ELECTRICAL AND

IGNITION

2
B

11669

BATTERY, CHARGING SYSTEM, AND

STARTING SYSTEM
Table of Contents
Page Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 3 Cylinder 16 and 24 Ampere Battery
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Charging Wiring Diagram . . . . . . . . . . . 2B-9
Recommended Battery . . . . . . . . . . . . . . . . 2B-1 3 Cylinder 16 Ampere Battery Charging
Wiring Diagram (with Small Voltage
Operating Engine without Battery . . . . . . . 2B-1 Regulator/Rectifier) . . . . . . . . . . . . . . . . 2B-10
Specific Gravity Readings . . . . . . . . . . . . . . 2B-2 4 Cylinder 16 and 24 Ampere Battery
Specific Gravity Cell Charging Wiring Diagram . . . . . . . . . . . 2B-11
Comparison Test . . . . . . . . . . . . . . . 2B-2 4 Cylinder 16 Ampere Battery Charging
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . 2B-2 Wiring Diagram (with Small Voltage
Charging a Discharged Battery . . . . . . . . . 2B-3 Regulator/Rectifier) . . . . . . . . . . . . . . . . 2B-12
Winter Storage of Batteries . . . . . . . . . . . . . 2B-3 3 Cylinder Battery Charging Diagram
with Battery Isolator . . . . . . . . . . . . . . . . 2B-13
Optional Voltage
Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 3 Cylinder Battery Charging Diagram
with Battery Isolator (Small Voltage
Battery Charging System Regulator) . . . . . . . . . . . . . . . . . . . . . . . . 2B-14
(9 Ampere Alternator) . . . . . . . . . . . . . . . . . 2B-4
4 Cylinder Battery Charging Diagram
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 with Battery Isolator . . . . . . . . . . . . . . . . 2B-15
Models Equipped with Rectifier . . . . . . 2B-4 4 Cylinder Battery Charging Diagram
Models Equipped with Regulator . . . . . 2B-4 with Battery Isolator (Small Voltage
Battery Charging System Regulator) . . . . . . . . . . . . . . . . . . . . . . . . 2B-16
Troubleshooting . . . . . . . . . . . . . . . . . . . 2B-5 Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . 2B-17
Stator Ohms Test Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18
(Alternator Coils Only) . . . . . . . . . . . . . . 2B-5 Starting System Components . . . . . . . . . . . 2B-18
Standard Stator (Alternator Coils) Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18
9 Amperes Output . . . . . . . . . . . . . . . . . 2B-6 Troubleshooting the Starting Circuit . . . . . 2B-18
16 Amp Alternator System Test . . . . . . . . . 2B-6 Starting Circuit Troubleshooting
(Large Finned Voltage Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . 2B-19
Regulator/Rectifier) . . . . . . . . . . . . . 2B-6 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21
16 Ampere Alternator System Test . . . . . . 2B-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21
(Small Voltage Regulator/Rectifier) . . . 2B-7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21
Optional 24 Amp Alternator System Test . 2B-7 Starter Cleaning, Inspection and Testing . 2B-22
(Large Finned Voltage Cleaning and Inspection . . . . . . . . . . . . 2B-22
Regulator/Rectifier) . . . . . . . . . . . . . 2B-7 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-22
Tachometer Terminal Block (Design 1) . . . 2B-8 Armature Test for Shorts . . . . . . . . . . . . 2B-22
Description . . . . . . . . . . . . . . . . . . . . . . . 2B-8 Armature Test for Ground . . . . . . . . . . . 2B-22
Testing Tachometer Terminal Block Checking Positive Brushes and
(Design 1) . . . . . . . . . . . . . . . . . . . . . 2B-8 Terminal . . . . . . . . . . . . . . . . . . . . . . . 2B-23
Tachometer Terminal Block (Design 2) . . . 2B-8 Testing Negative Brushes for
Description . . . . . . . . . . . . . . . . . . . . . . . 2B-8 Ground . . . . . . . . . . . . . . . . . . . . . . . 2B-23
Tachometer Terminal Block Starter Solenoid Test . . . . . . . . . . . . . . . 2B-23
(Design 1 and 2) . . . . . . . . . . . . . . . . . . . 2B-8 Brush Replacement . . . . . . . . . . . . . . . . . . . 2B-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 Starter Reassembly . . . . . . . . . . . . . . . . 2B-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-26

90-13645--2 495
Battery Recommended Battery
Precautions The 2-cycle Outboard type engine requires a 12 volt
battery with a “Cold Cranking Amperage” rating for
When charging batteries, an explosive gas mixture cranking and a “Reserve Capacity” rating. The mini-
forms in each cell. A portion of this gas escapes thru mum should be a “Cold Cranking Amperage” of 350
holes in vent plugs and may form an explosive atmo- amperes and a “Reserve Capacity” of 100 minutes for
sphere around battery if ventilation is poor. This ex- engines outlined in this manual.
plosive gas may remain in or around battery for sever-
al hours after it has been charged. Sparks or flames Operating Engine Without Battery
can ignite this gas and cause an internal explosion If desired (or in an emergency), engines equipped
which may shatter the battery. with an alternator can be started and operated with-
The following precautions should be observed to pre- out a battery (either disconnected or removed) if
vent an explosion. “Warning”, below, is followed.
1. DO NOT smoke near batteries being charged or
which have been charged very recently.
2. DO NOT break live circuits at terminals of batter-
ies because a spark usually occurs at the point
where a live circuit is broken. Always be careful
when connecting or disconnecting cable clamps
on chargers. Poor connections are a common
cause of electrical arcs which cause explosions.
3. DO NOT reverse polarity of battery cables on bat-
tery terminals.

90-13645--2 495 ELECTRICAL AND IGNITION 2B-1

Specific Gravity Readings 5. Avoid dropping electrolyte on boat or clothing, as
it is extremely corrosive. Wash off immediately
Use a hydrometer to measure specific gravity of elec- with baking soda solution.
trolyte in each cell.
Specific gravity of electrolyte varies not only with per-
centage of acid in liquid but also with temperature. As
temperature drops, electrolyte contracts, so that spe-
cific gravity increases. Unless these variations in spe-
cific gravity are taken into account, specific gravity ob-
tained by hydrometer may not give a true indication
of concentration of acid in electrolyte.
a
A fully charged battery will have a specific gravity
reading of approximately 1.270 at an electrolyte
temperature of 80
F (27
C). If electrolyte tempera-
ture is above or below 80
F, additions or subtractions
must be made in order to obtain a hydrometer reading
corrected to 80
F standard. For every 10
F (3.3
C)
above 80
F, add 4 specific gravity points (.004) to
hydrometer reading. Example: A hydrometer reading
of 1.260 at 110
F (43
C) would be 1.272 corrected
to 80
F, indicating a fully charged battery.
For every 10
below 80
F, subtract 4 points (.004)
from the reading. Example: A hydrometer reading of
1.272 at 0
F (–18
C) would be 1.240 corrected to
80
F, indicating a partially charged battery.
22532 SPECIFIC GRAVITY CELL COMPARISON TEST
a - Hydrometer
This test may be used when an instrumental tester is
Hydrometer measures percentage of sulphuric acid not available. To perform this test, measure specific
in battery electrolyte in terms of specific gravity. As a gravity of each cell, regardless of state of charge, and
battery drops from a charged to a discharged condi- interpret results as follows: If specific gravity readings
tion, acid leaves the solution and chemically com- show a difference between highest and lowest cell of
bines with the plates, causing a decrease in specific .050 (50 points) or more, battery is defective and
gravity of electrolyte. An indication of concentration of should be replaced.
electrolyte is obtained with a hydrometer.
When using a hydrometer, observe the following
Electrolyte Level
points: Check electrolyte level in battery regularly. A battery
1. Hydrometer must be clean (inside and out) to in- in use in hot weather should be checked more fre-
sure an accurate reading. quently because of more rapid loss of water. If electro-
lyte level is found to be low, then distilled water should
2. Never take hydrometer readings immediately af- be added to each cell until liquid level rises approxi-
ter water has been added. Water must be thor- mately 3/16″ (4.8mm) over plate. DO NOT OVER-
oughly mixed with electrolyte by charging for at FILL, because this will cause loss of electrolyte and
least 15 minutes at a rate high enough to cause result in poor performance, short life and excessive
vigorous gassing. corrosion.
3. If hydrometer has built-in thermometer, draw liq-
uid in several times to ensure correct temperature
before taking reading.
4. Hold hydrometer vertically and draw in just
enough liquid from battery cell so that float is free-
floating. Hold hydrometer at eye level so that float
is vertical and free of outer tube, then take reading
at surface of liquid. Disregard curvature where liq-
uid rises against float stem due to capillary action.

2B-2 ELECTRICAL AND IGNITION 90-13645--2 495

Charging a Discharged Battery 1. Remove battery from its installation as soon as
possible and remove all grease, sulfate and dirt
The following basic rules apply to any battery charg- from top surface by running water over top of bat-
ing situation: tery. Be sure, however, that vent caps are tight be-
1. Any battery may be charged at any rate (in am- forehand, and blow off all excess water thorough-
peres) as long as spilling of electrolyte (from vio- ly with compressed air. Check water level, making
lent gassing) does not occur and as long as elec- sure that plates are covered.
trolyte temperature does not exceed 125
F 2. When adding distilled water to battery, be ex-
(52
C). If spewing of electrolyte occurs, or if elec- tremely careful not to fill more than 3/16″ (4.8mm)
trolyte temperature exceeds 125
F, charging rate over plate inside battery. Battery solution or elec-
(in amperes) must be reduced or temporarily trolyte expands from heat caused by charging.
halted to avoid damage to the battery. Overfilling battery will cause electrolyte to over-
2. Battery is fully charged when, over a 2-hour peri- flow (if filled beyond 3/16″ over plate).
od at a low charging rate (in amperes), all cells are 3. Grease terminal bolts well with Quicksilver 2-4-C
gassing freely (not spewing liquid electrolyte), w/teflon, and store battery in COOL-DRY place.
and no change in specific gravity occurs. Full Remove battery from storage every 30-45 days,
charge specific gravity is 1.260-1.275, corrected check water level (add water if necessary), and
for electrolyte temperature with electrolyte level at put on charge for 5 or 6 hours at 6 amperes. DO
3/16″ (4.8mm) over plate. For most satisfactory NOT FAST CHARGE.
charging, lower charging rates in amperes are
recommended. 4. If specific gravity drops below 1.240, check bat-
tery for reason, and then recharge. When gravity
3. If, after prolonged charging, specific gravity of at reaches 1.260, discontinue charging. To check
least 1.230 on all cells cannot be reached, battery specific gravity, use a hydrometer, which can be
is not in optimum condition and will not provide op- purchased locally.
timum performance; however, it may continue to
provide additional service, if it has performed sat- 5. Repeat preceding charging procedure every
isfactorily in the past. 30-45 days, as long as battery is in storage. When
ready to place battery back in service, remove ex-
4. To check battery voltage while cranking engine cess grease from terminals (a small amount is de-
with electric starter motor, place red (+) lead of sirable on terminals at all times), recharge again
tester on positive (+) battery terminal and black (–) as necessary and reinstall battery.
lead of tester on negative (–) battery terminal. If
the voltage drops below 9-1/2 volts while crank-
ing, the battery is weak and should be recharged
or replaced.
Winter Storage of Batteries
Battery companies are not responsible for battery
damage, either in winter storage or in dealer stock, if
the following instructions are not observed:

90-13645--2 495 ELECTRICAL AND IGNITION 2B-3

Optional Voltage Battery Charging System
Regulator Test (9 Ampere Alternator)
1. Check battery voltage at Description
battery with engine running.
The battery charging system components are the sta-
2. If battery voltage is above 14.5 volts, replace volt-
tor, rectifier, and battery. Alternating current (gener-
age regulator. Check condition of battery as over-
ated in stator alternator coils) flows to the rectifier,
charging may have damaged battery.
which changes the alternating current to direct cur-
3. If battery voltage is below 14.5 volts, charge bat- rent for charging the battery.
tery; refer to “Charging a Discharged Battery”,
MODELS EQUIPPED WITH RECTIFIER
preceding. If battery can NOT be satisfactorily
charged, replace battery.
4. If battery accepts a satisfactory charge, check a
battery voltage while cranking engine; refer to
“Charging a Discharged Battery”, preceding. If
cranking voltage is not acceptable, replace bat-
tery. b
5. If cranking voltage is acceptable, disconnect end
of RED wire (located between rectifier (+) terminal
and starter solenoid) from rectifier. Secure RED
wire (from voltage regulator) to rectifier (+) termi-
nal with hex nut.
c
6. Connect RED (+) ammeter lead to (+) terminal of
rectifier and BLACK (–) ammeter lead to RED wire a - Stator
(disconnected in last step). b - Rectifier
c - Battery
IMPORTANT: For accurate test results the voltage
at battery with engine running, in next step, must MODELS EQUIPPED WITH REGULATOR
be 13.5 volts or less. It may be necessary to oper-
ate electrical accessories to drop voltage to 13.5 a
volts or less.
7. Run engine at 3000 RPM.
b
8. Meter should read between 7 - 9 amperes.
9. If meter reads 7 - 9 amperes, this indicates the
charging system is functioning properly and the
battery is being discharged because the amper-
age draw on the system is greater than the amper-
age output of the system. c
NOTE: With engine running at the following RPM’S,
the ammeter should indicate the following approxi-
mate amperes:
RPM AMPERES
IDLE 1
a - Stator
1000 4
b - Regulator
2000 8 c - Battery
3000 9
The charging system may be damaged by: 1) re-
10. If the meter reads less than 7 amperes, test the
versed battery cables, 2) running the engine with bat-
stator; refer to “Standard Stator (Alternator Coils)
tery cables disconnected and stator leads connected
Amperes Output”, following. If stator tests OK, re-
to rectifier, and 3) an open circuit, such as a broken
place voltage regulator.
wire or loose connection.

2B-4 ELECTRICAL AND IGNITION 90-13645--2 495

Battery Charging System 2. Use an ohmmeter and perform the following test.
Troubleshooting IMPORTANT: If stator is mounted on engine, black
stator lead (if provided) must be grounded to pow-
A fault in the battery charging system usually will erhead when testing.
cause the battery to become undercharged. Check
battery electrolyte level, and charge battery. See 3. Replace stator if readings are outside ranges
“Electrolyte Level”, and “Charging a Discharged shown.
Battery”.
Scale
If battery will NOT accept a satisfactory charge, re- Resistance
Test Leads Reading
(Ohms)
place battery. (x )
If battery accepts a satisfactory charge, determine 9 AMPERE STATOR
the cause of the charging system problem as follows. Between YELLOW .6 – 1.1*
.6 – 1.1*
1. Check for correct battery polarity [RED cable to stator leads (R x 1)
positive (+) battery terminal]. If polarity was incor- Between either No
No
rect, check for damaged rectifier. See “Rectifier YELLOW stator lead Continuity
Continuity
Test”, following. and engine ground** (R x 1000)
2. Check for loose or corroded battery connections. 16 AMPERE STATOR
3. Visually inspect wiring between stator and battery Between YELLOW .17 – .19
.17 – .19
for cuts, chafing; and disconnected, loose or cor- stator leads (R x 1)
roded connection. Between either No
No
YELLOW stator lead Continuity
4. Excessive electrical load (from too many acces- Continuity
and engine ground** (R x 1000)
sories) will cause battery to run down.
24 AMPERE STATOR
If visual inspection determines that battery connec-
tions and wiring are OK, perform the following stator Between YELLOW .05 – .15
.05 – .15
and rectifier tests. stator leads (R x 1)
Between either No
Stator Ohms Test No
YELLOW stator lead Continuity
Continuity
(Alternator Coils Only) and engine ground** (R x 1000)
NOTE: Stator can be tested without removing from * DC resistance of these windings generally is less
engine. than 1.5 ohms. If a reading (resembling a short) is
1. Disconnect both YELLOW (stator leads) from ter- obtained, this would be acceptable.
minals on rectifier (or terminal block). ** If stator is removed from engine, connect test lead
to black stator lead, if provided.
4. If meter readings are other than specified, replace
stator.

90-13645--2 495 ELECTRICAL AND IGNITION 2B-5

 9. With engine running at the indicated RPM’s, the
Standard Stator (Alternator Coils) ammeter should indicate the following approxi-
9 Amperes Output mate amperes:
IMPORTANT: Rectifier must be functioning prop- RPM AMPERES
erly for accurate test results to be obtained. IDLE 2
1000 10
1. If engine is equipped with a voltage regulator, 2000 17
disconnect voltage regulator leads at rectifier; 3000 18
reinstall hex nut on rectifier terminal that has 10. If ammeter indicates approximately 18 amperes
yellow stator lead. at 3000 RPM, this indicates the charging system
2. Remove red wire from (+) terminal of rectifier. is functioning properly and the battery is being
3. Connect RED (+) ammeter lead to rectifier (+) termi- discharged because the amperage draw on the
nal and BLACK (–) ammeter lead to red rectifier system is greater than the amperage output of the
wire. system.

4. Run engine at 3000 RPM. 11. If ammeter reads less than 18 amperes, test the
stator; refer to “Stator Ohms Test (Alternator Coils
5. Meter should read 7 - 9 amperes; if not, replace Only)” [18 Ampere Stator], preceding. If stator
stator. tests OK, replace voltage regulator/rectifier.
16 Amp Alternator System Test c
(LARGE FINNED VOLTAGE
REGULATOR/RECTIFIER)
1. Check battery voltage at battery with engine
running.
2. If battery voltage is above 14.5 volts, replace volt-
age regulator/rectifier. Check condition of battery
as overcharging may have damaged battery.
3. If battery voltage is below 14.5 volts, charge bat-
b
tery; refer to “Charging a Discharged Battery”, d a 21619
preceding. If battery can NOT be satisfactorily
charged, replace battery. a - Voltage Regulator/Rectifier c - Center Terminal
b - RED Harness Wire d - RED Sense Lead
4. If battery accepts a satisfactory charge, check
battery voltage while cranking engine; refer to NOTE: If one or more of the 3 terminals on the termi-
“Charging a Discharged Battery”, preceding. If nal block are shorted to ground, the battery charging
cranking voltage is not acceptable, replace battery. system output will be reduced.
5. If cranking voltage is acceptable, disconnect RED a
harness wire from center terminal.
6. Secure RED wire (d) on terminal (c) using hex nut.
7. Connect RED (+) ammeter lead to terminal (c)
and BLACK (–) ammeter lead to RED harness
wire (b).
8. Secure wires away from flywheel.
IMPORTANT: For accurate test results the voltage
at battery with engine running, in next step, must
be 13.5 volts or less. It may be necessary to oper-
ate electrical accessories to drop voltage to 13.5
volts or less.

26001
a - Terminal Block

2B-6 ELECTRICAL AND IGNITION 90-13645--2 495

16 Ampere Alternator System Test Optional 24 Amp Alternator System Test
(SMALL VOLTAGE REGULATOR/RECTIFIER) (LARGE FINNED VOLTAGE
REGULATOR/RECTIFIER)
1. Check battery voltage at battery with engine run-
ning. 1. Check battery voltage at battery with engine
running.
2. If battery voltage is above 14.5 volts, replace volt-
age regulator/rectifier. Check condition of battery 2. If battery voltage is above 14.5 volts, replace volt-
as overcharging may damage battery. age regulator/rectifier (a). Check condition of bat-
3. If battery voltage is below 14.5 volts, charge bat- tery as overcharging may have damaged battery.
tery; refer to “Charging a Discharged Battery”, 3. If battery voltage is below 14.5 volts, charge bat-
preceding. If battery can NOT be satisfactorily tery; refer to “Charging a Discharged Battery”,
charged, replace battery. preceding. If battery can NOT be satisfactorily
4. If battery accepts a satisfactory charge, check charged, replace battery.
battery voltage while cranking engine; refer to 4. If battery accepts a satisfactory charge, check
“Charging a Discharged Battery”, preceding. If battery voltage while cranking engine; refer to
cranking voltage is not acceptable, replace battery. “Charging a Discharged Battery”, preceding. If
5. If cranking voltage is acceptable, disconnect larg- cranking voltage is not acceptable, replace battery.
er diameter Red wire from STARTER SOLENOID 5. If cranking voltage is acceptable, disconnect RED
terminal. harness wire (b) from terminal (c).
6. Remove smaller diameter RED wire (SENSE 6. Secure RED wire (d) on terminal (c) using hex nut.
LEAD) from STARTER SOLENOID terminal and
7. Connect RED (+) ammeter lead to terminal (c)
connect to the POSITIVE (+) terminal of a 9 VOLT
and BLACK (–) ammeter lead to RED harness
transistor battery. Ground the NEGATIVE (–) ter-
wire (b).
minal of the 9 VOLT battery to the engine.
8. Secure wires away from flywheel.
7. Connect RED (+) ammeter lead to larger diameter
RED wire, and BLACK (–) ammeter lead to POS- IMPORTANT: For accurate test results the voltage
ITIVE terminal on STARTER SOLENOID. at battery with engine running, in next step, must
be 13.5 volts or less. It may be necessary to oper-
8. Secure wires away from flywheel.
ate electrical accessories to drop voltage to 13.5
9. With engine running at the indicated RPM’s, the volts or less.
ammeter should indicate the following approxi-
9. Run engine at 3000 RPM.
mate amperes:
10. Meter should read 20 or more amperes.
RPM AMPERES
IDLE 2 11. If meter reads 20 or more amperes, this indicates
1000 10 the charging system is functioning properly and
2000 17 the battery is being discharged because the am-
3000 18 perage draw on the system is greater than the am-
perage output of the system.
10. A reading of 18 amperes at 3000 RPM indicates
the charging system is functioning properly. The 12. If meter reads less than 20 amperes, test the sta-
battery is discharging due to the amperage draw tor; refer to “Optional 24 Amp Stator (Alternator
on the system is greater than the amperage out- Coils) Amperes Output”, following. If stator tests
put of the engine charging system. OK, replace voltage regulator rectifier (a).
11. If ammeter reads less than 18 amperes, test the b c a
stator; refer to “Stator Ohms Test (Alternator Coils
Only)”, [18 Ampere Stator], preceding. If stator
tests OK, replace voltage regulator/rectifier.

d 21619

90-13645--2 495 ELECTRICAL AND IGNITION 2B-7

Tachometer Terminal Block (Design 1)
DESCRIPTION
ALT YEL

Contains a diode which blocks high voltage AC GREY

pulses (180 VAC) coming from the stator and allows

TACH
low voltage DC pulses (20-30 VDC) to pass through ALT YEL
to be counted by the tachometer. This terminal block
(with diode) is only used with large, finned type regu-
lators. This block is BLACK in color.

WARNING
HIGH VOLTAGE is present at the tachometer
50644
block’s stator side terminals, while the outboard
is running. To avoid electrical shock, physical Tachometer Terminal Block (Design 2)
contact should not be made on these terminals or
ANY IGNITION RELATED COMPONENT WHILE DESCRIPTION
THE OUTBOARD IS RUNNING. This block is a junction point for stator and tachometer
IMPORTANT: The following ohm test is used to de- signal wiring. It contains no electrical components.
termine the proper functioning of the diode lo- This block is LIGHT GREY in color and is to be used
cated in the tachometer block. If the diode is ONLY with small, non-finned voltage regulators. No
OPEN (NO CONTINUITY IN EITHER DIRECTION), test is required for this terminal block.
the tachometer will be inoperative.
Tachometer Terminal Block
TESTING TACHOMETER TERMINAL BLOCK (Design 1 and 2)
(DESIGN 1)
REMOVAL
With outboard NOT running, remove all leads from
block. Using an ohmmeter, test block as shown, fol- 1. Remove two YELLOW alternator wires from
lowing. Continuity should be observed on the ohm- block.
meter with the needle swinging in only ONE direction. 2. Remove GREY tachometer wire from block.
NO CONTINUITY should be observed when test
leads are reversed. If CONTINUITY is observed in 3. Remove two attaching screws and remove diode
BOTH directions or NO CONTINUITY is observed in block.
either direction when leads are reversed, diode is de- INSTALLATION
fective and MUST BE REPLACED.
1. Secure diode block to powerhead with two
NOTE: There is only one diode located in the tachom- screws. Torque screws to 30 lb. in. (3.4 N
m).
eter block. It may be located either between the cen-
ter (TACH) terminal and the top (ALT) terminal or be- 2. Attach two YELLOW wires to “ALT YEL”
tween the center (TACH) terminal and the lower (ALT) terminals.
terminal. 3. Attach GREY wire to “GREY TACH” terminal.

ALT YEL
GREY

TACH

ALT YEL

50644

2B-8 ELECTRICAL AND IGNITION 90-13645--2 495

3 Cylinder 16 and 24 Ampere Battery
Charging Wiring Diagram
IMPORTANT: After electrical connections are
made, coat all terminal connections using Quick-
silver Liquid Neoprene (92-25711), to avoid corro-
sion.

a
BLK
BLACK
BLU
BLUE
GRY
GRAY
RED
RED
YEL
YELLOW

g
c
f

d
e

50405
a - Stator e - To Remote Control Harness
b - Terminal Block f - 20 Ampere Fuse
c - ToTachometer g - To Battery
d - Voltage Regulator/Rectifier h - Starter Solenoid

90-13645--2 495 ELECTRICAL AND IGNITION 2B-9

3 Cylinder 16 Ampere Battery
Charging Wiring Diagram (with Small
Voltage Regulator/Rectifier)
IMPORTANT: After electrical connections are
made, coat all terminal connections using Quick-
silver Liquid Neoprene (92-25711), to avoid corro-
sion.

BLK
BLACK
BLU
BLUE
GRY
GRAY
RED
RED
YEL
YELLOW

h
BLK

YEL

YEL

b
BLK

RED GRY
RED
RED

RED
BLK

f c
YEL

YEL

GRY

d
e
GRY
YEL
YEL
RED
RED

51000
a - Stator e - To Remote Control Harness
b - Terminal Block f - 20 Ampere Fuse
c - ToTachometer g - Battery (+) Positive Terminal
d - Votage Regulator/Rectifier h - Starter Solenoid

2B-10 ELECTRICAL AND IGNITION 90-13645--2 495

4 Cylinder 16 and 24 Ampere Battery
Charging Wiring Diagram
IMPORTANT: After electrical connections are
made, coat all terminal connections using Quick-
silver Liquid Neoprene (92-25711), to avoid corro-
sion.

BLK
BLACK
BLU
BLUE
GRY
GRAY
RED
RED
YEL
YELLOW
h

g
c
f

d
e

50406
a - Stator e - To Remote Control Harness
b - Terminal Block f - 20 Ampere Fuse
c - ToTachometer g - Battery (+) Positive Terminal
d - Voltage Regulator/Rectifier h - Starter Solenoid

90-13645--2 495 ELECTRICAL AND IGNITION 2B-11

4 Cylinder 16 Ampere Battery
Charging Wiring Diagram (with Small
Voltage Regulator/Rectifier)
IMPORTANT: After electrical connections are
made, coat all terminal connections using Quick-
silver Liquid Neoprene (92-25711), to avoid corro-
sion.

BLK
BLACK
BLU
BLUE
GRY
GRAY
RED
RED
YEL
YELLOW

YEL
YEL

RED GRY
RED
RED

RED
g
GRY

c
YEL

f
YEL

d
e
GRY
YEL
YEL
RED
RED

51001
a - Stator e - To Remote Control Harness
b - Terminal Block f - 20 Ampere Fuse
c - ToTachometer g - Battery (+) Positive Terminal
d - Voltage Regulator/Rectifier h - Starter Solenoid

2B-12 ELECTRICAL AND IGNITION 90-13645--2 495

3 Cylinder Battery Charging Diagram
with Battery Isolator
IMPORTANT: After electrical connections are
made, coat all terminal connections using Quick-
silver Liquid Neoprene (92-25711), to avoid corro-
sion.

BLK
BLACK
BLU
BLUE
GRY
GRAY
RED
RED
YEL
YELLOW j

i Move Red Lead From

Start Solenoid to
Position Shown
h d
g

Start e User Supplied Red Lead

Battery
(10 Gauge Minimum Diameter
with Protective Abrasive Sleeve
Installed) Move Lead From Red
Stud to Position Shown

Screw Size
f #10-16x3/8”
P/N 10-62568

50403
a - Stator f - Auxiliary Battery
b - Terminal Block g - Start Battery
c - To Tachometer h - To Remote Control Harness
d - Voltage Regulator/Rectifier i - 20 Ampere Fuse
e - Battery Isolator j - Starter Solenoid

90-13645--2 495 ELECTRICAL AND IGNITION 2B-13

3 Cylinder Battery Charging Diagram
with Battery Isolator (Small Voltage
Regulator)
IMPORTANT: After electrical connections are
made, coat all terminal connections using Quick-
silver Liquid Neoprene (92-25711), to avoid corro-
sion.

BLK
BLACK
BLU
BLUE
GRY
GRAY
RED
RED
YEL
YELLOW
j

YEL
YEL
BLK
BLK

RED GRY
RED

BLK

RED
GRY

Small c
YEL

Red
i
YEL

(Sense)Lead
RED

h
B1 d
A RED
g B2
GRY
YEL
YEL
RED
e Large Red RED
(Output) Lead

51051
a - Stator f - Auxiliary Battery
b - Terminal Block g - Start Battery
c - To Tachometer h - To Remote Control Harness
d - Voltage Regulator/Rectifier i - 20 Ampere Fuse
e - Battery Isolator j - Starter Solenoid

2B-14 ELECTRICAL AND IGNITION 90-13645--2 495

4 Cylinder Battery Charging Diagram
with Battery Isolator
IMPORTANT: After electrical connections are
made, coat all terminal connections using Quick-
silver Liquid Neoprene (92-25711), to avoid corro-
sion.

BLK
BLACK
BLU
BLUE
GRY
GRAY
RED
RED j
YEL
YELLOW

i Move Red Lead From

Start Solenoid to
h Position Shown d

g
e
User Supplied Red Lead
(10 Gauge Minimum Diameter
with Protective Abrasive Sleeve
Move Lead From Red
Installed)
Stud to Position Shown

Screw Size
f #10-16x3/8”
P/N 10-62568

50404
a - Stator f - Auxiliary Battery
b - Terminal Block g - Start Battery
c - To Tachometer h - To Remote Control Harness
d - Voltage Regulator/Rectifier i - 20 Ampere Fuse
e - Battery Isolator j - Starter Solenoid

90-13645--2 495 ELECTRICAL AND IGNITION 2B-15

4 Cylinder Battery Charging Diagram
with Battery Isolator (Small Voltage
Regulator)
IMPORTANT: After electrical connections are
made, coat all terminal connections using Quick-
silver Liquid Neoprene (92-25711), to avoid corro-
sion.

BLK
BLACK
BLU
BLUE
GRY
GRAY
RED
RED
YEL
YELLOW

YEL
YEL

b
RED GRY
RED

RED
GRY

Small
c
YEL

i Red (Sense)
YEL

Lead
RED

h B1
A RED d
g B2
GRY
YEL
YEL
e Large Red RED
RED
(Output) Lead

51050
a - Stator f - Auxiliary Battery
b - Terminal Block g - Start Battery
c - To Tachometer h - To Remote Control Harness
d - Voltage Regulator/Rectifier i - 20 Ampere Fuse
e - Battery Isolator j - Starter Solenoid

2B-16 ELECTRICAL AND IGNITION 90-13645--2 495

Rectifier Test d
a
c
WARNING
Disconnect battery leads from battery before b
testing rectifier. f
NOTE: Rectifier can be tested without removing from
engine.
e
1. Disconnect all wires from terminals on rectifier.
2. Use an ohmmeter (R x 1000 scale) and perform 07300
the following test. Refer to illustration for rectifier
a - Terminal d - Stator Terminals
terminal identification. b - Terminal e - Positive Terminal
c - Terminal f - Ground

Rectifier Test

Connect RED meter lead to ground,

BLACK lead alternately to terminals “a”
and “c”.

Continuity Indicated. No Continuity Indicated.

Connect BLACK meter lead to ground, Connect BLACK meter lead to ground,
RED lead alternately to terminals “a” RED lead alternately to terminals “a”
and “c”. and “c”.

No Continuity Indicated.
Continuity Indicated.
Connect BLACK meter lead to terminal “b”,
Replace Rectifier.
RED lead alternately to terminals “a” and
“c”.

Continuity Indicated.
No Continuity Indicated. Connect BLACK meter lead to terminal “b”,
Replace Rectifier. RED lead alternately to terminals “a” and
“c”.

Continuity Indicated.
No Continuity Indicated.
Connect RED meter lead to terminal “b”,
Replace Rectifier.
BLACK lead alternately to terminals “a” and
“c”.

No Continuity Indicated.
Continuity Indicated.
Connect RED meter lead to terminal “b”,
Replace Rectifier.
BLACK lead alternately to terminals “a” and
“c”.

No Continuity Indicated. Continuity Indicated. No Continuity Indicated. Continuity Indicated.

Rectifier tests OK. Replace Rectifier. Replace Rectifier. Rectifier tests OK.

90-13645--2 495 ELECTRICAL AND IGNITION 2B-17

Starting System
CAUTION
Starting System Components The starter motor may be damaged if operated
The starting system consists of the following compo- continuously. DO NOT operate continuously for
nents: more than 30 seconds. Allow a 2 minute cooling
period between starting attempts.
1. Battery
Troubleshooting the Starting Circuit
2. Starter Solenoid
Before beginning the starting circuit troubleshooting
3. Neutral Start Switch
flow chart, following, check first for the following
4. Starter Motor conditions:
5. Ignition Switch 1. Make sure that battery is fully charged.
Description 2. Check that control lever is in “neutral” position.
The function of the starting system is to crank the en- 3. Check terminals for corrosion and loose connec-
gine. The battery supplies electrical energy to crank tions.
the starter motor. When the ignition switch is turned 4. Check cables and wiring for frayed and worn in-
to “Start” position, the starter solenoid is activated sulation.
and completes the starting circuit between the battery
and starter. 5. Check in-line fuse in red wire; see diagram.

The neutral start switch opens the start circuit when

the shift control lever is not in neutral. This prevents
accidental starting when engine is in gear.

2B-18 ELECTRICAL AND IGNITION 90-13645--2 495

 Battery
Starter Solenoid

Starter

Starter Solenoid

Fuse Holder
(If Equipped)
(20 Amp Fuse)

Neutral Start Switch

(Located in Control Housing)
Ignition Switch
Starter Circuit
Starting Circuit Troubleshooting Flow Chart
Starter Motor Does Not Turn

SAFETY WARNING: Disconnect BLACK (starter motor)

cable from starter solenoid test point 1 BEFORE making
tests 1-thru-7 to prevent unexpected engine cranking.

TEST 1
Use an ohmmeter (R x 1 scale) and connect meter leads between
NEGATIVE (–) battery post and common powerhead ground.

No continuity indicated; there is an open circuit in the Continuity Indicated

BLACK negative (–) battery cable between the nega-
Proceed to TEST 2, on next page
tive (–) battery post and the powerhead.

Check cable for loose or corroded connections.

Check cable for open.

90-13645--2 495 ELECTRICAL AND IGNITION 2B-19

 TEST 2
No voltage reading; a - Disconnect BLACK ground wire(s) from Test Point 2.
proceed to TEST 3. b - Connect voltmeter between common engine ground and Test Point 2.
c - Turn ignition key to “Start” position.

TEST 3 12 Volt Reading*

a - Reconnect BLACK ground wire(s). Check BLACK ground wire for
b - Connect voltmeter between common engine ground and Test Point 3. poor connection or open circuit.
Reconnect ground wire to start-
c - Turn ignition key to “Start” position.
er solenoid; proceed to TEST 7.

No voltage reading; 12 Volt Reading

proceed to TEST 4. Defective starter solenoid.

TEST 4 12 Volt Reading*

a - Connect voltmeter between common Neutral start switch is open,
No voltage reading; engine ground and Test Point 4. or YELLOW/RED wire is
proceed to TEST 5. b - Turn ignition key to “Start” position. open between Test Points 4
and 3.

TEST 5 12 Volt Reading*

No voltage reading; Connect voltmeter between common Defective ignition switch.
proceed to TEST 6. engine ground and Test Point 5.

TEST 6
Connect voltmeter between common engine ground and Test Point 6.

12 Volt Reading*
No voltage reading; check RED wire be-
Check fuse in RED wire between test points 5 and 6.
tween battery (+) positive terminal and Test
Check for open RED wire between test points 5 and
Point 6.
6.

TEST 7
a - Connect voltmeter between common engine ground and Test Point 1.
b - Turn ignition key to “Start” position.

No voltage reading; 12 Volt Reading*

Defective starter solenoid. Should hear solenoid click; proceed to Test 8.

TEST 8
a - Reconnect BLACK (starter motor) cable to starter solenoid Test Point 1.
b - Connect voltmeter between common engine ground and Test Point 7.
c - Turn ignition key to “Start” position.

No voltage reading; check BLACK cable for 12 Volt Reading*

poor connection or open circuit. Check BLACK ground cable at starter for loose or cor-
roded connection, or open circuit. If cable is OK, check
* Battery Voltage starter motor.
2B-20 ELECTRICAL AND IGNITION 90-13645--2 495
Starter Motor Disassembly
Removal 1. Remove 2 thru bolts and commutator end cap,
taking care not to lose brush springs.
a
CAUTION
Disconnect battery leads from battery before
removing starter.
1. Disconnect battery leads from battery.
2. Disconnect YELLOW cable. a b
11646
3. Remove 4 bolts and remove starter clamps.
a - Thru Bolts
4. Remove starter. b - Commutator End Cap
5. Remove BLACK cable. 2. Pull armature from starter frame.
c 3. Remove locknut.

a
a b d

11659
a - Hold Armature Shaft With Wrench on Hex Portion of Drive
Assembly

4. Remove components from armature.

20412
a - YELLOW Cable c - Starter Clamps
e f g
b - Bolts (4) d - BLACK Cable
6. Remove 2 rubber collars and 2 rubber bumpers.
a
a

a b c d 11658
b a - Locknut e - Drive End Cap
11645 b - Spacer f - Armature Shaft
a - Rubber Collar b - Spacer (If Equipped) c - Spring g - Washer
d - Drive Assembly

90-13645--2 495 ELECTRICAL AND IGNITION 2B-21

Starter Cleaning, Inspection and 11. Check the armature for ground. See the following
procedure (“Testing”).
Testing
CLEANING AND INSPECTION Testing
1. Clean all starter motor parts. ARMATURE TEST FOR SHORTS
2. Check pinion teeth for chips, cracks or excessive Check armature for short circuits by placing on
wear. growler and holding hack saw blade over armature
core while armature is rotated. If saw blade vibrates,
3. Replace the drive clutch spring and/or collar if ten- armature is shorted. Recheck after cleaning between
sion is not adequate or if wear is excessive. commutator bars. If saw blade still vibrates, replace
4. Inspect brush holder for damage or for failure to armature.
hold brushes against commutator.
5. Replace brushes that are pitted or worn to less
than 1/4″ (6.4mm) in length.
6. Inspect the armature conductor (commutator bar
junction) for a tight connection. A loose connec-
tion (excessive heat from prolonged cranking
melts solder joints) results in a burned commuta-
tor bar.
7. Resurface and undercut a rough commutator as
follows:

CAUTION
Do not turn down the commutator excessively. 11669

a. Resurface the commutator and undercut the in- ARMATURE TEST FOR GROUND
sulation between the commutator bars 1/32″ 1. Set ohmmeter to (R x 1 scale). Place one lead of
(0.8mm) to the full width of the insulation and so ohmmeter on armature core or shaft and other
that the undercut is flat. lead on commutator.
b. Clean the commutator slots after undercutting. 2. If meter indicates continuity, armature is
c. Sand the commutator lightly with No. 00 sand- grounded and must be replaced.
paper to remove burrs, then clean the commu-
tator.
d. Recheck the armature on a growler for shorts
as specified in the following procedure (“Test-
ing”).
8. Open-circuited armatures often can be repaired.
The most likely place for an open circuit is at the
commutator bars, as a result of long cranking peri-
ods. Long cranking periods overheat the starter
motor so that solder in the connections melts and
is thrown out. The resulting poor connections then
cause arcing and burning of the commutator bars.
9. Repair bars, that are not excessively burned, by
resoldering the leads in bars (using rosin flux sol- 11675
der) and turning down the commutator in a lathe
to remove burned material, then undercut the
mica.
10. Clean out the copper or brush dust from slots be-
tween the commutator bars.

2B-22 ELECTRICAL AND IGNITION 90-13645--2 495

CHECKING POSITIVE BRUSHES AND STARTER SOLENOID TEST
TERMINAL
1. Disconnect all wires from solenoid.
Set ohmmeter to (R x 1 scale). Connect meter leads
2. Use an ohmmeter (R x 1 scale) and connect meter
between POSITIVE brushes. Meter must indicate full
leads between solenoid terminals 1 and 2.
continuity or zero resistance. If resistance is indi-
cated, inspect lead to brush and lead to POSITIVE 3. Connect a 12-volt power supply between sole-
terminal solder connection. If connection cannot be noid terminals 3 and 4. Solenoid should click and
repaired, brushes must be replaced. meter should read 0 ohms (full continuity).
4. If meter does not read 0 ohms (full continuity), re-
place solenoid.

b b

a
11673
a
1. 3.
a - POSITIVE (+) Brushes

TESTING NEGATIVE BRUSHES FOR GROUND a 4.

Set ohmmeter to (R x 1 scale). Place one lead of the
ohmmeter on the NEGATIVE brush and the other
lead on the end cap (bare metal). If the meter indi-
cates NO continuity, replace the NEGATIVE brush. 2.
Repeat this procedure on the other NEGATIVE
brush. 51809
a - 12-Volt Supply
b - VOA Leads

b
a

11674
a - NEGATIVE (–) Brushes
b - End Cap

90-13645--2 495 ELECTRICAL AND IGNITION 2B-23

Brush Replacement 2. If removed, reinstall parts on armature shaft. Use
a new locknut and tighten securely on end of
STARTER REASSEMBLY shaft.
1. If brushes were removed, replace as follows: e f g
a. Install POSITIVE brushes (along with POS-
ITIVE terminal) into commutator end cap.

b
i

h a b c d 11658
d
a - Locknut
d b - Spacer
c - Spring
e d - Drive Assembly
e - Drive End Cap
f f - Armature Shaft
c g - Washer
g
3. Lubricate helix threads on armature shaft with a
drop of SAE 10W oil.
11660
a - End Cap f - Split Washer 4. Lubricate bushing in drive end plate with a drop of
b - POSITIVE Brushes g - Hex Nut SAE 10W oil.
c - POSITIVE Terminal h - Long Brush Lead
d - Insulating Bushing i - Push Lead into Slot
e - Washer
b. Install NEGATIVE brushes (along with brush
holder).
c b
a

d d

b
11656
a - POSITIVE (+) Brushes
b - NEGATIVE (–) Brushes
c - Brush Holder
d - Bolts (Fasten NEGATIVE Brushes and Holder)

2B-24 ELECTRICAL AND IGNITION 90-13645--2 495

5. Position armature into starter frame. 7. Lubricate bushing (located in commutator end
cap) with one drop of SAE 10W oil. DO NOT over
6. To prevent damage to brushes and springs when
lubricate.
installing commutator end cap, it is recommended
that a brush retaining tool be made as shown: 8. Place springs and brushes into brush holder and
hold in place with brush retainer tool.
a
b
2”
2″

11661

90
a - Brush Retainer Tool

1-11/16″ Bend b - Bushing (DO NOT Over Lubricate)
9. Install armature into starter frame and align match
marks (a). Install commutator end cap onto starter
frame and align match marks (b). Remove brush
retainer tool. Install through bolts (c) and torque to
70 lb. in. (7.9 N·m).

1/2″
3/4″
c
c

3″

1-3/4″ a

Brush Retainer Tool Layout (Full Size)

b

18-Gauge Sheet Metal

Metric Scale
3″ = 76.2mm 11648
2″ = 50.8mm
1-3/4″ = 44.5mm a - Alignment Marks
1-11/16″ = 42.9mm b - Alignment Marks
3/4″ = 19.1mm
1/2″ = 12.7mm
c - Bolts [Torque to 70 lb. in. (7.9 N·m)]

90-13645--2 495 ELECTRICAL AND IGNITION 2B-25

Installation 2. Install components as shown.

1. Install 2 rubber collars and 2 rubber bumpers. 3. Connect battery leads to battery.

a l c b
a

i
e
b 11645
a - Rubber Collars
k d
b - Rubber Bumpers j
a
f
i
h
g

19452
a - Starter
b - Rubber Mount, oil tank
c - Clamp, upper
d - BLACK Cable
e - Bolt and Lockwasher
f - Clamp, lower
g - J-Clip (If Equipped)
h - BLACK Negative (-) Battery Cable
i - Bolts [Torque to 14.5 lb. ft. (19.7 N·m)]
j - Fuse Holder (If Equipped)
k - YELLOW Cable [Torque to nut to 60 lb. in. (6.7 N·m)]
l - Fuse Holder (If Equipped)

2B-26 ELECTRICAL AND IGNITION 90-13645--2 495