
VR095late model S.e.V. maRcHal,ReplaceS: VolVo penta 841688-5 Plastic case,12 Volt
R751FitS: meRcRuiSeR &meRcuRy VeRadooutBoaRdS12 Volt, 30 Amp
R832FitS: VolVo penta12 Volt, 30 Amp
VR404pReStolite maRineReplaceS: o.m.c. 38344012 Volt
R950 (neW)yamaHa o/B tilt/tRim RelayReplaceS: yamaHa 6E5 81950-011991 & up 115 HP, 1991 - 2004 130 HP,1991 & up 150 HP,1991 - 2000 175 HP,1991 - 1999 200 HP
R951 (neW)yamaHa o/B tilt/tRim RelayReplaceS: yamaHa 6E5 8195A-011991 & up 115 HP, 1991 - 2004 130 HP,1991 & up 150 HP,1991 - 2000 175 HP,1991 - 1999 200 HP
VR405pReStolite maRine FitS: cRuSadeR, palmeR, uniVeRSal, etc.ReplaceS: cHRySleR 284752712 Volt
VR406pReStolite maRineReplaceS: pleaSuRecRaFt RO98002, etc. 12 Volt
74
VoltageRegulatoRS &
miScellaneouS itemS
VR407pReStolite maRineFitS: oWenS yacHt, etc.ReplaceS: cHRiS cRaFt 16.60-0003112 Volt
VR512FitS: paRiS RHone/Valeo A13N147M, A13N148M late model VolVo penta 858840 12 Volt
BK899Replacement brushesFitS: most HitacHi jet ski, small outboard and snowmobile starters
BK900Replacement brushesFitS: ameRican-made permanent magnet outboard starters
dV225Fits: Valeo starter nos. D9R116, D9R144 used on VolVo penta diesel engines, starter No. 97225
dV450CW Rotation,11 tooth gearFitS: High performance Gear Reduction Starter 30470
m883Regulator assemblyFitS: late model mandoReplaceS meRcRuiSeR 811883
BH450 Brush Holder AssemblyFitS: 30460, 30470 High performance starters
dV456FitS: delco 14MT, 30456 Starters w/cW Rotation9-tooth gear
dV457FitS: delco 14MT, 30457 Starters w/ccW Rotation9-tooth gear
dV460FitS: High performance
30460 Gear Reduction Starter cW Rotation, 9 tooth gear
75
miScellaneouS itemS
m525Reservoir kitFitS: 6275Replaces: meRcRuiSeR includes: Reservoir, cap,o-rings, mounting screw
m531Reservoir kitFitS: 6227Replaces: Volvo includes: Reservoir, cap, o-rings
m532 Fits meRcRuiSeR 883166a2
m533 Fits VolVo-penta 3858077New style reservoir kit, heavy duty 4-screw mount. Improved design, will only fit late model oildyne pumps equipped with 4 mounting ears.includes: Reservoir, screws, cap, o-rings.
pa450S1¾” Plunger for SW450Fits 30460
pa450l2¼” Plunger for SW450Fits 30470
pa924Plunger to fit SW924Replaces: Force 839126-1
SR102Prestolite repair kitFitS: pReStolite 2-brush outboard starters
SR104Prestolite repair kitFitS: pReStolite 4-brush outboard starters
SR107 BRuSH loading toolmakes brush loading as simple as 1-2-3Perfect tool for loading outboard starter brushes.Fits most all size and shape caps.
mBK450Mounting bolt kit for gear reduction startersFitS: 30470 starter, 2 long mounting bolts, ⅜”-16 N.C. threads This kit will also fit all delco gear reduction starters w/staggered bolt mounting pattern
Required when replacing a 10mt Starterwith a gear Reduction Starter.
Will not Fit metric engines or 10mt starters.
mBK460Mounting bolt kitFitS: 30460 starter, ⅜”-16 N.C. threadsThis kit will also fit DELCO 10MT stylestarters w/1 short & 1 long mounting bolt
Will not Fit metric engines
tm001electrical technical manual
This easy-to-understand technical reference is written by Mechanics for Mechanics. Procedures are explained in basic terms with illustrated examples.
76
miScellaneouS itemS
dK440drive spring /retainer kit
taK217Screws, O-ring, and adapter for tilt/trim motorsFitS: 6217, pReStolite eRH4102
taK247Mounting bolts, flat washers, O-ring and couplers fortilt/trim motorsFitS: 6247 & 6248
dV1000HeaVy-dutyidler gear assemblySea-Doo, PWC 951cc
dV440 HeaVy-duty Replacement drive gearFitS: KaWaSaKi PWC 440 - 550cc
dV500HeaVy-duty Replacement drive gearFitS: yamaHa PWC 500cc
dK500drive spring/retainer kit
taK276Mounting bolts, O-ring, fill capand shaft adapters fortilt/trim motorsFitS: 6274 & 6276
WH800Wire connector.Fits alternators 20800, 20810, 20815, 20840, 20850,65050 & 65055
WH826Wire connector.Fits alternators 20826, 20827 & 20828
WH830Wire connector.Fits alternators 20820, 20821, 20822, 20825 & 2083060073, 60074 & 60076
dK580drive spring/retainer kit
dV650 HeaVy-duty Replacement drive gearFitS: Sea-doo pWc 580, 650, 720cc9-tooth drive gear
dV700 HeaVy-duty idler gear assembly FitS: yamaHa PWC 650, 701, 760cc
dV744HeaVy-duty idler gear assemblyFitS: polaRiS PWC 650-750cc
dV750HeaVy-duty idler gear assemblyFitS: KaWaSaKi 650, 750, 900cc
PArT NUmberQUiCk reFereNCe
chRis cRaft16.60-00031................ VR40716.61-00026................. 4011516.61-00042................. 5014216.61-00043................. 5014116.61-00044................. 5016016.61-00045................. 5016116.61-00048................. 5014116.61-00050................. 5016016.61-00051................. 5016116.61-00053................ VR406
chRysleR177917....................... SW7742095509.......................501102098300......................VR4052847527......................VR4052855927.......................501102875927.......................501102875928.......................501093527501.......................401123527502.......................40112449541-1........................6216455541...........................6216460917-1.................... SW295480955...........................5393490955...........................5393575955...........................5382F6169551........................5393
cRusadeR22611......................... SW29539049...........................6010439064...........................6010439200...........................6007542016......................... SW97542090...........................3045642091...........................3045742150...........................304579006320..................... SW774RU0050....................... SW456RU0050A.................... SW463RU0050B.................... SW463R130014..................... SW295
delco8400027.......................208228600514.......................208508600515.......................208408000500.........................54009000735.... 30470 & MBK4509000762.... 30470 & MBK4509000763.......................304609000768.... 30470 & MBK4509000789.... 30470 & MBK4509000819.... 30470 & MBK4509000820.......................304609000821.... 30470 & MBK450
delco9000822.......................304609000839.... 30470 & MBK4509000840.... 30470 & MBK4509000849.... 30470 & MBK4509000884 S/P.................304339000884 H/P..... 30470 & MBK4509000885.... 30470 & MBK4509000887.......................304629000888.......................304599000940.... 30470 & MBK4509000974.........................540019010612 ....................3045719010615 ....................3045719010617 ....................3045619020600.....................2081019020601.....................2080019020604.....................2081019020606.....................2082019020608.....................2082519020609.....................2080019020611.....................2081519020612 ....................2081519020616.....................2083019020617.....................2082119020703.....................2084019020704.....................2085019020706.....................2084019020707.....................20850
foRce811902........................DV394819222........................DV393819479A1.......................6276819480A1.......................6276820595........................SR39450-819085......................539350-819968-1...................732550-820193......................539450-F616955-1.................5393827675A1.......................625587-F660917................... R04089-F460917-1............ SW295F15189.........................SR393F15190......................... BK900F177917...................... SW774F575955......................... 5382F616955..........................5393
hitachiS106-07B .......................3421S106-07E .......................3421S106-07F .......................3421S108-80..........................3420S108-80A........................3420S108-80B........................3420S108-87A........................3423S108-94..........................3412S108-94A........................3412S108-94B........................3412S108-94C........................3412
hitachi S108-97..........................3422S108-97A........................3422S108-99B........................3425S108-112....................... 3412S108-120........................3412S114-221........................3424S114-221E......................3424S114-221F......................3424S114-221G......................3424S114-221H......................3424S114-221J......................3424S114-263B......................3427S114-303......................98180S114-303A....................98180S114-323........................3426S114-323A......................3426S114-323B......................3426S114-323C......................3426S114-415........................3410S114-415A......................3410S114-437........................3444S114-483......................98185S114-551........................3442S114-551A......................3442S114-552........................3428S114-552A......................3428S114-555........................3440S114-559B......................3429S114-561........................3446S114-571........................3410S114-571A......................3410S114-660........................3428S114-660A......................3428S114-660B......................3428S114-667........................3410S114-673........................3444S114-674....................... 3442S114-677........................3446S114-815......................98185S114-817A....................98185S114-828B......................3430S114-836A......................3431S114-838A......................3432S114-867........................3433S114-867A......................3433
honda31200-ZV5-0130.............344631200-ZV5-003...............344631200-ZV6A-0130..........344631200-ZW5-003..............344736120-ZV5-821...............6239
KawasaKi13101-3701.................DV75013101-3703.................DV75013101-3705.................DV75013101-3706.................DV75059051-3005.................DV44059051-5007.................DV440
maRine pwR471200.........................20830471201.........................208304711210.......................208301210-000......................600500170-000......................304590171-000......................304570172-000......................304600174-000.....30470 & MBK450
maRineR50-97072M ................... 342450-97072T..................... 342450-97693M ................... 342050-804312T1 ................ 3430
meRcuRy12449...........................6005013037......................... SW97513310..........................DV38013310-1.......................DV38013310T1......................DV38014336A6.........................627514336A8.........................627514336A9.........................627514336A15 ..................... 627514336A17...................... 627514336A20...................... 627515382......................... SW97515386..........................SR38015386-001...................SR38017631.......................... TR21817631A1...................... TR21817649.............................621817649A1.........................621817649A02.......................621817649T...........................621818525A1 .......................M52525661......................... SW66125661-1 ..................... SW66125661T1..................... SW66125942......................... 5374-632082......................... SW08232701...........................2010233261......................... SW97543076..........................DV38543076T........................DV38547456A1.......................2010247886......................... SW62247886T....................... SW622514995.......................... 555154981......................... SW98154293A5..................... SW92554293A10................... SW92654293A11................... SW92554293A13................... SW92656045...........................2010257380..........................DV36659755...........................2010262351A1......................AR35162351A2..................... AR35163292.......................... BK90065057......................... SW98165057A1..................... SW981
PArT NUmberQUiCk reFereNCe
meRcuRy65057T1..................... SW98168571-1...................... DV36268575......................... DV37768575-3.......................DV39668575T2......................DV36569729...........................2010275383..........................SR37975384.......................... BK90075384-1....................... BK90075661..........................DV38078403A1.......................6005078403A2.......................6005078477...........................2010479215..........................SR3808M0007971....................34328M0031551....................62508M0058226.................AR3518M0064020..................208508M6000803..................208508M6000804..................208408000500.........................5400802587....................... DV393802587T..................... DV393802587T01................. DV393802639........................DV380802639T......................DV380802640........................DV325802640T......................DV325802665T......................DV394803822T .................... SW774805447T.......................60065805884T.......................60065807057.......................... R202807652T.......................60055807653T.......................60060809155..........................M874809162..........................M875809463....................... SW463809463-1.................... SW463809463A1................... SW463809885A1.......................6276809885A2.......................6276809885T2.......................6276811628...........................6279811674...........................6276811874..........................M874811874T........................M874811875..........................M875811875T........................M875811883..........................M883811883T........................M883811888..........................M888811902....................... DV394813447...........................6276816770........................AR351816770T......................AR351817119A1.....................60050817119A4.....................60050819222........................DV393819222A1....................DV393820583........................DV325820586........................SR325820586T......................SR325821509.......................... R509823653A5.......................6270823653A9...................... 6270
meRcuRy825096T01................. SW945827675A1.......................6255828151.......................... R151828151A1...................... R151828506.........................20850828708...........................6250828708A1.......................6279828708T.........................6250850402...................... DV45786177-1...................... DV381862030T ......................20810862031T ......................20800862031T1 ....................20800863077T ......................20815865202T........................ R202865380A13 ....................6275875285T1 ....................20840875286A-1 ...................2085087828.............................6218878265A1...................... 6250878265A4...................... 6250881247A1 ....................20850881248T ......................2084088183A5.........................627588183A6.........................627588183A11.......................627588183A12.......................6275882751A1...................... R151882751A04.................... R751883166A2 .....................M53289902......................... SW975889955 ........................20840889955T01...................20840889956 ........................20850891736T.........................6218891754T......................DV365893907A02.....................6276898265015..................DV381898265016.................. BK90092459A3.........................627092459A4.........................627092459A8.........................627092497A3.......................6005096562..........................DV36796564T........................SR36798555...........................6005098555A1...................... 6005099186.............................627899186-1..........................627899186-T..........................627850-F514955................... 555150-F575955................... 538250-12121A2...30470 & MBK45050-12177A2...30470 & MBK45050-12872......................5016950-17251A3..................3045750-29105..................... 5374X50-30829........................536650-30842..................... 5374X50-30955.......5374 W/ DV37050-31976........................537450-32403.................... 5374-650-32411..................... 5374X50-32703......................30119
meRcuRy50-37274A4....................537450-37345A1....................536650-38890A1....................536650-41583........................538550-41583T......................538550-44369A1....................538850-44415........................538050-45120......................3011950-45822........................537450-46282......................3011950-47454......................3045650-47455......................3045750-48643A1....................537450-514955..................... 555150-55601A2....................536650-56886......................7020050-57465A1....................537750-575955......................538250-57867A1....................537450-58059......................9010550-58788........................537450-58788A3....................537450-59799......................3011950-60315........................537550-60594A1....................538450-60594T01..................538450-64975..................... 5378X50-65436........................537550-65784A1..................3045750-65785A1..................3045650-66015........................537550-66015-1.....................539250-66015-2.....................537550-66015-3.....................539250-66015-T.....................539250-66015T1 ...................537550-67341........................537450-69863A1 .................3011950-69864A1..................3011950-69865......................5016950-69865A1..................5016950-72467........................537750-72550......................5014350-72550A1..................5014350-72550A2..................5014350-72550R2..................5014350-73521 .......................537950-73521T..................... 537950-76965A1..................3045750-76965A3..................3045750-76965A4..................3045750-77141........................538050-77328A1..................3011950-77328A3..................3011950-79472........................538050-79472-1.....................538050-79472T2....................538050-79604A1..................3045650-79604A3..................3045650-79821A2..................3011950-79822A1..................3011950-79822A2..................3011950-79823A1..................3011950-8M0033984...............536750-8M6001043...............5400
meRcuRy50-8M8021116.............3047050-803900T....................555150-803903T....................538250-804312T1 ................ 343050-805991....................1221350-806963A2................3046050-806963A4................3046050-806964A2.... 30470 & MBK45050-806964A3.... 30470 & MBK45050-806964A4.... 30470 & MBK45050-806965A2................3046050-806965A4................3046050-807904A1................3043350-808011A1................3045750-808011A4................3045950-808011A05..............3045950-812428A3.... 30470 & MBK45050-812429A2................3046050-812604A2.... 30470 & MBK45050-81490M.....................342450-818445-2...................539550-818445-3...................539550-818445-5...................539550-819085......................539350-819085-1...................539350-819085T1..................539350-819271......................539750-819968-1...................732550-819968-2...................732550-819968-3...................732550-819968-4 ..................732550-819968T4..................732550-820193......................539450-820193-1 ..................539450-820193A1..................539750-820193T1..................539450-820193003................539450-822330A2.... 30470 & MBK45050-822462......................539650-822462-1...................539650-822462T1..................539650-825095......................342650-830308......................536450-830308T....................536450-832997 .....................732650-832997-1...................732650-832997-2...................732650-832997003............... 732650-833153......................538150-833153-1...................538150-833153-2...................538150-833153-3...................538150-833153-5...................538150-833153T4..................538150-834749 .................... 536250-84917M.....................342050-852570T....................535950-853329T....................540050-853869......................539350-853869T....................539350-854636T ...................536550-856996T ................ 5381X50-859168T....................5359
PArT NUmberQUiCk reFereNCe
meRcuRy50-859169T................... 536450-859170T................... 536550-859170T1................. 536550-859171T .................. 536250-859377T....................536050-863007A1 ...............3043350-864340A2.... 30470&MBK45050-86976..................... 5381X50-881368T1..................343250-881368T2..................343250-884044T....................536050-884045T ...................536550-884238T ...................538050-888151T....................536450-888160T....................536550-888161T....................536050-892339T....................540050-892339T01................540050-893886T....................536450-893887T....................536550-893888T....................536050-893889T....................536750-893890T....................539650-893891T....................537550-893892T....................539250-893893......................538050-898265001................536250-898265002................539350-898265003................732550-898265005................537950-898265006................536650-898265007................538550-898265008................538150-898265009................539550-898265010................537750-898265011................538250-898265012................538850-898265013............. 5381X50-90983A1................... 536750-90983T1 ...................536750-92669M.....................342450-96359M.....................342050-97072M ................... 342450-97072T .................... 342450-97499A2..................3045650-97499A3..................3045650-97499R2..................3045650-97499R4..................3045650-97693M ................... 342050-99417A2..................3012450-99418A2... 30470 & MBK45050-99419A3..................3045786-865202T................... R20287-18211....................... R21187-61053.................... SW27587-803632T................ SW29589-15857.................... SW27589-18080.................... SW98489-F460917-1............. SW29589-F654924-1............. SW92489-68258.................... SW27589-68258A4................ SW27589-76416A1................ SW39489-76545.................... SW275
meRcuRy89-76545T.................. SW27589-803629T................ SW92489-817109A1.............. SW10989-817109A2.............. SW10989-817109A3.............. SW10989-818864.................. SW06489-818864T................ SW06489-818997A1.............. SW09789-818997A2.............. SW09789-818997T1.............. SW09789-818998A1.............. SW09789-818998A2.............. SW09789-818999A1.............. SW09989-818999A2.............. SW09989-825096.................. SW94589-825096T................ SW94589-846070.................. SW058H/D VERSION......... SW058HD89-850187A1.............. SW09789-850187T1 ............. SW09789-850188A1.............. SW09989-850188T1.............. SW09989-850189.................. SW05489-850189T................ SW05489-850408.................. SW45689-853654A1.............. SW27589-889273.................. SW92489-889274.................. SW92589-91975.................... SW05489-94318.................... SW058H/D VERSION......... SW058HD89-96054.................... SW05489-96054T.................. SW05489-96158.................... SW05889-96158T ................. SW058392-2940..................... TR217392-8262..................... TR217392-9250..................... TR217F391926....................... PA924F391926-1................... PA924
B.R.P - O.m.c.172588...........................6228172853........................ TR208172869....................... SW340173692........................AR104173944...........................6228174942...........................5376175019...........................5376277628....................... SW081321648........................DV376328381........................SR372378444 ...................... SW081380095....................... SW622380361...........................6209380973........................VR404381166.........................40152381519.........................40152381781.........................30119382138...........................6209382220...........................6209383440........................VR404
B.R.P - O.m.c.383443.........................40152383575 ...................... 5372X383622....................... SW622383691...........................5370384163...........................5371384198.........................30119384233.........................40152384777...........................5370384781........................DV371384914 ....................... 5372X385401...........................5376385529...........................5372385844........................SR371385949........................DV372385952........................ BK900386430...........................5369386591...........................5376386657...........................5370387094...........................5373387277...........................6206387683........................DV373387684...........................5371387768........................SR376388955........................AR103389275...........................5371389398....................... SW622389493....................... SW622389954...........................5372390124........................AR103391264...........................6220391511...........................5387391735...........................5370392133...........................5376393259...........................6220393570...........................5386393988...........................6220394176........................ 6220X395207...........................5373395419....................... SW622395840...........................6220396235...........................5387397023...........................5387432925...........................5363433226...........................6243433850........................ BK900433852........................SR363434495...........................6241434496...........................6241434517...................... JSA517434795...........................6220435532...........................6242435548...........................6244437666...........................6244437801...........................6242438529...........................6241438531...........................6241438786.......................... 6238438878...........................5363439937...........................6238
B.R.P - O.m.c.580841........................AR103581305........................AR103581366........................AR104581528....................... SW340581603........................AR103581778........................AR104582048...........................6206582155...........................6206582195.......................... R473582304........................AR104582307........................AR103582399........................AR103582472.......................... R473582473.......................... R473582708....................... SW622583408........................AR103583473...........................5390583482...........................5389583940........................AR104584107...........................6206584128....................... SW268584416.......................... R473584580 ...................... SW580584608...........................5368584613...........................5361584799...........................5387584818...........................5398584980...........................5399585050...........................5370585051...........................5372585056...........................5389585057...........................5372585058...........................5370585059...........................5390585060...........................5386585061...........................5376585062...........................5373585063...........................5371585197.......................... 5370585265........................SR376585266........................SR372585267........................DV372586100........................DV372586101........................DVK89586102........................DVK76586147.......................... R473586180....................... SW622586224.......................... R473586274...........................5361586275...........................5368586276...........................5369586277...........................5398586278...........................5376586279...........................5389586280...........................5371586281...........................5370586283...........................5372
PArT NUmberQUiCk reFereNCe
B.R.P - o.M.C.586284...........................5399586285...........................5386586286...........................5363586287 ..........................5363586288...........................5373586289...........................5387586392........................DV387586411...........................5387586730 ..................... SW730586731.......................... 5387586767.......................... R767586768...........................5358586774....................... SW590586842....................... SW394586890...........................5387586897...........................5387586957...........................5387587020....................... SW595587045...........................5358763454...........................5369778991...........................5390778992...........................5373778993...........................5371778994...........................5386778995...........................5361778996...........................5398979768...........................6211979774....................... SW774979937...........................6211980801....................... SW394981074.........................30124981078.........................30119981186.........................40152981187.........................40152981410....................... SW268981638...........................6211981703....................... SW394981821.........................70200982058...........................6204982069...........................6211982073...........................6211982107.........................30124982121.........................30124982151........................ TR211982187....................... SW268982189....................... SW394982200.........................30119982311........................ TR204982364.........................20104982706...........................6204983019...........................6220983248.........................30124983195 ..........................6214983318...........................6211983424.........................60125983444.........................30119983446...........................6220983790.........................30124984356...........................6206984456...... 30470 & MBK450984536.........................70212984565.........................60125984628.........................70216
B.R.P - o.M.C.985063....................... SW268985064....................... SW730985237...........................6220985465.........................60125985466.........................60125985799....................... SW984985964.........................40152985966.........................30124986008.........................60125986280...........................6245986505...... 30470 & MBK450987774.........................60070987811.........................70125987883....................... SW125987969.........................70200988012.........................70125988013.........................70212988217.........................30460988247.........................601253850216..................... SW4633850525.... 30470 & MBK4503850526.......................304603853839..................... SW3943853853.......................601253853869..................... SW9843853945.........................62453853982.... 30470 & MBK4503853998..................... SW9843854182.......................601253854190.......................701253854194..................... SW1253854750.......................304603854751.... 30470 & MBK4503854809.......................601253855177.... 30470 & MBK4503855882.......................304603856600.......................600703857298.......................601253857533........................ R4733857561.......................600703857747.... 30470 & MBK4503858463.......................304603860566.... 30470 & MBK4503860769...................... 601255004518.................... JSA5185005254 ........................62385005374.........................62415005376.........................62415005831.........................62485006319.........................62475036732.........................6240
PlsRCRaFTR13001 ...................... SW394R130014..................... SW295R200000.......................70201RA097002 ....................40147
PlsRCRaFTRA097006 ....................60108RA097007 ....................20815RA097007A...................20821RA097007B...................20825RA097007C ..................20822RA097009.....................20826RA122001.....................70200RA122002.....................70201RA122004.....................70108RA122008.................... 30456RA122009.................... 30459RA122014.....................70125RA122015.....................30433RA122019.....................30462RU0050....................... SW456RU0050A.................... SW463RU0050B.................... SW463
PolaRis3240120......................DV744
sea Doo29550089....................DV650
sieRRa18-5600..........................537318-5601..........................536618-5602..........................537418-5603........................3045918-5604..........................537518-5605..........................537918-5606..........................538818-5608..........................538018-5609....................... 5381X18-5610..........................539218-5611..........................536718-5612..........................536318-5613..........................539318-5614..........................539718-5617..........................536118-5618..........................732518-5619..........................538718-5620..........................539518-5621..........................539618-5622..........................539418-5623 .........................536818-5624..........................538918-5626..........................537018-5627..........................539018-5628..........................538618-5629..........................537618-5630..........................537118-5631..........................539818-5632..........................539918-5634..........................537218-5635..........................537018-5636..........................537718-5639..........................536718-5640......................... 537318-5641......................... 536618-5642..........................5375
sieRRa18-5643......................... 538018-5644......................... 539318-5645......................... 537618-5646......................... 537118-5647......................... 537218-5648......................... 537018-5649......................... 537718-5650.......................DV36618-5651.......................DV38518-5655.......................DV37618-5656.......................DV37718-5658.......................DV38118-5659.......................DV32518-5671.......................DV39018-5673.......................DV39318-5674.......................DV38018-5675.......................DV38718-5677.......................DV39418-5678.......................DV38918-5679.......................DVK7218-5680.......................DVK7618-5682.......................DV39618-5697....................... BK90018-5702......................... R95218-5704......................... R83218-5705......................... R47318-5707.......................AR35118-5708.......................AR10318-5709.......................AR10418-5710.......................VR40518-5711.......................VR40418-5712.......................VR40718-5714.......................VR09518-5727.......................VR40618-5728.......................VR40518-5729......................... R21118-5800......................... R01218-5801...................... SW39418-5802...................... SW98118-5803...................... SW77418-5804...................... SW97518-5807...................... SW08118-5808...................... SW62218-5811...................... SW46318-5812...................... SW26818-5813...................... SW26818-5814...................... SW34018-5815...................... SW27518-5816...................... SW05418-5817...................... SW05818-5818...................... SW06418-5819...................... SW09718-5820...................... SW09918-5821...................... SW94518-5822...................... SW92618-5823...................... SW58018-5833...................... SW59018-5834 .................... SW10918-5835 .................... SW29518-5836...................... SW66118-5837...................... SW98418-5838...................... SW975
PArT NUmberQUiCk reFereNCe
sieRRa18-6955........................6017018-56001.....................SR41018-56002.....................SR44618-56003.....................SR42018-56004.....................SR42418-56005.....................SR42618-56006.....................SR42818-56007.....................SR42918-56008.....................SR44018-56009.....................SR444
suzuKi31100-87D00................. 344231100-87D10................. 344231100-92E00................. 344231100-94400..................341231100-94401..................341231100-94402..................341231100-94500 ................ 344431100-94510 ................ 34443C8-76010-10.................341231100-94511 ................ 344431100-94512 ................ 344431100-94600..................344431100-94601................. 344431100-94610................. 344431100-95600................. 344031100-95601................. 344031100-96310..................341231100-96311..................341238100-87D01 .................626938100-87E20-OED..........626838100-92E00-0ED......... 626838100-92E00-0EP ..........626838410-94540.......... R950/951
tohatsuFM5900.......................... 3410353-76010-1A0...............3410353-76010-04.................3410353-76010-300...............3410
univeRsal275753.........................40112277584.........................40145288182.........................60108288759.........................60108
volvo1214764........................ R0401324492 ....................... R6701501832........................ R8321504952-1..................... R952241812 ......................... R6703581774 ..................... 972253586765.........................62273587625.... 30470 & MBK4503803113.......................972253850216-7.................. SW463
sieRRa18-5841...................... SW77418-5842...................... SW41218-5843...................... SW42418-5900........................3011918-5901........................3045618-5902........................3045718-5903........................7020018-5904........................7020118-5905..... 30470 & MBK45018-5906........................1011318-5907........................3045618-5908........................3045718-5910..... 30470 & MBK45018-5911........................3046018-5913..... 30470 & MBK45018-5914........................7020018-5915........................7020118-5916........................7021618-5917........................7021618-5918........................1011318-5919........................3046018-5920........................7012518-5936........................1241218-5938........................1242018-5939....................... 8010818-5943........................8010818-5945........................6505518-5950........................2010218-5951........................2010418-5954........................4011218-5956........................2010218-5957........................6005018-5959....................... 8010818-5960........................6006018-5963........................4015218-5964........................4015218-5965........................6006518-5966........................6005018-5967........................6005518-5972........................6012418-5979....................... 6007218-5982........................6016018-5983........................2081018-5984........................2082018-6250.......................SR10218-6251.......................SR10418-6252....................... TR20818-6253....................... TR21718-6254....................... TR21718-6257..........................621418-6258..........................623918-6259..........................626718-6260........................6012518-6261........................6007018-6262........................6012218-6263........................6010818-6264......................... R03618-6265........................6007118-6266......................... R04018-6267......................... R21118-6268......................... R17718-6269...................... SW340
sieRRa18-6270........................7021218-6271......................... R67018-6273-1.......................627818-6274..........................622418-6275........................3043318-6276........................7021218-6277..........................624418-6278........................8415018-6280..........................624218-6281..........................623818-6282..........................732618-6283..........................538118-6284........................8413518-6285..........................624318-6286..........................625518-6287...................... SW45018-6288........................2082518-6291...................... SW12518-6292........................1011318-6293........................2080018-6298........................2081518-6299........................2083018-6410..........................342018-6411..........................342218-6412..........................342418-6413..........................342618-6414..........................344018-6415..........................342818-6416..........................344418-6417..........................344218-6418..........................341018-6420..........................342118-6421..........................342318-6422..........................342518-6423..........................342718-6424..........................342918-6425..........................343018-6426..........................343118-6427..........................343218-6432..........................341218-6433..........................344618-6434..........................536918-6435..........................536018-6436..........................536218-6437..........................536418-6438..........................536518-6439..........................538218-6440..........................540018-6441..........................555118-6443........................3046218-6450........................2082118-6451........................2082718-6452........................2082618-6453........................2082218-6454........................2084018-6455........................2085018-6754..........................620918-6755..........................620418-6756..........................622818-6758..........................622318-6759..........................622018-6760..........................6265
sieRRa18-6761..........................620618-6762..........................621618-6763..........................621718-6764..........................621118-6765..........................627018-6767..........................620818-6767-1.......................620818-6769..........................627518-6769-1.......................627518-6770..........................622718-6771.........................M52518-6772..........................621818-6773..........................625018-6774......................... 627918-6775......................... 627418-6777..........................627618-6778........................ M53218-6779..........................624518-6780..........................624118-6781......................... 626018-6783......................... 624018-6785......................... 626918-6786......................... 626818-6787..........................626118-6788..........................626418-6789..........................626618-6811..........................626618-6812..........................626618-6813..........................627518-6814..........................620618-6815..........................624818-6816..........................622818-6817..........................623218-6821..........................626718-6822..........................622418-6824..........................538418-6825....................... 5381X18-6826..........................535818-6827..........................344418-6828..........................538518-6829..........................535918-6838..........................622518-6841........................6012518-6842........................6012518-6843........................6007518-6845........................6007618-6847........................6007618-6848........................6007418-6851............... BI-1202-3A18-6852.....................BI-160218-6854.....................BI-160318-6855.....................BI-070218-6860......................WH80018-6861..........................342918-6863..........................536818-6864..........................539718-6925........................8413518-6932........................9818518-6937........................9818018-6946........................3047018-6952........................60150
PArT NUmberQUiCk reFereNCe
VOLVO3850525-1.....30470 & MBK4503850927-9....................601253853839-3.................. SW3943853853-4....................601253853869-0.................. SW9843853982-1.....30470 & MBK4503853998-7.................. SW9843854182-7....................601253854190-0....................701253854194-2.................. SW1253854750-1....................304603854751-9.....30470 & MBK4503854809-5....................601253855177-6.....30470 & MBK4503856600.......................600703856003-3....................304603856004-1.....30470 & MBK4503856596.........................62273857298.......................601253857265-7......................62243857561.......................600703857747..... 30470 & MBK4503857813.......................600713858071 ........................62323858077 .......................M5333859054..................... SW4633860082...................... 600723860171...................... 600703860566..... 30470 & MBK4503860764..... 30470 & MBK4503860769.......................600703860798.......................600713861575.........................62333862308.......................304603862612.......................600743862613.......................600763862665.......................600733862985.......................304593885317.... 30470 & MBK4503884950.......................60073594043........................DV225594054....................... SW2256643474-7..................... R670818721....................... SW975829029-8.................... SW814829527-1......................97225831725-7....................... R952834625-6......................80108834804-7.................... SW814834852-6.................... SW814834893-0......................50142835121-5......................50142835334-4......................50141835635-4......................70200839367-0....................... R832839586-5..................... TR222841066-4......................70200841177-9....................... R177841377-5......................30456841378-3......................80108841656-2.................... SW975841762-8......................80108
VOLVO841765-1......................80108841766-9......................80108847308.........................97308847561-8......................80200849561-6......................80200849747-1......................60160849748-9......................60175850834-3........................6223851126-3..................... TR223852565-1.................... SW565852928-1........................6224853083-4........................6224853084-2........................6224853544-5....................... R670853545-2....................... R670854346-4........................6227854357-1....................... R040854437...........................6227854525-3........................6232854531-1.......................M531855326-5......................30124855332-3.................... SW975855334.........................30459857298.........................60125858838-6......................80108858839-4......................80108859252-9......................97225859618-1.................... SW225859623-1.....................DV225860334-2......................95949870670-7....................... R670872018-7......................80108872235-7......................80108872241-5......................10113872272-0....................... R177872300-9....................... R670872449-4........................6224872720-8.....................VR135872926-1......................80108873051-7........................6224873120-0...................BI-0702873549-0......................10113875356-8 ................... TR221876037-3....................... R832876038-1....................... R670876039-9....................... R952876040-7....................... R040
westeRBeKe16762...........................1210123953...........................1210431227...........................1210130594...........................8605033486...........................3045634552...........................9817521129980.....................3045942847...........................60104
yamahaCS3-43880-00................625919-1400-10...................60075
yamaha 6BR-81800-00................34336BR-81800-01................34336CJ-81800-00.................34326C5-81800-00.................34326E5-43880-01.................62676E5-43880-02.................62676E5-81840-10..............SR4266E5-81800-11................ 34266E5-81800-12................ 34266E5-81941-10............. SW9416E5-81941-11............. SW9416E5-81950-01................ R9506E5-8195A-01................ R9516F5-81800-10................ 34236F5-81800-11................ 34236G1-8194A-10............ SW9456G1-81940-00............ SW9456G1-81941-10............ SW9456G5-43880-00 ...............62656G5-43880-01 ...............62656G5-43880-02................62656H1-43880-00............... 62676H1-43880-02................62606H3-81800-10................34226H3-81800-11................34226H4-81800-10............... 34256H4-81800-11............... 34256H4-81800-12............... 34256H5-43880-02................62646H5-43880-09................62646J4-81800-00................ 34236J4-81800-01.................34236K7-81800-10................ 34286K8-81807-10..............DV5006L2-81800-10 ................34216L2-81800-11 ................34216L2-81800-20 ................34216M6-8183E-00.............DV7006M6-8183E-01.............DV7006N7-81800-00............... 34286N7-81800-01............... 34286N7-81800-10............... 34286N7-81840-00.............SR4286N7-WS818-01 ............. 342861A-81800-00 ............... 342961A-81800-01 ............... 342961A-81840-00..............SR42961A-81941-00............. SW94161H-81800-00 .............. 342861H-81800-01 .............. 342861H-81800-10 .............. 342862X-43880-00.................626662X-43880-01.................626662X-43880-09.................626662Y-43880-01.................625962Y-43880-02.................625963P-81800-00.................343364E-43880-00 ................624064E-43880-01 ................624064E-43880-03.................6240
yamaha 65W-81800-00................536465W-81800-01................536465W-81800-02................536465W-81800-03................536465W-81941-00............ SW09967C-81800-00.................536567C-81800-01.................536567C-81800-02.................536567F-43880-00.................626167F-81800-00.................343067F-81800-01.................343067F-81800-02 ...............343067H-43880-00................624067H-43880-01................624067H-43880-04................624068F-81800-00 ................343168F-81800-01.................343168V-43880-00.................624068V-43880-01.................624068V-43880-03.................624068V-81800-00.................343268V-81800-01 ............... 343269J-43880-01.................626369L-81800-00 ................3429663-81840-11..............SR424682-81800-11................ 3421682-81800-12................ 3421688-43880-10................ 6267688-81800-10 ............... 3427688-81800-11 ............... 3427688-81800-12 ............... 3427688-81950-10............. SW950689-81800-11.................3420689-81800-12.................3420689-81800-13.................3420697-81800-10.................3424697-81800-11.................3424697-81800-12.................342499999-03249..................3424
YANMAR128170-77010..............98180128170-77010D............98180128270-77200..............84135129608-77010..............98185129698-77010..............98185129772-77200..............84150171008-77010..............98185X211447009............... SW487