200hp Johnson Starter not engaging

[Knockerjoe]

Hi, I have a 94 200hp Johnson Ocean Pro. The starter pinion will not engage sometimes. This problem has been intermitant since I bought the boat 3 years ago. Here is what i have done so far:<br />Went from a single battery with no battery switch to a dual battery with perko switch. <br />Replaced all battery cables. Cables run a long distance because of bracket. Used 2 gauge wire.<br />Relaced starter solenoid.<br />Removed starter and cleaned and lubed pinion shaft.<br />Hooked up jumper power pack directly to starter and does not repeat, started works strong.<br />I still have the same problem and it has been getting worse.<br />Usually it happens on the first start in the morning. Pinion will not engage for 2 or 3 turns of the key than will engage. Then will engage for most of the day sometimes repeating.<br />Any suggestions will be appreciated!

 

[Walker]

Re: 200hp Johnson Starter not engaging

Make suer your ground to motor is clean as well as the pos to solenoid and solenoid to starter wire.

 

[Knockerjoe]

Re: 200hp Johnson Starter not engaging

I have taken off every wire and cable in the system, cleaned and inspected.

 

[angus63]

Re: 200hp Johnson Starter not engaging

Remove starter assembly. Use a penetrating oil to clean the bendix and shaft. Use a light lube oil sparingly on the shaft. Reassemble and enjoy.<br />Edit: I see you did clean and lube, but excess oil and grease causes "stiction" and will result in bendix sticking after a sit. remove excess lube and use a real light oil sparingly.

 

[Knockerjoe]

Re: 200hp Johnson Starter not engaging

I have already done what you said (taking upart cleaning bendix and shaft) by reading and researching other posts. Any other ideas?

 

[flips]

Re: 200hp Johnson Starter not engaging

How is your boat battery,when you jump start to starter motor it works fine,this is with a booster battery.If battery is good maybe your wires are to long .When you had starter motor out did you check your brushes for wear also look for lose wires in starter.Also check that new solenoid new doesnt always mean good.<br />Cheers.

 

[Knockerjoe]

Re: 200hp Johnson Starter not engaging

I did not take the main section of the starter apart only the section with bendix and shaft. My next step may be to rebuild the starter although the starter works fine with the battry booster hooked up directly.

 

[flips]

Re: 200hp Johnson Starter not engaging

If it works fine with booster batt direct to starter motor .I would say starter is good.<br />What happens if you put booster bat on other batterys. What happens when you connect to solenoid with booster batt and take other batteries off.