Just a heads-up to anyone replacing a starter in an I/O Mercrusier.

I've replaced dozens of Mercrusier starters and I always use the best new
starters available from the same supplier. I've never had a premature failure of
the starter itself.

I replaced one in a 3.0 about a month ago and it was the first starter that came
with new mounting bolts.

Customer called Sunday with a complaint that the starter was making a funny
noise. Turns out the long mounting bolt had failed/sheared off (see link below).
There was nothing unusual about the install and I know I didn't over tighten it.

Luckily, with the help of an angle drill, mirror and an ez-out, I was able to
make everyone happy but I am going to rethink using supplied bolts.

http://www.rovatune.com/starterbolt.jpg

Larry

"Larry W" wrote in message
...
Just a heads-up to anyone replacing a starter in an I/O Mercrusier.

I've replaced dozens of Mercrusier starters and I always use the best new
starters available from the same supplier. I've never had a premature
failure of the starter itself.

I replaced one in a 3.0 about a month ago and it was the first starter
that came with new mounting bolts.

Customer called Sunday with a complaint that the starter was making a
funny noise. Turns out the long mounting bolt had failed/sheared off (see
link below). There was nothing unusual about the install and I know I
didn't over tighten it.

Luckily, with the help of an angle drill, mirror and an ez-out, I was able
to make everyone happy but I am going to rethink using supplied bolts.

http://www.rovatune.com/starterbolt.jpg

Larry


Made in China?

Eisboch

"Larry W" wrote in message
...
Just a heads-up to anyone replacing a starter in an I/O Mercrusier.


I replaced one in a 3.0 about a month ago and it was the first starter
that came with new mounting bolts.

Customer called Sunday with a complaint that the starter was making a
funny noise. Turns out the long mounting bolt had failed/sheared off (see
link below). There was nothing unusual about the install and I know I
didn't over tighten it.



Quite a few years back, MercCruiser, Volvo, and OMC had starter bolt
breakage problems with the 3.0L motor due to vibration the first year GM
changed to the small-diameter permanent-magnet starter housing. Each company
sent out service bulletins about, and incorporated into the following years
line-up, an L-shaped bracket from the back of the new starter to the engine
block. The bracket kept the starter from wobbling when the motor was idling,
thus keeping the bolts intact without breaking.

See your dealer for the bracket and hardware as I'm guessing that it was
probably not installed and tightened like it should have been. One bolt on
the back of the correct starter has a threaded stud for the bracket,
lockwasher, and nut. There is a threaded hole in the engine block for a
bolt to fasten the other end of the bracket.

Bill Grannis
service manager

Billgran wrote:
"Larry W" wrote in message
...
Just a heads-up to anyone replacing a starter in an I/O Mercrusier.

I replaced one in a 3.0 about a month ago and it was the first starter
that came with new mounting bolts.

Customer called Sunday with a complaint that the starter was making a
funny noise. Turns out the long mounting bolt had failed/sheared off (see
link below). There was nothing unusual about the install and I know I
didn't over tighten it.



Quite a few years back, MercCruiser, Volvo, and OMC had starter bolt
breakage problems with the 3.0L motor due to vibration the first year GM
changed to the small-diameter permanent-magnet starter housing. Each company
sent out service bulletins about, and incorporated into the following years
line-up, an L-shaped bracket from the back of the new starter to the engine
block. The bracket kept the starter from wobbling when the motor was idling,
thus keeping the bolts intact without breaking.

See your dealer for the bracket and hardware as I'm guessing that it was
probably not installed and tightened like it should have been. One bolt on
the back of the correct starter has a threaded stud for the bracket,
lockwasher, and nut. There is a threaded hole in the engine block for a
bolt to fasten the other end of the bracket.

Bill Grannis
service manager



Thanks Bill,

I've replaced many starters with the bracket but didn't know about the service
bulletin. I'm going back and install one today.

I think Tim is right that this was just a bad bolt. According to the customer
they only used the boat twice since the replacement.

Larry

On Jul 31, 9:36*am, Larry W wrote:
Billgran wrote:
"Larry W" wrote in message
...
Just a heads-up to anyone replacing a starter in an I/O Mercrusier.

I replaced one in a 3.0 about a month ago and it was the first starter
that came with new mounting bolts.

Customer called Sunday with a complaint that the starter was making a
funny noise. Turns out the long mounting bolt had failed/sheared off (see
link below). There was nothing unusual about the install and I know I
didn't over tighten it.

Quite a few years back, MercCruiser, Volvo, and OMC had starter bolt
breakage problems with the 3.0L motor due to vibration the first year GM
changed to the small-diameter permanent-magnet starter housing. Each company
sent out service bulletins about, and incorporated into the following years
line-up, an L-shaped bracket from the back of the new starter to the engine
block. The bracket kept the starter from wobbling when the motor was idling,
thus keeping the bolts intact without breaking.

See your dealer for the bracket and hardware as I'm guessing that it was
probably not installed and tightened like it should have been. One bolt on
the back of the correct starter has a threaded stud for the bracket,
lockwasher, and nut. There is a threaded hole in the engine block for *a
bolt to fasten the *other end of the bracket.

Bill Grannis
service manager

Thanks Bill,

I've replaced many starters with the bracket but didn't know about the service
bulletin. I'm going back and install one today.

I think Tim is right that this was just a bad bolt. According to the customer
they only used the boat twice since the replacement.

Larry- Hide quoted text -

- Show quoted text -

Yes, Larry. Notice where the bolt broke, right at the base of the
threads.
From what I understand, that when cutting the threads, sometimes the
die will stress the bolt at the base of the thread. it's not common,
but it does happen.

By the looks of the threaded end, evidently all was clean when it was
installed. I'm glad you were able to dig it out, especially in the
position you had to work with.

I know you've already done the work, but I probably would have put one
of the origional bolts back in.

Tim wrote:
On Jul 31, 9:36 am, Larry W wrote:
Billgran wrote:
"Larry W" wrote in message
...
Just a heads-up to anyone replacing a starter in an I/O Mercrusier.
I replaced one in a 3.0 about a month ago and it was the first starter
that came with new mounting bolts.
Customer called Sunday with a complaint that the starter was making a
funny noise. Turns out the long mounting bolt had failed/sheared off (see
link below). There was nothing unusual about the install and I know I
didn't over tighten it.
Quite a few years back, MercCruiser, Volvo, and OMC had starter bolt
breakage problems with the 3.0L motor due to vibration the first year GM
changed to the small-diameter permanent-magnet starter housing. Each company
sent out service bulletins about, and incorporated into the following years
line-up, an L-shaped bracket from the back of the new starter to the engine
block. The bracket kept the starter from wobbling when the motor was idling,
thus keeping the bolts intact without breaking.
See your dealer for the bracket and hardware as I'm guessing that it was
probably not installed and tightened like it should have been. One bolt on
the back of the correct starter has a threaded stud for the bracket,
lockwasher, and nut. There is a threaded hole in the engine block for a
bolt to fasten the other end of the bracket.
Bill Grannis
service manager
Thanks Bill,

I've replaced many starters with the bracket but didn't know about the service
bulletin. I'm going back and install one today.

I think Tim is right that this was just a bad bolt. According to the customer
they only used the boat twice since the replacement.

Larry- Hide quoted text -

- Show quoted text -

Yes, Larry. Notice where the bolt broke, right at the base of the
threads.
From what I understand, that when cutting the threads, sometimes the
die will stress the bolt at the base of the thread. it's not common,
but it does happen.

By the looks of the threaded end, evidently all was clean when it was
installed. I'm glad you were able to dig it out, especially in the
position you had to work with.

I know you've already done the work, but I probably would have put one
of the origional bolts back in.

Tim,

Yup, old bolt back in.

I do a lot of starters on the 8 lakes I service especially this year with the
amount of rain we've had. People don't realize the need for a decent cover or
automatic bilge - that's OK with me.

Larry

Does anyone have a link to example pictures or catalog of the "L
shaped starter bracket" referred to earlier by billgran (Bill
Grannis)?

I have a 1999 Sylvan 21’ bow-rider with a 5.7L Mercruiser which I
purchased used last year. I have had numerous problems with the
starter failing to engage properly with the flywheel, have replaced
starter motor 3 times, replaced the flywheel, had 2 different licensed
Mercruiser mechanics charge me over 2K in repair bills and they both
threw their hands up and stated they don’t know what is causing it to
fail continually.

I read these messages which got me thinking about the possibility of
the starter shifting / flexing away from the flywheel. I jammed a
wooden wedge between the starter housing and a longitudinal rib on the
boat frame and I have not had a problem since. I am cautiously
optimistic this is the cause of my problems and would like to locate a
bracket to fix the starter robustly to the engine block and prevent
shifting.

If anyone has pictures or a link to a site showing this type of
bracket, I would really appreciate it. I would prefer to buy a bracket
off the shelf if possible or I could have one made up. Example
pictures would be really useful in that case.

Thanks,

Mark

"Billgran" wrote:
"Larry W" wrote in message
...
Just a heads-up to anyone replacing a starter in an I/O
Mercrusier.


I replaced one in a 3.0 about a month ago and it was the
first starter
that came with new mounting bolts.

Customer called Sunday with a complaint that the starter was
making a
funny noise. Turns out the long mounting bolt had
failed/sheared off (see
link below). There was nothing unusual about the install and
I know I
didn't over tighten it.



Quite a few years back, MercCruiser, Volvo, and OMC had
starter bolt
breakage problems with the 3.0L motor due to vibration the
first year GM
changed to the small-diameter permanent-magnet starter
housing. Each company
sent out service bulletins about, and incorporated into the
following years
line-up, an L-shaped bracket from the back of the new starter
to the engine
block. The bracket kept the starter from wobbling when the
motor was idling,
thus keeping the bolts intact without breaking.

See your dealer for the bracket and hardware as I'm guessing
that it was
probably not installed and tightened like it should have been.
One bolt on
the back of the correct starter has a threaded stud for the
bracket,
lockwasher, and nut. There is a threaded hole in the engine
block for a
bolt to fasten the other end of the bracket.

Bill Grannis
service manager

--
Posted at author's request, using moderated http://www.BoatingForumz.com interface
Thread archive: http://www.BoatingForumz.com/Mercrus...pict99801.html

On Sep 8, 6:22*pm, mark wrote:
Does anyone have a link to example pictures or catalog of the "L
shaped starter bracket" referred to earlier by billgran (Bill
Grannis)?

I have a 1999 Sylvan 21’ bow-rider with a 5.7L Mercruiser which I
purchased used last year. I have had numerous problems with the
starter failing to engage properly with the flywheel, have replaced
starter motor 3 times, replaced the flywheel, had 2 different licensed
Mercruiser mechanics charge me over 2K in repair bills and they both
threw their hands up and stated they don’t know what is causing it to
fail continually.

I read these messages which got me thinking about the possibility of
the starter shifting / flexing away from the flywheel. I jammed a
wooden wedge between the starter housing and a longitudinal rib on the
boat frame and I have not had a problem since. I am cautiously
optimistic this is the cause of my problems and would like to locate a
bracket to fix the starter robustly to the engine block and prevent
shifting.

If anyone has pictures or a link to a site showing this type of
bracket, I would really appreciate it. I would prefer to buy a bracket
off the shelf if possible or I could have one made up. Example
pictures would be really useful in that case.

Thanks,

Mark


Mark , If your starter is the full sized model (10MT delco) then send
me your address and I'll mail you one. I have some just laying around.
one is yours for the asking.

It's the same bracket as off a 350/400/454 chevy truck from about 1976
up to about 2000.

Tschnautz at g mail dot com

The bracket shape depends on the starter. Do you hare the Delco direct
drive unit-(5" dia motor, big/heavy) or the newer,smaller planetary
drive starter. If big Delco, I have a bracket for you.
JR


mark wrote:
Does anyone have a link to example pictures or catalog of the "L
shaped starter bracket" referred to earlier by billgran (Bill
Grannis)?

I have a 1999 Sylvan 21’ bow-rider with a 5.7L Mercruiser which I
purchased used last year. I have had numerous problems with the
starter failing to engage properly with the flywheel, have replaced
starter motor 3 times, replaced the flywheel, had 2 different licensed
Mercruiser mechanics charge me over 2K in repair bills and they both
threw their hands up and stated they don’t know what is causing it to
fail continually.

I read these messages which got me thinking about the possibility of
the starter shifting / flexing away from the flywheel. I jammed a
wooden wedge between the starter housing and a longitudinal rib on the
boat frame and I have not had a problem since. I am cautiously
optimistic this is the cause of my problems and would like to locate a
bracket to fix the starter robustly to the engine block and prevent
shifting.

If anyone has pictures or a link to a site showing this type of
bracket, I would really appreciate it. I would prefer to buy a bracket
off the shelf if possible or I could have one made up. Example
pictures would be really useful in that case.

Thanks,

Mark

"Billgran" wrote:
"Larry W" wrote in message
...
Just a heads-up to anyone replacing a starter in an I/O
Mercrusier.


I replaced one in a 3.0 about a month ago and it was the
first starter
that came with new mounting bolts.

Customer called Sunday with a complaint that the starter was
making a
funny noise. Turns out the long mounting bolt had
failed/sheared off (see
link below). There was nothing unusual about the install and
I know I
didn't over tighten it.



Quite a few years back, MercCruiser, Volvo, and OMC had
starter bolt
breakage problems with the 3.0L motor due to vibration the
first year GM
changed to the small-diameter permanent-magnet starter
housing. Each company
sent out service bulletins about, and incorporated into the
following years
line-up, an L-shaped bracket from the back of the new starter
to the engine
block. The bracket kept the starter from wobbling when the
motor was idling,
thus keeping the bolts intact without breaking.

See your dealer for the bracket and hardware as I'm guessing
that it was
probably not installed and tightened like it should have been.
One bolt on
the back of the correct starter has a threaded stud for the
bracket,
lockwasher, and nut. There is a threaded hole in the engine
block for a
bolt to fasten the other end of the bracket.

Bill Grannis
service manager


--
--------------------------------------------------------------
Home Page: http://www.seanet.com/~jasonrnorth

On Jul 30, 9:37 pm, Larry W wrote:
Just a heads-up to anyone replacing a starter in an I/O Mercrusier.

I've replaced dozens of Mercrusier starters and I always use the best new
starters available from the same supplier. I've never had a premature failure of
the starter itself.

I replaced one in a 3.0 about a month ago and it was the first starter that came
with new mounting bolts.

Customer called Sunday with a complaint that the starter was making a funny
noise. Turns out the long mounting bolt had failed/sheared off (see link below).
There was nothing unusual about the install and I know I didn't over tighten it.

Luckily, with the help of an angle drill, mirror and an ez-out, I was able to
make everyone happy but I am going to rethink using supplied bolts.

http://www.rovatune.com/starterbolt.jpg

Larry

Then again, I've seen seemingly countless OE bolts broken off in the
block. especially 350 chevy's. Oh and naturally it would mostly break
on the 'inside" bolt, too!