40 hp Merc Starter Issue

[Barley109]

I have a 40 hp Mercury engine with a jet prop attached. The Starter is an electric start and just clicks when key is turned. We hooked up a car battery directly to the starter and tried again....Just Clicks. Last season we noticed that it was not raising to engage with the teeth on the engine and it looked dry so we greased it a little and whammo, started right up for a few times. Pulled it out for the first time this weekend and bam - Nuthin but clicks.<br />Can the starter be rebuilt by an amateur?<br />What kind of cost is of one of these rebuild kits in terms of first timer headaches?<br /><br />Thanks for your help and direction!<br /><br />Mark in PA

 

[John Reynolds]

Re: 40 hp Merc Starter Issue

I "rebuilt" my starter for my 40 hp Mercury mark 55E. It was doing like yours, the clicking being the starter selonoid (or relay) but no action from the starter. Mostly, I cleaned it up and replaced the brushes. Starter works good! My starter had four brushes, but most have two, I heard. I got the brushes at NAPA. Had to do a little soldering. If the brushes get worn to the point that they no longer make good connection to the commutator of the starter's armature, then you get a big fat nothin' like your gettin'. I took the feild coils out, and sprayed and soaked them with a poly coating for added insulation. I greased the ends of the armature so that it would turn easier. The main thing was the brushes, which were badly worn. One was almost gone. it's pretty easy; there are two long bolts that go through it length-wise that hold it all together. What is your motor?

 

[kenroughty]

Re: 40 hp Merc Starter Issue

I got my starter apart to see if the brushes needed to be replaced, but they were ok. I hAve the one with 4 brushes. How do you get the brushes to stay in while putting the thing back together? I only have 2 hands, but it seems you need 4 to keep the springs and brushes in. <br /><br />Thanks,<br />Keith