Starter or Fly Wheel??

[Jorgy79]

Our 1979 Johnson 140hp outboard was rebuilt a few years back; however, one part was not replaced. The cog on the starter motor which engages the fly wheel is worn. When we try to turn the motor over it squeals loudly, but we always seem to eventually get it going. The last time we tried starting the motor, the cog would not pop up to grab the fly wheel, but still seems to want to engage, but it still has that squealing sound.

Does this sound like the started AND the cog need to be replaced? If so, does anyone know where the cheapest reliable site is to purchase one? And most importantly, is it difficult to replace?

I appreciate your help!

Jorgy

[Solarman]

It really depends on IF the pinion gear on the starter is still available.

If you have a starter/ alternator repair shop locally, you could take the boat buy there and ask if the pinion gear has to be replaced (because of the squealing), he might lube it to see if that fixes it? He might also be able to look up the pinion gear to see if available?

I have two motors that the pinion gear tends to rust up (from humidity), and I continually lube them up to prevent them from sticking, and not engaging the flywheel. If they are not fee to spindle up when the starter first turns they won't engage.

The starter is not difficult to replace, compared to just the pinion gear assy.

If you plan to remove starter, take a few pics to know where wires and mounting clips need to go, before taking parts off.

Good luck. Post back when able if any other questions.

[Jorgy79]

flywheel / Starter 140hp

I appreciate your reply.

Because the cog doesn't engage, is that why we get the squealing sound? Or would that be the starter making that noise?

Also, the cog is pretty worn so when it did engage, the teeth don't grab well. The flywheel itself is in great condition. Can the cog alone be replaced? And if so, is that part pretty easy to replace ourselves? Would that still entail taking the complete starter off?

We did try lubing the cog by lifting it manually.

Sounds like we may have to bring it in (??)

[Jorgy79]

Johnson 140h fly wheel

Could it possibly be the solenoid? Would that cause an issue with the cog engaging?

[Solarman]

The cog as you call it, is the pinion gear. This pinion gear has a centrifugal cloth attach to another gear inside it. When the starter first starts to spin the clutch engages and the internal gear rides a great on the starter shaft. This engages the pinion gear. If pinion gear, or the clutch assy is worn, it should be replaced. The pinion gear and clutch assy should have a part number at your local dealership. If that pinion gear assy is not available, you will have to replace the starter, which should come with a new pinion gear assy already on the starter. Ask the parts person to be certain the new starter has the pinion gear (no need to by a starter if not included).

The starter is much easier to replace than the pinion gear assy is.

Good luck.