Pull Start to Electric conversion??

[moi]

Turned 70 last month so I'm figuring it's time for me to have the convenience of electric start. Motor is a 20 horse Merc, s/n 0G093738 sold to me as a 1996 model but I think it's a '94. To make this as painless ($$$) as possible, the plan is to not include any kind of charging system. Just install a ring gear on the existing flywheel, an OEM equivalent starter and a starter solenoid. Seems to me that with a reasonably sized starting battery I should be able to get way more starts out of the thing for a days worth of my kind of fishing.

Wondering if anyone know of a reason why this wouldn't work or what kind of glitches I might run across. Don't know yet what kind of flywheel puller I'll need either..

 

[Jeep Man]

Re: Pull Start to Electric conversion??

It can be done, the biggest problem is cost. The changeover is close to what the motor is worth. Your two choices is to sell your motor and buy another that is electric start, or.... Buy a blown motor that requires a new power head or bottom end, salvage the parts you need and transfer them to your motor.

 

[moi]

Re: Pull Start to Electric conversion??

Thanks for the reply Jeep Man. But if the parts prices I'm finding on-line are anywhere near accurate I should be able to get it done for under $200.00. And around here a 20 HP Merc is worth a lot more than that. Also, I'm finding that some of the same parts are used on the 15, 20 and 25 HP engines as well, and for multiple years too. Just wish I didn't have to pop for a flywheel puller just for this one-time use.

 

[halfmoa]

Re: Pull Start to Electric conversion??

Just wish I didn't have to pop for a flywheel puller just for this one-time use.

I don't know if "Western Taxachusetts" has Autozone stores but they'll loan you one for the day for free. You just have to give them 20 bucks that they give back to you when you return the tool.

Oh, and you'll probably have to buy your own grade 8 bolts for the puller. If it comes with grade 8, and it probably won't, I'm sure they'll be bent.

 

[carholme]

Re: Pull Start to Electric conversion??

moi;

Your s/n comes up as a model:

10202014D MERCURY 1994 20

Parts listing:

http://www.crowleymarine.com/mercury-outboard/368.cfm

If you look under Accessories, you will see the various kits available and get an idea of the prices.

Service Manual P/N: 90-826883R03

http://1manual.com/Mercury manuals/Service Manual PDFs/TwoStroke/826883r2/cover.pdf

You must have Adobe Acrobat reader installed to use this manual. If you scroll down to the lower part of the opening page, you will see the various engine components in red. Click on the one you want and when the first page opens, click on the "Save As" icon at the top LH corner of the page and you can save it to your computer.

Gerry

 

[moi]

Re: Pull Start to Electric conversion??

Great info Gerry/carholm, much appreciated. After checking the price of a flywheel puller, will have to find an Autozone like halfmoa suggested. $300.00 bucks for a simple puller is nuts!

 

[Moody Blue]

Re: Pull Start to Electric conversion??

Here is a link to a combo lifting ring / flywheel puller for under $50. I've got one just like it and it works great.

http://www.ebay.com/itm/Mercury-Mar..._Accessories_Gear&vxp=mtr&hash=item5647583a1f

I did the electric conversion for my dad on his Evinrude motor and it was pretty straight forward.

I bought everything "used" on-line for about $200. Needed a flywheel, starter motor, starter motor mount, neutral start switch (and bracket), starter switch, battery cables and of course a battery. My dad had the battery and I had some cables that worked out perfectly. Took a few months to find the parts but I had all winter to do the research.

 

[water world]

Re: Pull Start to Electric conversion??

you can buy electric start kit from mercury and it has charging system. you will also need start button kit. part number for kit
50-90983A5 retail price $274.94. ring gear bolts to flywheel. button kit approx $60.00. standard three bolt puller will remove flywheel.
threads in flywheel are metric.

 

[Barnacle_Bill]

Re: Pull Start to Electric conversion??

I wish I could find one for my 9.9 that cheap. Best I can do is $430 and that is without a charging circuit.

 

[moi]

Re: Pull Start to Electric conversion??

you can buy electric start kit from mercury and it has charging system. you will also need start button kit. part number for kit
50-90983A5 retail price $274.94. ring gear bolts to flywheel. button kit approx $60.00. standard three bolt puller will remove flywheel.
threads in flywheel are metric.

WW, you must be Santa Clause 'cause I think I just found my Christmas present. And from the looks of the illustration I found for the kit, the start button & harness are included. Many thanks for the help.

 

[lagunaron]

Re: Pull Start to Electric conversion??

I don't know if "Western Taxachusetts" has Autozone stores but they'll loan you one for the day for free. You just have to give them 20 bucks that they give back to you when you return the tool.

Oh, and you'll probably have to buy your own grade 8 bolts for the puller. If it comes with grade 8, and it probably won't, I'm sure they'll be bent.

I just bought a flywheel puller could have most likely made one all it is is a flat piece of steel 4x4x1/2 with a center tapped hole and some smaller holes on different bolt circles most likely for other flywheels I got it from mercury parts express for 84.00 .

 

[lagunaron]

Re: Pull Start to Electric conversion??

I am in the same boat I am 64 years old and have a 1985 mercury 18XD outboard and it is a bear to pull start so I am going to convert it to electric start I bought the conversion kits from mercury parts express here are the part numbers ELECTRIC START KIT #50-90983A5 TILLER HANDLE HARNESS BUTTON #87-823609A7 and a FLYWHEEL PULLER #91-25733A3 hope this helps.

 

[moi]

Re: Pull Start to Electric conversion??

Well, I finally popped for the starter kit but don't expect to get it until the new year. I don't have the flywheel puller issue solved either so will have to beg, borrow or fabricate one when I need one. Thanks to all for the feedback & ideas.

 

[lagunaron]

Re: Pull Start to Electric conversion??

I just got my puller only setback is that I could have made one in my garage. You can borrow it after I am done with it. Hope this helps.

 

[moi]

Re: Pull Start to Electric conversion??

I just got my puller only setback is that I could have made one in my garage. You can borrow it after I am done with it. Hope this helps.

Don't know if your puller would work on my motor. The part number I get for my motor flywheel puller is 91-83164M. And they want approx. $300.00 if I want to buy one. I like the idea of making one in the shop/garage but I would need to find out the size of the bolts.
BTW lagunaron, where are you located??

 

[lagunaron]

Re: Pull Start to Electric conversion??

Don't know if your puller would work on my motor. The part number I get for my motor flywheel puller is 91-83164M. And they want approx. $300.00 if I want to buy one. I like the idea of making one in the shop/garage but I would need to find out the size of the bolts.
BTW lagunaron, where are you located??

I am in Parma Ohio.The draw bolt is a 1/2-13x3.625 square head and then there are (4)1/4-20x2.500 hex heads (3)1/4-20x3.000 hex heads (3) 10-24x3.000 oval heads (3)12-24x3.000 round heads the 1/2-13 bolt has a 30 degree point on it also there is a .810 dia. x 3.000 long pin with a .625 pilot dia x1/8 long on one end and at the other end there is a 30 degree x3/8 dia hole for the 1/2 bolt to pilot in the .625 pilot dia most likely pilots into the tapped hole on top of the power head now that I have the puller I was able to measure it and it is 3.500x3.500x1/2 thick and has a 1/2-13 tapped hole located 1.750 from one edge and 1.500 from the other edge and ther are (6) .200 dia. thru holes in the plate and also (13) .300 dia thru holes in the plate all of these holes are on different bolt circles most likely this is a universal puller to fit on different motors this puller can be made in the garage better yet in the shop if you got access to a drill press or a bridgeport mill. Hope this helps you out. Where are you located?

 

[moi]

Re: Pull Start to Electric conversion??

I am in Parma Ohio.The draw bolt is a 1/2-13x3.625 square head and then there are (4)1/4-20x2.500 hex heads (3)1/4-20x3.000 hex heads (3) 10-24x3.000 oval heads (3)12-24x3.000 round heads the 1/2-13 bolt has a 30 degree point on it also there is a .810 dia. x 3.000 long pin with a .625 pilot dia x1/8 long on one end and at the other end there is a 30 degree x3/8 dia hole for the 1/2 bolt to pilot in the .625 pilot dia most likely pilots into the tapped hole on top of the power head now that I have the puller I was able to measure it and it is 3.500x3.500x1/2 thick and has a 1/2-13 tapped hole located 1.750 from one edge and 1.500 from the other edge and ther are (6) .200 dia. thru holes in the plate and also (13) .300 dia thru holes in the plate all of these holes are on different bolt circles most likely this is a universal puller to fit on different motors this puller can be made in the garage better yet in the shop if you got access to a drill press or a bridgeport mill. Hope this helps you out. Where are you located?

I'm in a small town, Monson, in the west-central part of Massachusetts.
From your description I think you're right about yours being a "universal" puller. I found an illustration of the one for my motor and it's a typical round disc with a center threaded hole and three holes located on the circumference to bolt to the flywheel. There are no dimensions with the illustration so I won't be able to do any fabrication until I can access the flywheel. The bolts in the drawing are described as 10mm bolts but no thread count is provided so that will be an issue too. I'm set with the drill press and have some stock that I think will work out after I cut off a piece. Probably will start that today.

 

[Barnacle_Bill]

Re: Pull Start to Electric conversion??

I've pulled a lot of flywheels using one of these. http://shop.advanceautoparts.com/webapp/wcs/stores/servlet/product_13-Piece-Harmonic-Balancer-Puller-Set-Autocraft_9021507-P_N3491_T%7CGRP2083_____ I used it today to pull the flywheel off a 2000, 9.9, 4 stroke Mercury today. I did have to buy the metric bolts but that was no big deal.

 

[moi]

Re: Pull Start to Electric conversion??

I've pulled a lot of flywheels using one of these. http://shop.advanceautoparts.com/webapp/wcs/stores/servlet/product_13-Piece-Harmonic-Balancer-Puller-Set-Autocraft_9021507-P_N3491_T%7CGRP2083_____ I used it today to pull the flywheel off a 2000, 9.9, 4 stroke Mercury today. I did have to buy the metric bolts but that was no big deal.

Now that's interesting....Can you tell me what size (with thread count) the metric bolts were and were they class 8 bolts??

 

[lagunaron]

Re: Pull Start to Electric conversion??

I'm in a small town, Monson, in the west-central part of Massachusetts.
From your description I think you're right about yours being a "universal" puller. I found an illustration of the one for my motor and it's a typical round disc with a center threaded hole and three holes located on the circumference to bolt to the flywheel. There are no dimensions with the illustration so I won't be able to do any fabrication until I can access the flywheel. The bolts in the drawing are described as 10mm bolts but no thread count is provided so that will be an issue too. I'm set with the drill press and have some stock that I think will work out after I cut off a piece. Probably will start that today.

Good luck Moi hope every thing works out good for you keep me informed if you run in to any glitches. I can not start on my motor till spring time when I get the boat home out of winter storage. I will be working on my motor stand in the mean time. MERRY CHRISTMAS and keep in touch.