1976 6HP Johnson 6R76A Recoil starter pinion gear

[Royce Brown]

I broke the pinion gear on my 1976 6HP Johnson outboard, need to replace the old plastic gear, the teeth were heavily worn and I seem to have snapped off a piece that I believe the retaining clip latches onto. When I pull the cord it sounded really "chunky" compared to the normal sound, and I located a broken piece of what looks like a plastic washer in the bottom of the motor case.

I've found videos walking through how to redo the recoil assembly but I'm not sure how to remove the actual pinion gear (P/N 318447). A roll pin (P/N 309686) appears to hold the pinion on but I don't know how to remove it, does it just pull out or is there some type of trick to it?

Thanks, Royce

 

[F_R]

It is a tight fit. Use a hammer and pin punch to remove it. With starter removed from motor so you can support it while driving on it.

 

[Royce Brown]

Thank you. I assume you use the same method to drive the pin back in....

 

[Tim Frank]

I use a c-clamp to reinstall.

 

[Royce Brown]

During disassembly of the starter recoil assembly I came to notice that the Cam Follower (P/N 0398682) is missing from the assembly.

Is this something that I should replace or can I reassemble without & continue to use as purchased? It started and ran without the follower....

Thanks, Royce