Me again ugh Force 120 hp now a flywheel question

[griggsmars]

It's me again, trying to resolve the many problems with my probably 96-99 Force Mercury 120 hp motor. Now it is the flywheel, my flywheel was pretty damaged with broken magnets. I took the numbers off the flywheel (261-9007-c4) and tried to find a match. I found a flywheel on ebay with 261-9007-c4 stamped in it and ordered it. The problem is -although the same number is punched in it- my flywheel is 9-7/8 diameter with 98 teeth, the one I purchased is 9-5/8 with 95 teeth. The teeth seem to be at the same distance apart and mesh up perfectly when placed next to each other and turned. I looked everywhere to find the exact match to my flywheel but had no luck. My stator fits right in to the flywheel, so I will try it out but I am not confident that it will work out. Any thoughts? Sorry for all the posts Thank you, Griggsmars

 

[Redbarron%%]

You are looking at the casting numbers and that might be misleading.
If the ID of the flywheel is the same then it might well work for you and any mismatch at the starter be inconsequential.
You can look up the exact part # at one of the many dealers who have the parts listed on their website.

 

[pnwboat]

As long as the stator and trigger assy. fit properly, and the teeth on the starter engage fully with the teeth on the flywheel, it should be fine.

Just to be sure, measure the diameter of the trigger magnet located around the center hole of both flywheels. They should be the same.

 

[griggsmars]

Thank you, I will check that today.

 

[griggsmars]

Can I have the magnets replaced on my flywheel?

 

[griggsmars]

I tried to put the flywheel on today. The trigger and stator fit good and flywheel went right on, but being a smaller diameter the starter gear just barely touched the flywheel teeth when engaged. I am still trying to find the part number for a 96-99 flywheel. Thanks

 

[Redbarron%%]

261-859236T14

 

[Redbarron%%]

If you check Craigslist etc you can find 1996 + motors with flywheels for less than the cost of a new one.
Magnets can be epoxied in place, but you need to find an old flywheel.
There is a difference in the early and late flywheels as the later ones are for the CDM ignition and the earlier are for CDI.
The hub diameter and the arrangement of the trigger magnets are different in the earlier and later flywheels.
The magnets get rust between the magnets and the flywheel and come loose.

 

[griggsmars]

Thank you for the info, I'll start looking up that part #. I do have my original flywheel with the damaged magnets, if you know of some place that will glue on new magnets. Thanks again.

 

[griggsmars]

Man, the cheapest used flywheel of that part # is $400 + shipping New is over $600. My flywheel is in good condition, its just the magnets went to crap. I would love to find a company that would epoxy new magnets on to my flywheel. Any thoughts? Thank you

 

[pnwboat]

Contact this seller and see if they can give you the dimentions of the flywheel. I'm pretty sure it will work, but you need to verify.

Flywheel

 

[Redbarron%%]

Look for unloved 90 and 120 hp Force outboards in your area. The flywheel magnets are the same, but the hub and trigger magnets are different.
The trigger magnets have never given me a problem.
I buy flywheels when I can find them cheap when someone is parting put a Force (by Mercury) 90 or 120.

 

[jerryjerry05]

Myself, I've not had much luck in re-gluing magnets except the older ones that are one long band (pre 94/95)
Like Redbarron suggested look for scrap outboards and maybe you'll find a good flywheel?

 

[Redbarron%%]

Jerry, when all you can find are flywheels with the rust working it's way under the magnets you have to do something. I have had reglued magnets come loose as I was "learning" the technique, but have learned that you have to clean the magnets very well and also brighten up the flywheel surface where the go as well.
I have been using JB weld with a light coating on both magnet and flywheel and then making sure that they are well seated.
Unfortunately there is no way that I have to verify that the balance has not been thrown off with the process. At least no way that I have access to at a reasonable cost.
Also Good Morning and thanks again for all of your very good advice on these motors.
The collective information posted here is a really big reason I have been able to keep the FOrce motor in my Sport Jet Hobie running.
Without your and the others posting here the FOrce would be truly abandoned and laying out in the weeds.

 

[griggsmars]

Thank you for the advice. I reached out to James Foster from South Central Outboards, he got right back to me and said he had the flywheel I need. It is being shipped now. Thanks again

 

[jerryjerry05]

Let us know how it pans out??

 

[griggsmars]

Yes, I will ! Thank you again

 

[griggsmars]

I put on the new stator and flywheel on and she fired right up. Thank you to everyone for all your help!