Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

[CH1968]

I try to start, and I see / hear the bendix gear spinning, but does not rise to engage the flywheel.

Next steps in troubleshooting this one?

Byte

 

[emdsapmgr]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

You may have a loose or corroded wiring connection. Recheck them, esp the battery connections. You can try to jump the starter direct from a fresh battery. If the starter kicks the engine over with no problem, you know it is not the starter. At that point, have a close look at the starter solenoid.

 

[etracer68]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

The shaft that the gear is on may need some light oil. It may be rusted, or have dirt on it. You should be able to rotate it by hand one way , and it just spins, and the other way ( clock wise looking down at it) it should screw up to engage the flywheel.

 

[CH1968]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

Thanks very much for your quick replies. Problem Fixed!!

It was Battery connections,,,,,

I incorrectly connected my battery up today (+ terminal to - lead, & - terminal to + lead).

Tried to start the damn thing and wondered why it would not start -

I cranked it over about 5 times and observe the bendix spinning but no engagement.

I then gave up and went inside - with battery still connected (for the next 5 hours).

I then had a look at the battery (lighting not the best in my garage) and found the error and quickly disconnected. I then reconnected battery correclty, and started first wack.

What I am now deeply concerned is damage to electrics (i.e. regulator and stator) - as the flywheel heated up BIG time for a long time.

What are your thoughts guys?

What does a very hot Flywheel mean?

Should I test any electrics for damage, if so - how?

CH1968

 

[1946Zephyr]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

Flywheel heating up?? That is a new one on me. The only thing I could think of, is it's dragging on something. Does it spin free by hand?
You might have to pull the flywheel and see how things under it look.

 

[CH1968]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

yeah - the flywheel heated up so much while the battery terminals were incorrectly connected. It was like a huge heat sink, and i was getting scared actually.

as soon as i disconnected the battery, the flywheel imediately began to cool slowly.

Anyway - the flywheel spins freely, and is no longer hot or even warm.

Best way to remove the flywheel and what tools do i need to do this (link)?

would i have cooked anything else not under the flywheel?

and, i need to replace my worn bendix gear - can these be acquired separately? how do i replace it?


CH1968

 

[JWhit]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

the stator is under the flywheel, so it's possible that is what heated up. to remove you'll need a puller and there are posts out there on how to do this. as for bendix, not sure as i've only rebuilt with new brushes and if it's moving up ok now not sure if you need to rebuild

 

[CH1968]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

the outboard still starts ok now.

can the stator still function normally, even if it has been heated up?

what is the sympton of a stator blown and/or not working?

Bendix still moves ok up and down on it's shaft.

CH1968

 

[emdsapmgr]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

The stator has two types of coils. Ones which charge the battery and ones which run the ignition. They are separate. Your charging coils probably got hot. Keep an eye on your boat's voltmeter to make sure the charging system is still functioning.

 

[jonesg]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

Rectifier/regulator blew. Does the tach still work?

 

[CH1968]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

i do not have a tach or voltmeter attached/connected in any way.

How else can i determine if the charging system is still functioning?

Where do i locate the rectifier/regulator?

if i remove the flywheel, how do i determine if the stator is still ok?

the outboard now kicks over and starts - does this have any bearing on the condition of all of these parts?

i.e. - if the stator or rectifier blew and stopped working. would the outboard still be able to start?

CH1968

 

[hidef]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

Do you have a portable volt / ohm meter? Even a cheap one from Radio Shack will work. With the outboard off check the battery voltage on the hot side of the starter solenoid. It should read some where around 12.5 to 13.4 volts depending on the condition of your battery. Now start the engine and then check your voltage again. You should see an increase in voltage if you do the system is charging and everything is fine. I would expect to see somewhere around 14 Volts with the engine running. If you see no increase in voltage you might have smoked something and you are going to have to do some resistance checks. For that you are going to want the service manual and it will tell you what you need to do. You don't have to rip the fly wheel off to determine if the stator is shot.

 

[CH1968]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

Thanks for reply.

Yes, I have a multi-meter that can display voltage.

I assume 'hot side of starter solenoid' is the point where the positive power lead connects to the starter solenoid - is this correct?

Where is the starter solenoid located? (on the starter motor??)

I will attempt to obtain the manual, over the next few days.

CH1968

 

[hidef]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

It will be located near the starter. Follow the wires from the battery. The red one is the hot one. You can order a manual at www.marineengine.com they ship priority post. The also have the engine schematics and parts breakdown for your engine.

 

[boobie]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

Just put your volt meter across the battery and it will probably tell you better on what's going on in the charging system. From reading your post I suspect you blew the rectifier and maybe hurt the charging system coils under the flywheel.

 

[CH1968]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

OK - I did some testing on the starter solenoid and across the battery - before and after running of outboard.

With the outboard off, I measured the battery voltage on the +ve side of the starter solenoid (12.49v).

I then ran the outboard and measured the voltage in the same location (12.50v - no change).

These same readings occurred across the battery.

I do not observe an increase in voltage - which may imply the system is not charging.

As a result, I probably need to perform those resistance checks being referred to......

This non-charging of system may have always been present (and before this latest incident), but was not measured at all since my ownership of this outboard.


Edit - Just bought myself a brand new OMC Rectifier - time to operate....


CH1968

 

[CH1968]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

i was successful in getting the flywheel off - yippy!

However, upon removing the rectifier, i snapped one of it's mounting bolts because it was locked in solid due to salt build up.

I also broke it's female thread (in block itself - shown in photo) in the process of trying to remove the rectifier because of this snapped bolt.

The snapped bolt is not an issue as I can easily replace it.

However, how should I approach this broken thread (in block), before i re-install the new unit (see attached picture below - first one on right hand side?



I have also spent considerable time flushing hot water down this cavity and repeatedly cleaning/scrapping/etc... It does look alot better since that photo as taken btw.

How should I best minimise the amount of salt/calcination build up within this water cavity and the system - now that the rectifier is off and have easier access to the water cooling system ?

I notice the 2 holes at the bottom of this cavity were blocked somewhat with gunk and wonder if this blockage would help contribute to overheating??

Also, I have just discovered a possible hole that is not supposed to be there. It is seen at the top of the cavity in the middle - as shown in this picture below.





Should I be concerned about this hole? If so, what do I need to do about it?





CH1968

 

[CH1968]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

......... thoughts?

 

[CH1968]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

what type of welding needs to be used to repair this johnson 1989 110HP 2T block (weld back on a broken thread for a bolt hole in the water cavity)?

CH1968

 

[jonesg]

Re: Bendix Gear Not Rising to Engage FLywheel (Johnson 1989 110HP 2T)

JB weld the hole or have it welded.
You might want a welder to have a look if the broken lug can be welded back in place, or a machine shop.
Then just get a heli-coil insert to replace the threads.
You might want to use one of the salt away type products to clear the water passages.