Flywheel And Starter Jamming Up

[IDFISHER]

On a '94 60 HP Johnson.....About once out of every 30- 50 starts or so, the points of the teeth of my flywheel and starter bendix will jam up together. When it does this, I have to spin the flywheel backwards to get them to disengage. Would a new bendix gear solve this?

 

[Crosbyman]

it should release have you check for dried up grease etc...

 

[IDFISHER]

it should release have you check for dried up grease etc...

Yes, the bendix is lubed and spins freely and will fall back down. The problem here is the teeth of the gear and flywheel not meshing and getting jammed with one another.

 

[F_R]

A common cause is the flywheel teeth are buggered up on their lower ends. Usually just a few teeth where the starter most often engage it. The rest probably are fine.

 

[racerone]

Those newer flywheels are cast iron.-----Every time the pinion hits them a wee bit of damage is done.-----They never had this issue with older flywheels that had a steel ring gear on them.----Any pictures of the damage in the 3 areas where motor typically stops ?

 

[IDFISHER]

Here are the 3 spots on the flywheel that are a little chewed up and 1 photo of the good teeth for reference. The flywheel definitely looks more chewed than the starter.

 

[racerone]

Typical damage !!----I have seen that before.------You need to replace the flywheel.-----Was not available new few years ago.-----Appears to be available now for $400 US or so.----At least it is now listed on ----evinrudeparts.ca ----at $500 in Canadian funds.-----Or search on E-BAY.

 

[Crosbyman]

any chance a welding shop could build up and reshape a few teeth with a file. ?

 

[racerone]

It is cast iron.-----Flywheel needs to be replaced !!!----This issue did not exist on flywheels before this fiasco started in 1991.----I work alone and have seen a number of these.----So I know there have been many failures.----Maybe I will come up with a proper repair / rework on these.-----It is a shame that the bean counters make these changes.-----But we know they had to compete and are now gone the way of the DODO.----But on the other hand it appears to me that some parts for older Johnson / Evinrude motors are now available again.----And listed at a lower price than years ago !!

 

[tphoyt]

I know a guy that tried brazing the teeth for this problem. The time spent prepping alone was insane. In the end the repaired worked but it didn’t last long.
I wouldn’t waste your money if you were thinking about going this route. You shouldn’t have to much trouble locating a new or good used flywheel.
Best

 

[Crosbyman]

TRY the AOMCI site classified want adds somebody must have one

lots of dealers sell parts if you search the wb

try Tim's outboard

 

[IDFISHER]

Thanks for all of the replies. As far as replacing the flywheel goes. Is it as simple as removing the flyweel nut, using a puller to get the old one off, and putting the new one back on? Is there a risk of throwing off timing or messing anything else up? I'm only semi-mechanical lol.

 

[tphoyt]

It’s just like you said. Easy as that.
Put the flywheel on dry as in don’t put any grease on the tapers. You can polish the tapers if needed with some 600 grit wet dry paper but you likely won’t need to.

 

[havoc_squad]

Need to verify timing pointer lines up with TDC accurately using piston stop tool when installing new flywheel. It would also be a good time to verify via Joe Reeves method that max timing is at least 4 degrees less than what is specified in service manual.

Use torque wrench to tighten to factory service manual specs. Do not use impact gun for tightening, only to remove.