Mercury 50-879150A85 User manual

90-879312059 JUNE 2009 © 2009 Mercury Marine Page 1 / 6
50-879150A85
STARTER MOTOR KIT
75/90/115 EFI, 80/100 EU EFI FOURSTROKE
IMPORTANT: This document guides our dealers, boatbuilders, and company service
personnel in the proper installation or service of our products. If you have not been trained
in the recommended servicing or installation procedures for these or similar Mercury
Marine products, have the work performed by an authorized Mercury Marine dealer
technician. Improper installation or servicing of the Mercury product could result in
damage to the product or personal injury to those installing or operating the product.
NOTE: After completing installation, place these instructions with the product for
the owner's future use.
Components Contained in Kit
41588
c
d
e
f
i
g
a
b
h
Ref. Qty. Description Part Number
a 1 Starter motor assembly 879345T77
b 1 Cable assembly 84‑93388A8
c 4 Bolt (M8 x 45 hex flange) 10‑885526 45
d 4 Washer 12‑43430
e 2 Hose clip 54‑8M0040205
f 2 Nylon push‑in screw 10‑8M0037204
g 1 J‑clamp 54‑814634
h 2 Oetiker clamp (15.7 mm) 54‑888988‑015
i 1 Hose 32‑8M0040122

STARTER MOTOR KIT
Page 2 / 6 90-879312059 JUNE 2009
Starter Removal
! WARNING
Performing service or maintenance without first disconnecting the battery can cause
product damage, personal injury, or death due to fire, explosion, electrical shock, or
unexpected engine starting. Always disconnect the battery cables from the battery
before maintaining, servicing, installing, or removing engine or drive components.
1. Disconnect the battery cables from the battery.
2. Slide the red protection boot off of the starter power cable. Remove the positive (+)
cable from the starter solenoid. Retain the nut and lockwasher.
3. Disconnect the yellow/red wire bullet connector.
4. Bend/straighten the two J‑clips securing the crankcase ventilation hose to gain access
to the mounting bolts.
a
c
b
21931
a - Red protection boot
b - J‑clips securing the crankcase ventilation hose (2)
c - Yellow/red exciter wire
5. Remove the four bolts securing the starter mounting brackets. Remove the starter.
Discard the bolts and J‑clips.
6. Remove the Oetiker clamps securing the water hose to the cylinder block and fuel
supply module.

STARTER MOTOR KIT
90-879312059 JUNE 2009 Page 3 / 6
7. Remove the water hose and discard.
c
b
a
41700
a - J‑clips
b - Bolts (M8 x 40) (4)
c - Water hose
Starter Installation
NOTE: If the mounting bushings are not installed in the starter housing, refer to Mounting
Bushing Installation .
1. Assemble one of the mounting bolts with the metal J‑clip and a washer.
NOTE: The metal J‑clip is assembled on top of the washer on the lower right starter
mount.
2. Install the new starter onto the cylinder block.
3. Secure the starter with the new M8 x 45 bolts and washers. Tighten the bolts to the
specified torque.
4. Install the 15.7 mm Oetiker clamps onto the new water hose ends and install the hose
onto the fittings on the powerhead and fuel supply module.
5. Secure the water hose with the J‑clip and plastic clip. Allow sufficient clearance
between the hose and the lower left starter mounting bolt.
6. Crimp the two hose clamps securing the water hose.
IMPORTANT: Use only tool 91‑803146T (or Snap‑On equivalent YA3080) to crimp the
full circle hose clamp. Using a different tool could result in a crimp that is too loose or too
tight. Do not use a screw type hose clamp, it may damage the hose.
3924

STARTER MOTOR KIT
Page 4 / 6 90-879312059 JUNE 2009
Hose Clamp Tool Kit 91‑803146A04
5819
Aids in the installation of high pressure (Oetiker ®) hose
clamps. Clamp Tool (91‑803146T)
41688
ab
cd
e
f
f
a - Starter
b - Washer and bolt (M8 x 45) (4)
c - J‑clip
d - Plastic clip
e - Water hose
f - Oetiker clamp (15.7 mm) (2)
Description Nm lb‑in. lb‑ft
Starter mounting bolts (M8 x 45) 21 185
7. Remove the bolt securing the negative (–) battery cable to the cylinder block.
8. Apply Loctite 242 Threadlocker to the bolt threads.
9. Route the starter ground cable as shown.
10. Clean the cylinder block ground and cable connections.
11. Secure the starter ground cable and the negative (–) battery cable to the cylinder block
with the bolt. Tighten the bolt to the specified torque. Apply Liquid Neoprene to the
bolt and cable ends.
12. Install the two plastic hose clips onto the crankcase ventilation hose.
13. Secure the two clips to the starter with the nylon push‑in screws.
14. Connect the yellow/red wire bullet connector.
15. Install the positive (+) cable to the starter solenoid. Secure the cable with the retained
nut and lockwasher. Tighten the nut to the specified torque.
16. Apply Liquid Neoprene to the starter solenoid wire terminals.

STARTER MOTOR KIT
90-879312059 JUNE 2009 Page 5 / 6
17. Allow the Liquid Neoprene to dry and slide the red protection boot over the starter
solenoid positive (+) cable connection.
41680
a
g
ih
d
e
f
b
c
a - Crankcase ventilation hose
b - Hose clips
c - Plastic push‑in screw
d - Yellow/red wire
e - Positive (+) cable
f - Nut, lockwasher, and red protection
boot
g - Starter ground cable
h - Negative (–) battery cable
i - Bolt
Description Nm lb‑in. lb‑ft
Starter positive (+) cable nut 10 90
Ground cable bolt 17 150
Tube Ref No. Description Where Used Part No.
66 Loctite 242 Threadlocker Ground cable bolt 92-809821
Tube Ref No. Description Where Used Part No.
25 Liquid Neoprene
Starter solenoid wire
terminals, ground cable end,
negative battery cable end and
ground bolt
92- 25711 3

STARTER MOTOR KIT
Products of Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, MotorGuide, Mercury
Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo One, Bravo
Two, Bravo Three, Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero
Effort, VesselView, Zeus, Axius, Total Command, Skyhook, SeaCore, M with Waves logo, Mercury with
Waves logo, and SmartCraft logo are all trademarks or registered trademarks of Brunswick Corporation.
Mercury Product Protection logo is a registered service mark of Brunswick Corporation.
W6250 Pioneer Road
Fond du Lac, WI 54936-1939
Page 6 / 6 90-879312059 JUNE 2009
Mounting Bushing Installation
Lubricate the rubber mounts with water and install into the starter housing.
41692
a
b
c
a
a - Rubber mount (2)
b - Spacer
c - Starter housing