Starter turns fine but won't engage flywheel.

[Procraft Bob]

1994 Mercury 115 hp. starter turns fine but won't engage flywheel. Worked fine until third time out this year, (yesterday) and gave no warning of impending disaster. Doesn't seem to be lacking current/power, gear on starter is clean and in good condition, but it doesn't attempt to "thrust up" and engage flywheel to attempt to start engine. Engine runs fine and all other electrical is fine as well. Before I purchase a new (50-66015) starter for a buck and a half, is there any way to check to see if the starter is just "dirty or "stuck?" [Original starter was replaced in 1998 according to date code on unit, but it's still pretty old.]

Sorry if there is already a thread on this matter; I searched but couldn't find a suitable match. Appreciate the help and advise. I want to get back on the water soon, so I'll get a starter ordered if that's the likely choice. Regards in advance.

 

[racerone]

Those starters are elegantly easy to take apart for inspection / repair.--------I test them all the time and install aftermarket brushes at $5.00 a set.-----Easy to do !!---------Don's rush out and buy a new starter.---------Now I had an after market starter do just what yours is doing and it may be a small manufacturing defect on the bendix.-------Perhaps use a small o-ring underneath the bendix as a " stopper " so it does not jam.

 

[Chris1956]

Gee, Clean the bendix. Sometimes the gear gets stuck and will not go up and engage the flywheel. If that is not the issue, it is likely the starter is not spinning fast enough. That could be a bad connection, bad brushes or a bad starter winding.

 

[Procraft Bob]

Thanks, guys for the tips and encouragement. I'm about to take it off and apart.

 

[gm280]

Odd to read this. This week I was helping my neighbor with his Onan Emerald Plus 4000 RV generator. He had a starter burn up on it and so he ordered a new one and a starter solenoid as well. Everything came in and was installed. All worked great for about 20 minutes and then the starter wouldn't engage the flywheel anymore. If spun like a top but no engagement. So we took the starter off and found out that the bendix gear was locked against the bottom of the starter plate and while it would spin, it couldn't sling it forward to engage the flywheel because it was stuck solid. Looking at the old one you could see a little clearance between the bendix gear and the plate. But the new one didn't have such a clearance and would get wedged there and stuck. So I removed the toothed gear and manual sanded it down to allow that clearance and reinstalled it again. Works perfectly now, it doesn't stick at all. So even new parts have some issues some times and you can either send them back and wait another few weeks, or make them work and move on. It was merely a few thousands of an inch clearance, but it make all the difference. That could be the same possibility with the start here as well...

 

[Procraft Bob]

Dears Sirs:

Thanks to you guys I'm back on the water in less than 1/2 day. Your suggestion, Rear Admiral, about the bendix gear getting stuck on the shaft was "exactly" the problem, and pointed me to the ultimate solution. .2 washers (modified with my grinder so they would fit down in the collar of the starter housing) to keep the gear from dropping down on the shaft so far that it could become "stuck" again, and not be able to "throw up" into position to engage the flywheel did the trick. Too bad I didn't know how simple it would be to break free; I might have been able to pry it loose yesterday with a screwdriver and not missed my fishing trip. Oh well, I waded the Lillie pads at a local lake instead, and caught a couple which I ate for lunch today. Couple perch, and a couple crappie.

Oh yea, it cost me $0.85 to buy the 5 washers, (although I only needed to use three) for the fix job. I guess I overspent......... LOL

Thanks again, gentlemen. Sounds like the generator problem above was the same issue/fix, Captain gm280. Tight lines!!!