Starter Problems

[lockednatrunk]

So here is my story:

I have a 1999 Larson 186 LXi BR with a 4.3L Volvo Penta Gi that I recently bought from a friend. When we bought it, would click once when you turned the key but wouldn't start. It would do this a few times before finally turning over and starting the engine. My initial thought was that the battery was going bad so I had it tested. It was bad, so I replaced it but it didn't fix the problem.

I then moved to the slave solenoid. The voltage across it was fine while trying to start it but I thought, "what the heck? I will make a jumper anyway and see if maybe it is an intermittent problem." Even with a jumper, bypassing the slave, I still had the problem which led me to believe the starter was bad (because I could hear the solenoid switch engaging and disengaging). I took the starter apart and noticed the brushes were pretty gunked up so I decided to have it rebuilt.

I took the starter to a local shop and had them rebuild it. I got it back and noticed they replaced the solenoid anyway which i guess is typical for a rebuild. After re-installing the starter on the boat and attempting to crank it, i can hear the starter spinning but not engaging the flywheel. My first reaction was that maybe the bendix was seized (because the teeth on the flywheel are fine). I took it back off, lubed the shaft, and moved the bendix with some pliers (i couldn't reach it with my fingers).

I then decided to bench test the starter to see if the bendix was moving at all. During the test, i noticed that it would come about 3/4 of the way up the shaft while it was spinning. I would think the bendix should go the entire length of the shaft and spin against the bearing on the other end. Could this be why my starter is not engaging the flywheel?

I called the shop who rebuilt the starter and they said for me to bring the starter in and they would look at it. They mentioned something about the possibility of someone crossing the wires. I plan to take the starter by tomorrow but I wanted some other thoughts on the matter.

 

[ebird99]

Re: Starter Problems

OK, I'm not an expert, but here is what I think I know. Did they rebuild the starter and not put on a new bendix? If so your story sounds like it needs a bendix for a happy ending. I had my starter off and put on a new bendix, when I did the bench test with a 12V charger/starter the bendix gear did not spin to the top however when hook up to the motor it worked fine. Good Luck

 

[lockednatrunk]

Re: Starter Problems

So the bendix must extend all the way down the shaft to engage the flywheel? That would explain why I can't hear it hitting the flywheel. I also tested the starter while it was connected to the boat but not bolted in. This also yielded the same results (bendix not extending the entire length of the shaft).

I can't tell if they put a new bendix on, but that is something i will definitely bring up when i take the starter back tomorrow.

Any other thoughts?

 

[bomar76]

Re: Starter Problems

How could you look at it and not be able to tell if the bendix was new or not?

 

[lockednatrunk]

Re: Starter Problems

Considering that this is the first bendix I have seen, I have nothing to compare it to. I would assume that a new bendix would be somewhat shiny. Since that is all i have to go by, then i would say they did not install a new one during the rebuild because the bendix that is on the starter is dull and appears to be used.

 

[lockednatrunk]

Re: Starter Problems

There weren't any shims on the starter when I removed it. Unless they were very thin and were stuck to the starter and were removed when the shop rebuilt it.

I took the starter to the shop today and they tested it. They tried to tell me that it was fine. I went back to where they were testing it and the bendix was coming out further than it was when i tested it but it still wasn't coming out all the way. They asked that i leave it with them and they would call me when they were finished looking it over.

About 20 minutes later, I received a call saying they were finished with it and that I could come and pick it up. I asked what was wrong and they said there was some in the way of the plunger, not allowing it to extend all of the way.

I plan to test it and install it tonight. Hopefully it works this time.

 

[lockednatrunk]

Re: Starter Problems

Eureka! It seems as if they got it right this time! I bench tested the starter when I got it home and the bendix went all the way to the end of the shaft. I then installed the starter on the boat and she fired right up on the first try! I let it run for a minute or two in an effort to charge the battery since I had been cranking on it for the last few days.

I checked it a few more times and it cranks on the first try every time now. WOO HOO!!