See full version: How to Test a Mercury Outboard Solenoid
Ground the black lead on the voltmeter to the block and touch the terminal end of the large red wire at the solenoid with the voltmeter's red lead. This wire must be the wire from the battery. The wire can be seen coming up through the lower cover. The other large terminal can be seen going to the starter. There should be 12 volts at the terminal from the battery. If there isn't, there is a problem with the battery or terminal. [links]
Check the small wire on the solenoid by removing it with a small wrench. With the black lead grounded as before touch the red lead to the small wire end as someone turns the key to start. There should be 12 volts every time the key is moved to the start position. This is the voltage to actuate the solenoid. If there is no voltage when the key is turned to the start position, there is a problem with the wire to the switch exits or a bad switch.
Set the voltmeter to 20 volts. Remove the cowl or engine cover from the engine to gain access to the solenoid. The solenoid on an outboard is usually on the right side of the engine, looking at it from the back looking toward the front of the boat.
The solenoid on a Mercury outboard motor is used to actuate the starter. It is nothing more than a remotely activated switch. It takes considerable amperage to operate the starter, which in turn requires a large diameter wire to carry the load. There are four terminals on the solenoid--two large-diameter posts and two small-diameter posts. A large wire (4-gauge or larger) goes from the B+ post on the solenoid and the other large post has the large diameter wire going directly to the starter. When the solenoid is not energized, there is an open circuit between these two large wires. When power from the key is sent to the small terminal of the solenoid, it energizes and causes the solenoid to create a closed circuit to the starter. [links]
Reconnect the small wire to the solenoid. If there is 12 volts to the large wire from the battery, and 12 volts to the small wire when the key is in the start position, the solenoid should click and there should be voltage on the other large terminal. Check this terminal if the solenoid does not click for 12 volts. If there is no voltage, the solenoid is bad and needs to be replaced. If there is 12 volts then the starter is bad.
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turn the key, starter still just spins fast but does not shoot up and engage with flywheel.
I have a '91 75hp mariner 3 banger. I've had intermittent issues with my starter just spinning and not engaging the flywheel over the last year, but now it doesn't work at all. I've read several threads on here about this, and I think I've tried everything.
heres what I've done:
-fully charged battery (recently passed load test)
-removed all cables from solenoid, starter, and battery and polished them to a shine, also battery posts
-put a couple drops of oil on the starter above the bendix here
-next I jumped the starter with booster cables from ground on battery to ground on block, positive to post on starter, and the starter still just spins and doesn't shoot up. more
Serial Numbers for Mercury Marine Outboards and Mercruiser Sterndrives are unique sets of numbers used to identify certain objects such as Marine Engines, Boats, Automobiles, Software, etc. In the case of Mercury Outboard Parts, Mercruiser Engine Parts, and Mercruiser Sterndrive parts it's the Serial Number that's used to identify the configuration of the Mercruiser Engine, Mercury Outboard or Mercruiser Sterndrive. For example if you own a 2003 Mercruiser 350 Mag MPI Sterndrive Engine and need to replace the Fuel Cooler the Mercruiser Serial Number is important because Mercruiser changed the design of the Fuel Cooler midway through that model year. Although you have a 2003 Model Sterndrive Engine it's the Serial Number that identifies which model of Fuel Cooler your Mercruiser Engine is equipped with.
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