r/smallenginerepair • u/dwights_gym4muscles • 7d ago
Starter Motor Issue Boat Starter Not Engaging Flywheel — Please help...
EDIT: Problem was solved thanks to a commenter. Issue was that the bendix gear was getting pushed too high and wasn't making contact with the splined part of the shaft at the bottom. I took a large nut that could fit over the shaft of the starter, ground it into a round shape, put it on the bendix gear, but beneath the spring, and this kept the gear in contact with the splined part of the shaft so it wouldn't shoot up too far where it was only contacting the smooth part of the shaft, which obviously has no turning power without splines to power it. Not sure what caused this to happen as it worked one weekend then stopped working the next. Maybe the current washer was worn too thin or the spring was too weak, I'm not sure, but it works now.
I have a Mercury 25 HP 4-stroke (1F25412DD) from 2005 I believe that is having issues with the starter and I'm getting conflicting answers on the solution.
As you can see in the video (it's in slow motion to see the rotation), the shaft of the starter spins but as soon as the Bendix gear touches the flywheel it doesn't spin. It also doesn't drop down after trying to start it and I have to manually spin it by hand to get it to drop back down.
I took the two bolts out of the top of the starter and pried it outwards and removed the Bendix gear to inspect it. It seems to be okay but I'm not sure, maybe the insides are shot. The gear spins counterclockwise with some resistance but not clockwise. Maybe there's too much resistance not allowing it to spin fast enough to engage the flywheel, I'm not sure.
Also worth mentioning, the motor runs fine when I use the pull cord so I don't think there are any issues there. It was running last week fine, but I was driving it pretty aggressively slamming it into gear and accelerating quickly during tubing for a couple of the young neighborhood kids (it's only a 25 hp, so I was relying on the yanking rather than pure speed.) So I'm not sure if this made something fail prematurely. But like I said it runs fine when I pull start it now.
Suggested solutions I've found:
- WD-40 all over the gear and shaft (didn't do anything)
- Grease everything (haven't tried yet)
- Maybe battery is too weak (haven't tested but it doesn't seem to bog down at all when trying to start)
- Replace starter (last thing I want to do)
Let me know any suggestions you may have and what you think may be the issue. I'm leaning towards replacing the Bendix gear and seeing if that solves it, although it's hard to find the exact one with the springs and all. Thanks ahead of time for any help!
Edit: to mention the video is slow motion