2002 mercury 2 stroke 90hp

[thew3954]

Launched the boat end of May. Used a few times with no problems. Lately, i have had what I think is a starter motor issue? Turning the key over gets a click out of the starter and small turn of that spindle/cog at the top of the starter. The cog will not rotate more than a mm, and it will not move up to engage the flywheel. Is this a ground issue, or is this commonly just a bad starter? If it is a bad starter, it seems like it would be pretty straight forward to replace? The boat is on cape cod, and the local whaler/merc dealer i am sure is more than a week backed up at this point. I would not mind saving a few dollars, but I am concerned that it might be something other than just the starter?

thanks for the help

 

[narvlebenoit]

Re: 2002 mercury 2 stroke 90hp

Could be a bad connection clean your battery post and the rest of the connection.Make sure the battery is fully charged.

 

[thew3954]

Re: 2002 mercury 2 stroke 90hp

thanks.. i cranked down on the posts at the battery. sounds like I should check to see how clean the connections are? I am not sure if the battery is fully charged. Pretty dead at the begining of the season, and I jumped it off a portable battery/booster. Will a low battery cause the "click" and not the cog to jump up to the flywheel?

thx

 

[brunogreco]

Re: 2002 mercury 2 stroke 90hp

I would say a bad/dirty connection or a weak battery would definitely cause that problem.

 

[thew3954]

Re: 2002 mercury 2 stroke 90hp

pulled the battery and charged it. talked to a local merc mechanic about the issue. he said low battery, or possibly charger or cilinoid(sp).
sand papered the terminal ends, and tightened the bolts. still the exact same issues. small clicking and no love. He said that I could jump the terminals on the cilinoid?? Any help before I either buy a new starter? or take it to the mechanic?

thanks

 

[longshanks]

Re: 2002 mercury 2 stroke 90hp

how old is your battery? I recall having a similar problem, and the battery was around 5 years old, completely shot...

good luck

 

[lncoop]

Re: 2002 mercury 2 stroke 90hp

When you turn the key does the starter make a "whirring" noise and spin the shaft? If so, take a look at the bendix. It may just be slightly seized to the shaft. It's a fairly common problem with that model. If so, squirt a couple drops (not too much) of 3 in 1 oil (not WD40) on the shaft then spin the bendix between your thumb and forefinger to loosen it up.

 

[thew3954]

Re: 2002 mercury 2 stroke 90hp

The bendix moves slightly when the key is turned. more of a click sound. I can rotate the bendix up if I turn it by hand. I think counterclock wise. The battery is only a year old. thanks

 

[hkeiner]

Re: 2002 mercury 2 stroke 90hp

Performing systematic troubleshooting is sometime a good way to resolve a problem such as yours. The attached guide may help. It is for a different motor and so the points to test would be different, but the methodology would still apply. I you need more exact step-by-step troubleshooting guidance, a Mercury OEM shop manual for your motor would have it. Good luck.

http://forums.iboats.com/attachment.php?attachmentid=26803&d=1240510980

http://forums.iboats.com/attachment.php?attachmentid=26031&d=1239400111

http://forums.iboats.com/attachment.php?attachmentid=26032&d=1239400124

 

[thew3954]

Re: 2002 mercury 2 stroke 90hp

Thanks for the oem info. I just ordered the book. Is there a specific meter that is typically used. I have a few for the house, but would think a 12v meter would be different?

Thanks

 

[hkeiner]

Re: 2002 mercury 2 stroke 90hp

A simple multimeter (ohmmeter and voltmeter) is all you need to troubleshoot the starting circuits/system. If you were troubleshooting the ignition circuit/system, it would require a DVA meter for some of the tests. You don't appear to have a problem with the ignition system, only the starting system.

 

[sunray18ft]

Re: 2002 mercury 2 stroke 90hp

i have a 2002 mercury 90hp 2 stroke witch had the same problem. i cleaned all connections to starter then replaced the starter solenoid. the motor works fine now