Mercruiser 3.0L starter problem (Bracket Measurement included)

[P3_sailor]

I started hearing a screach while starting the other day and it was coming from the back of the engine. It was only while the starter was engaged so I figured it was the starter. I did get some water in it a few months ago. It was the day I bought it (never had a boat before) so I got some pointers from the lady I bought it from and went to launch it at the base. I got it in the water and soon found out about this little thing called a bilge plug. Anyway it did get some water in it. I took it out yesterday to check it out and it was pretty rusty. I followed the instruction in the manual and took it apart. I cleaned it out and put some new grease the gears. It looks like I have the PG260 as the bolts are straight across from eachother and it has a bracket on the back. I got it all put back together today and tested it out like it says in the manual, although the manual says which connectors to test it on, it wasn't real clear which post was which on the solenoid. So I connected the 12v from a battery to the post where the yellow/red wire is and touch the negative from the battery to the post that has the wire going to the brush blocks (had those disconnected) The solenoid actuated fine. So I put it back on the engine and hook everything back up and when I go turn the key to the start position I hear the motor spinning but the solenoid doesn't seem to be pushing the gear out. I hooked everything back up just as it came out. I'm sure that I did because the nut and post for the brush wire had black paint on them and the post for the battery and fuse had green corrosion on it. I figured I would run it past some of the experts on here to make sure I have it hooked up right. I figure I broke it while I had it apart. I can get a new one but I figured I'd try to see if I could fix it first. It was starting before I took it out so I probably should have left it alone.
Here's a picture of the solenoid and it's connections.

Here's a shot of the flywheel clearance. There was no shims or spacer when I took it out.

Any advice would be greatly appreciated. Oh and the motor is from a 1999 Bayliner Capri 1952 cuddy with the 3.0L merc and alpha 1 outdrive. From what I've found looking at the serial numbers though the engine is from 1998. Thanks for your help

 

[myoldboat2]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

I've gone through some starters for my 1974 Merc 140. I went through some Arco starters, but had terrible luck and their support was even worse. Now I'm running a DB Electrical # 13251931 "Mercruiser 3.0 Marine Starter Long-Short Mount 6563 SDR0059" which cost about 60 bucks. Happy with the starter and the company. Once a starter starts acting up I've never had much luck with it, so I just replace it. The local shops can't rebuild them for the cost of today's throw away starters.

 

[xltier]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

i think you got the 2 big wires crossed.on my chevy boat motor the wire from the casing goes to the lower stud.

 

[P3_sailor]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

i think you got the 2 big wires crossed.on my chevy boat motor the wire from the casing goes to the lower stud.

I thought maybe I had done that but that battery stud post had the green corrosion and the other paint. Is will something bad happen if I swap them and it's wrong? Don't want to zap anything.

 

[P3_sailor]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

I've gone through some starters for my 1974 Merc 140. I went through some Arco starters, but had terrible luck and their support was even worse. Now I'm running a DB Electrical # 13251931 "Mercruiser 3.0 Marine Starter Long-Short Mount 6563 SDR0059" which cost about 60 bucks. Happy with the starter and the company. Once a starter starts acting up I've never had much luck with it, so I just replace it. The local shops can't rebuild them for the cost of today's throw away starters.

Wow, that looks just like it. $60 bucks! Thanks for recommending that, I might get 2 to have a spare around. Why the heck do the others I found cost $180?

 

[jtybt]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

Not sure what you connected the ground wire to...but connecting to anything but ground could very well burn up some wiring.

 

[myoldboat2]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

Wow, that looks just like it. $60 bucks! Thanks for recommending that, I might get 2 to have a spare around. Why the heck do the others I found cost $180?

No problem. Now my turn to ask a question. This is your first pic:

Where did you get that silver bracket that ties the end of the starter to the block (I assume where the old bracket for the big starters used to connect)? I rigged up some stiff wire to do that but I would like a bracket like that. Most new starters don't come with a bracket.

 

[P3_sailor]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

It was already on it. It's a pain to line up to get the bolt in. There are two holes in the side that mounts to the block and neither of them line up so you have to bend it a little. You would have to find a site with an illustrated parts breakdown to find a part number. There isn't any kind of part number stamped on it.

 

[myoldboat2]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

Even if it's a pain, I would transfer it to any new starter you mount. People (including me) have had broken starter bolts with the new starters that use just the two aft bolts. There is disagreement over whether the lack of bracket contributes to the breaking (some think it's just loose bolts), but I would sure keep that bracket in place.

Any part number would be from the starter mfgr. That's not your original starter, is it?

 

[P3_sailor]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

I don't know if it's the original. I just bought the boat 4th of July weekend. I'll definitely keep it on there, don't want to break anything.

 

[jtybt]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

Myoldboat,
If you can't find a bracket, I can fabricate one for you if you get me some fairly good Pix and dimensions. I wouldn't be able to drill the holes accurately so I'd leave that to you.

Id also need good pix of the space it would go in.

PM me the engine year etc,etc so I can maybe look one up.

 

[myoldboat2]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

Here's the pics of my goofy wired support. Not worth much, I'm afraid. P3_sailor, I'm sending you a PM, hoping to get dimensions from your bracket.

 

[jtybt]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

MOB2

Is that a 5/16" stud at the end of the starter?

Is the end of the starter directly below the mounting hole on the block?

Looks about 4" between the end of the starter to the mounting hole.

I just found a stock bracket/big starter. Check/compare stock starter and small starter mounting position. That'll give me something to copy.

 

[myoldboat2]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

> Is that a 5/16" stud at the end of the starter?

I'm not sure. That's my only starter right now, on the boat! I have to get a friend over with small enough arms to get down in there.


> Is the end of the starter directly below the mounting hole on the block?

No, the ultra-fancy support (the green wire) goes fore on the boat a few inches in going from the block stud to the starter stud.


> Looks about 4" between the end of the starter to the mounting hole.

I was hoping to measure that, but couldn't get at it when I tried today. I'll try to get someone with smaller hands and arms who can get a ruler or tape down in there.


> I just found a stock bracket/big starter. Check/compare stock starter and small starter mounting position. That'll give me something to copy.

I'm not sure what you mean. My old giant heavy stock starter is long gone. I think I might have the bracket somewhere, not sure. The old bracket was a glorified gusset bracket. But in this case, the starter stud is fore of the block stud and the smaller diameter of the starter means a longer reach.

 

[jtybt]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

That's part of what I wanted to know. In the diagram online, the block showed a 'mid point' mounting bracket for the large starter. A measurement between those two block mounting holes would make a better base for a bracket then just the 'end' bracket. Also measure the point where the end stud on the starter lines up between those two mounting holes on the block. I also need to know if the two mounting holes are on the block surface or, as it looked in the diagram, the aft hole was in a mounting boss away from the surface of the block.

I may be able to get down to a merc dealer/mechanic and get lucky if he has a 3.0 block in the yard. Gotta drop an engine in a boat in the morning, though.

 

[rodbolt]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

there were a few 3.0L engines by both volvo and mercruiser that had the fwd end bracket. the threaded hole in the block is already there but not all PGM starters have the stud in the upper starter case bolt.
its a very good idea to have it.
most starter bolts break because they are loose.
and NEVER reuse the starter bolts on a PGM starter.
once the knurled end has been wiped down it cannot refit the counter bore in the threaded hole in the bolk and will now allow the starter to walk ever so sligtly leading to yet another sheared bolt.

 

[P3_sailor]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

My new starter will be here on the 17th. The boat is at the storage lot right now. When I install the new one I'll get a few pictures and measure the length and the angle of it. It didn't look like any kind of special mounting bolt on the starter itself. It was held onto the end of the top starter bolt with a second nut.

 

[myoldboat2]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

Thanks P3.


rodbolt> once the knurled end has been wiped down it cannot refit the counter bore in the threaded hole in the bolk and will now allow the starter to walk ever so sligtly leading to yet another sheared bolt.

Can you say more about that? Are you saing the knurled starter bolts are designed to permanently deform when they are tightened down? I never reuse starter bolts, but I'd like to learn more about this. Thanks.

 

[P3_sailor]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

Here's the starter bracket. I wrote all of the measurements on the paper. If you can't see them let me know and I'll post them. I couldn't find my angle measuring tool. but the drawing is traced right from the bracket. Hope this helps some guys out.

 

[myoldboat2]

Re: Need Mercruiser 3.0L starter problem help

Re: Need Mercruiser 3.0L starter problem help

Excellent job, P3! Thank you. Question--by the two 23/64" holes--does your block have two studs, or do you choose one hole to use? Mine only has one stud.