'78 Evinrude starter gear

[Fullspectrum]

I thought I solved this problem, but now it's constantly happening. The starter gear will not pop up to catch the flywheel when I start the motor. Instead it will remain down and spin by itself. I noticed that when I take a flat head screw driver and push the coil that's around the shaft up and hold it there...I can then spin the gear upward. Once I do this...the motor will start until the gear gets stuck again. Then I would have to reopen the cover and redo the procedure I just mentioned. Does anybody have any solutions as to why the starter gear would remain stuck when I shut the motor off.

 

[Gary H NC]

Re: '78 Evinrude starter gear

Have you tried a little light machine oil on the shaft?

 

[HighTrim]

Re: '78 Evinrude starter gear

What is the current Voltage at the battery?

Then what is the voltage drop to the starter?

 

[Fullspectrum]

Re: '78 Evinrude starter gear

I have not tried machine oil yet, but probably will give it a try after this snow storm passes.

I just tested my battery with a Minn Kota battery reader and it's showing that my battery is "Full" at "12.9 V." Is that where the volts suppose to be at?

Could I spray some WD-40 on the gear and shaft as well?

 

[Theoutdoorsman]

Re: '78 Evinrude starter gear

I have not tried machine oil yet, but probably will give it a try after this snow storm passes.

I just tested my battery with a Minn Kota battery reader and it's showing that my battery is "Full" at "12.9 V." Is that where the volts suppose to be at?

Could I spray some WD-40 on the gear and shaft as well?

It'd be best to use the machine oil for this application. WD40 tend to "dry up" rather quickly and offers only a temperary means of lubrication. You might try it to see if this is ideed the solution to your problem and later add some heavier oil. It wouldn't hurt it.

 

[tashasdaddy]

Re: '78 Evinrude starter gear

90% of starter problems are bad connections. remove and clean both ends of the battery cables, so that they are shiney, also the cable from the solenoid to starter. check for nicks in the cables. and make sure the connectors are on the wire good. the cable tend to corrode from the inside out, if nicked, corroded wires, and connections, heat up and cause resistance to the follow of electricity, thus the starter doesn't get enough. you can also take jumper cable pos battery post to large post on starter. with a good connection, the engine should spin. then if the starter is good clean everything and retest. then trouble shoot solenoid. starters can be rebuit at a starter/alternator shop, much cheaper than a new one.

also have the battery load tested at the auto parts store, free, i've had new batteries go bad

 

[HighTrim]

Re: '78 Evinrude starter gear

OK your battery is fully charged (full is 12.65 Volts). I would also load test it, this can be done for free at about any auto store that sells batteries.

In lieu of sewing machine oil, use 3 in 1 oil, I would stay away from WD-40 for this application.

With that battery out of the boat (because I know you are getting it load tested right ) it is a good time to polish those connections like. Don?t just look at them, make them shine! Also inspect the wiring thoroughally, buldges in the insulation or crunching as you flex it are a sure sign that the wiring is corroded internally. Replace as needed.

Disconnect and inspect the large red harness plug in the cowl. Clean it as best you can with electrical contact cleaner, smear some grease around the contact edges and reconnect. Now use the ignition switch to try and start the engine. If it works every time the connector was the culprit. If not, you now need your trusty voltmeter.

Put the POS voltmeter lead on the small terminal on the solenoid. The NEG lead goes to ground. Have someone turn the ignition key to START. If you don't see 12V troubleshoot the harness between the engine and control box. If 12V is present every time, the switch is good.

Measure the voltage at the starter (+) terminal while somebody turns the key over to "start" - if you get within half a volt or so of the battery voltage(12.65), the starter is likely faulty.

If you get a bad voltage at the starter (with clean tight connections), measure the voltage at the solenoid small terminal with the yellow/red wire with the key turned over to "start" you should read within a half-volt of battery voltage(which is again, 12.65), otherwise you have a wiring fault between the keyswitch & solenoid. Good voltage at solenoid but bad voltage at starter means faulty solenoid.

Now connect a single jumper cable between the POS battery terminal and directly to the large terminal on the starter. If the starter spins each time you do that, the solenoid is likely the culprit.

Connect another jumper cable to the NEG battery terminal and a good ground (bare bolt head or bracket) on the engine. Now do the same test you just did. If the starter now goes ok, you have a negative battery cable problem or the solenoid is bad.

 

[samo_ott]

Re: '78 Evinrude starter gear

I have a different answer. I had a buddy with an old 25hp and he had the same (similar?) problem. Turned out the shaft was slightly bent and the gear could not go up on it's own.

 

[Fullspectrum]

Re: '78 Evinrude starter gear

The motor ran fine up until just recently. I will do all that was mentioned here and see if these tips will help solve the problem. If not...I'll be back. Thanks!