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The electric starter on the Evinrude 25 is readily accessed by removing the engine cover. It has only one wire -- yellow with red stripes -- to disconnect and connect. The starter is usually grounded through the mounting bracket. A grounding strap may be present on some older models; it must be disconnected as part of the starter replacement process.
Items you will need
9/16-inch socket and socket wrench
5/16-inch open-end wrench
Removing the Old Starter
Remove the nut on the negative battery post, marked "NEG." Remove the black, negative battery-grounding-cable from the post before beginning work on the starter.
Twist the motor-cover latch; swing the back of the cover forward to remove it. The latch is found at the rear-center of the back of the cover. Set the cover aside for later reinstallation.
Tag and disconnect the yellow and red power cable from the terminal on the bottom of the starter; remove the nut from the terminal with an adjustable wrench. Look for a separate grounding cable on the starter; if one is found, tag and disconnect it from the starter.
Use a 9/16-inch socket and socket wrench to remove the two mounting bolts threaded through the mounting bracket. Lift the starter motor away from the motor's power head.
Installing the New Starter
Set the starter motor in place on the power head. Thread the retaining bolts through the mounting bracket and tighten securely. Attach the grounding cable you disconnected from the old starter -- but tagged and left in place -- if the starter motor requires a separate ground cable.
Slip the ring terminal over the terminal on the bottom of the new starter motor. This is the yellow and red power cable that runs from the solenoid; it was tagged when you removed the old starter. Tighten the terminal nut snugly with an adjustable wrench. Replace the motor cover and reconnect the battery cable.
Attach a garden hose to a water source. Attach a flushing attachment to the garden hose, and place the "ear muffs" of the flushing attachment over the water inlets of the motor. Turn the hose on full force. Start the motor to test the starter.
Turn off the water and disconnect the hose from the water source and the flushing attachment. Store the hose and put the flushing attachment away.
- Always use a 5/16-inch open-end wrench when removing the nut from the negative post of a marine battery. The positive post uses a 3/8-inch nut. If the lettering or cable color is obscured by dirt or oil, the 5/16-inch wrench won't fit on the positive post.
- Apply a a coating of spray-vinyl electrical insulation to the terminals of the starter.
- "Evinrude Repair Manual -- 2.5 to 250 HP Models, 2001-2009"; Seloc; 2009