Starting System
90-864260200 AUGUST 2009 Page 4A-7
If longer battery cables are required, the cable gauge size must increase. See chart following for correct wire size.
a - Wire size by cross‑sectional
area (gauge)
b - Battery cable length
NOTE: Engine starting batteries should be located as close to engine as possible.
To select proper size positive (+) and negative (–) battery cables using the following procedure and chart:
1. Add the positive and negative cable lengths together.
2. Divide by 2 to obtain the average cable length.
IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical contact. Use electrical grade (rosin flux) solder
only. Do not use acid flux solder, as it may cause corrosion and a subsequent failure.
Average Cable Length Cable Size (Gauge)
Up to 1.1 m (3.5 ft.) 25 mm² (4)
1.1 ‑ 1.8 m (3.5 ‑ 6 ft.) 35 mm² (2)
1.8 ‑ 2.3 m (6 ‑ 7.5 ft.) 50 mm² (1)
2.3 ‑ 2.9 m (7.5 ‑ 9.5 ft.) 50 mm² (0)
2.9 ‑ 3.7 m (9.5 ‑ 12 ft.) 70 mm² (00)
3.7 ‑ 4.6 m (12 ‑ 15 ft.) 95 mm² (000)
4.6 ‑ 5.8 m (15 ‑ 19 ft.) 120 mm² (0000)
Starter
Starter Removal
!
WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death
due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery
before maintaining, servicing, installing, or removing engine or drive components.
1. Disconnect the battery cables from the battery.
2. Disconnect the wires from the solenoid terminals.
3. Remove the starter mounting bolts.
4. Pull the starter assembly away from the flywheel and remove from the engine.
a - PG260G1
b - PG260L
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