Breaking starter bendix gears like crazy!

[surfsidewood]

I have a 1990 Evinrude 150 that is chewing up bendix gears. I've put three different starters on in the last two months. The third starter actually only lasted 2 trips. The first time out with it the nut and bushing that hold the gear on flew off. I thought maybe the factory just didn't tighten it down good. So I found it under the cowling and put it back together nice and tight. Then today I took the boat out, and the third time I started it, it completely broke the gear in half and ripped it off of the plate that it is connected to. The starter meshes well with the flywheel, and was not making any weird noises, no grinding, nothing. The clearance looks good. I'm stumped on this one. I would try to shim it but the way that it bolts to the case, does not allow any room for shims at all. Does anyone have any idea what this could be?
Thanks in advance for any help.

 

[scmutiger]

Re: Breaking starter bendix gears like crazy!

1: loosen all three bolts on the starter

**** 2: tighten the front bolt first (torque to spec) while holding the starter gear in the flywheel teeth so it fits perfectly


3: torque the other two bolts per spec

 

[surfsidewood]

Re: Breaking starter bendix gears like crazy!

Got the new starter, and put it on the way it says. I guess all I can do now is wait. I'll post again soon. Anybody have any ideas why this would be happening?