1995 Force 90 Hp ate another starter

[rcb130]

Hello All,
Motor is a 1995 Force 90 Hp 3 cylinder S/N 0E104323.
Customer brought it to me after letting it sit for 2 years without being prepared for storage. It was running but sounded like a chainsaw at wide open throttle.
I slowed it down to a near normal idle. It then stalled out,
I checked the DVA readings for the Stator,trigger and output to the coils. I found the trigger and output from switch box to coil to be low, so I replaced both.
Still no start. Checked the fuel going to carbs and found it was nearly pure two cycle oil. All the gas had evaporated away from sitting. Replaced fuel filter, plugs,
and rebuilt carbs. Pumped primer bulb till fresh fuel came out at carbs.
Noticed starter shaft was bent. Replaced starter. No start. Noticed new starter shaft is bent already. All starter mounting bolts are tight. Lower starter mounting bracket in place and tight. Owner tells me he had replaced a starter due to a bent shaft for a total of three starters.
Compression is 120, 116 , 122 on cylinders.
No evidence of water in cylinders.
What would be causing this motor to eat starters?
Thanks
rcb130

 

[Derrick Fronckowiak]

Wow, seems like something is out of alignment. I'm assuming there is no warpage on the flywheel, no jacked up teeth on the flywheel, right? Also, when the starter is removed, how do the mounting holes for the starter look? Are any of them wallowed out/elongated? Also, (this might be a stretch) are you sure that if the exact correct starter for that motor? If the clearance between the starter shaft is too little (too close) to the flywheel, then when the starter pinion rotates and engages the teeth on the flywheel the load might be so great that it bends the starter shaft. Some automobiles have shims that are installed on the starter mounting pad to ensure the correct clearance (and loading) between the starter gear and the flywheel gear teeth. Shimming on these starters I really don't know about but would consider it before replacing one starter after another. Jiggz and JerryJerry might know more about this.

 

[rcb130]

What are jacked up teeth on flywheel? Never heard that term before.Will check for deformed mounting holes. It is the starter listed for this motor. There is no place for shimming an outboard starter on this motor.
Thanks
rcb130

 

[rcb130]

Following Derrick's suggestion I looked at the mounting holes. One is deformed (elongated) and the other is just enlarged. Is there a way to fix this or is this motor trash?
rcb130

 

[Jiggz]

I'm quite sure there is way to enlarge the deformed hole and maybe even the enlarged hole and use some kind of helicoil or inserts. To ensure the inserts stays use red thread lock especially one for high temp. If not sure how to do this, this is basically the same as repairing spark plug holes with broken thread.

 

[jerryjerry05]

You'd have to make sure the "repaired" holes are in exactly the right spot or it's gonna happen again.
You might be able to sleeve the holes and take up some slack.

Is the bottom bracket in place?

 

[rcb130]

Thanks to all for your input.
Yes the bottom bracket is in place and all fasteners are tight. Personally I do not think this repair is feasible unless the motor is knocked down and placed in a jig
to ensure correct alignment of the drilling fixture.
Thanks
rcb130