Bendix gear and temp switch

[nslsubject]

No, they are not related (as far as I know). I have a 1993 Evinrude 90/65 model# E90JLETS with two problems:

1) The bendix gear is pretty chewed up and sometimes jams in the flywheel teeth (which are in good shape) when I try to start. It jams tight enough that the starter won't spin, won't slide up farther or back into place. While it's a simple enough matter to pop the engine cover and free the gear, it seems like the right thing to do is replace the offending bendix. Can I replace just the gear on top of the starter shaft? Is it as easy as it looks by removing locknut, nut, gear? Any idea of the price for one?

2) I have acquired a constant warning horn upon turning the key on. When I unplug both temp switch leads, it still blares. There is no obvious short in the tan wire on the wiring harness but I haven't gotten an electrical tester yet to check where I can't see. My question is this - if I need to test/replace one or both temp switches, how do I remove them? The leads seem to come directly out of some spongy foam plug without any obvious means of removal. I just got an OMC manual for my engine, looked in the "test your temperature switch" section and found the helpful advice, "Remove temperature switch." The manual apparently assumes that I have some working knowledge of my engine, (which I obviously don't or I wouldn't be asking).

I'd appreciate any info from you who DO have some working knowledge.

Thanks

 

[luckyinkentucky]

Re: Bendix gear and temp switch

Do a forum search on 'Warning Horn'. You will find more than enough topics to fit the bill. This topic gets brought up almost every day now.

 

[nslsubject]

Re: Bendix gear and temp switch

There do seem to be a lot of horn related issues. I must have read 50 of them. (I did search before posting.) While I haven't read every single one, none of them has metioned how to remove the temp switch should that be necessary. I think I have enough information to track down the problem, I'm just not sure how to remove the switch if I need to.

 

[cortes]

Re: Bendix gear and temp switch

There do seem to be a lot of horn related issues. I must have read 50 of them. (I did search before posting.) While I haven't read every single one, none of them has metioned how to remove the temp switch should that be necessary. I think I have enough information to track down the problem, I'm just not sure how to remove the switch if I need to.

On my 88spl, you have to remove the water jacket cover and gasket from the head to get to the temp switch.

 

[nslsubject]

Re: Bendix gear and temp switch

Thanks Cortes. I suspect that's the case in my engine as well, although clearly I don't know for sure. Will it be obvious what to do once I remove the the water jacket cover and gasket? Is it safe to assume I'd need a new gasket once I have removed the old one? This is all for future use at this point. I purchased an electrical tester and between selectively unplugging 1) the VRO harness, 2) both temp switch leads, 3) the external oil tank sensors and 4) using the continuity tester, I have (I think) narrowed the warning horn problem down to somewhere between the external oil tank sensor leads and the main wiring harness plug.

BTW - does Cortes have anything to do with Annacortes? I used to live in that part of the world.

 

[rickdb1boat]

Re: Bendix gear and temp switch

Many times the warning horn itself is at fault. If you rule out all other causes, replace the horn. The Bendix (Drive gear) can be replaced. It is about $30.00. I would also get the spring and spacer kit too. It's about $14.00...

 

[nslsubject]

Re: Bendix gear and temp switch

Thanks rickdb1boat. I see you are just a couple hours down the road from me. I'm not positive but I don't think it's the horn. With the oil reservoir switch disconnected, I get no constant horn when I turn on the key, unless I also disconnect the tan wire from the temp switch and ground it. Then I do get a constant horn. While I understand the need to figure out the grounding problem, for the time being, am I okay to keep the oil reservoir sensor disconnected? I have over a gallon of oil in the reservoir and only ten gallons of fuel. It's hard to imagine running low on oil on my next trip out.

Does disonnecting the reservoir sensor have any effect on the VRO (which is still plugged in?

 

[rickdb1boat]

Re: Bendix gear and temp switch

No harm to the VRO by disconnecting the wiring. Just keep a careful eye on the oil level. How bout' them Tigers???