1999 Mariner 90hp starter pinion

[codcatchernz]

Have had problems with this engine breaking teeth off starter motor pinion.<br />Have looked at other mercury/mariner engines and have noticed chamfer on the leading edge of the fly wheel. Ours does not have this chamfer.<br />Could anyone else confirm is this motor meant to have this chamfer on the leading edge of the fly wheel?

 

[Silvertip]

Re: 1999 Mariner 90hp starter pinion

Was the starter or flywheel ever changed? Could be the pinion is not correct for the flywheel or the pinion is correct but the engine has had the flywheel replaced with an incorrect unit. That said, I just checked my 1998 75 HP Merc and the flywheel is not chamfered but the pinion gear is.

 

[codcatchernz]

Re: 1999 Mariner 90hp starter pinion

Brought the engine new so presume all parts are factory fit, have replaced 2 pinions now, both had chamfers on them, have never heard of this problem so interested to know the cause. All timings of the engine are correct so hoping engine is not kicking back

 

[Silvertip]

Re: 1999 Mariner 90hp starter pinion

Kickback may very well be a contributing factor. I have a friend who I fish with regularly. His 50HP Merc has jammed the pinion in the flywheel on two occasions but has never broken anything. I noticed that both times the engine seemed to kick back at start up. Upon inspection, I noticed the grooves in the starter shaft were fairly dirty and sticky so we cleaned that up and it's not been a problem since.