Thread: How to replace the starter in a 2001 Mercury 40HP ELPTO?

When it rains it pours!

As my Sea Nymph has other issues (see that newly posted thread), I also experienced a major issue in my newly revamped 1980’s Lowe Olympic 1652 JON boat that I use for hunting and over the last four months made improvements that makes if have more utility AND safer for me, so I can safely fish out of it!!!

However, none of the changes should have caused this issue in the 2001 Mercury outboard motor, a Mercury model 1041412YD 40 HP ELPTO, as IT WOULDNT START last weekend!

Now at first I thought it might be the starting battery as it’s more than six years old but it’s not.

When I turn the ignition key, all I get is a very small click from the motor area. It started last Saturday but we got it started the first time by pushing up on the starting motor gear shaft with the screwdriver while trying to start it. Then back to just a click. Finally had to use the pull rope…we finally made it back to the ramp.

I went over to work on it today and tried a new battery to no effect. Then I tried running a jumper cable to the output end of the solenoid to no effect.
Then I tried to run the jumper cables directly to the starter and…

I mucked up BIG TIME and missed the positive connection and hit a different bolt that was actually a ground and the SPARKS flew.

Just hope I didn’t cause additional damages..

Then I decided it most likely was a starter issue and proceeded to try and unbolt it to try simply running the jumper cable ends to it and I got two of three bolts off, as the third is underneath at the bottom of the lower lip of the motor case, making it very difficult to get at.

IT looks like I will need a rather short ratchet extension that bends or is jointed to get at that bolt…but I did not have one so I quit.

HOWEVER, I am open to suggestions, counsel, etc., as to how to get the starter off, or, am I barking up the wrong tree? AND, whether or not there are additional repairs Imcan make that I am missing?

I have attached a photo of the area in question.

Thank you in advance for your assistance.