Stuck pinion drive gears

[TVZ]

The pinion drive gear (starter gear) on my 1971 Evinrude 40 has a bad habit of occasionally getting stuck and not retracting because the gears get stuck together rather than meshing properly (See photo; you can't quite see it, but the teeth are stuck, tooth against tooth). I then take a bolt, hold it against the gear, and use a hammer to knock it down. Any idea how I can permanently fix this? I have replaced it, but only w/ a used one, as that was all I could find. Would it be good to grease these gears? Anything else I can try?

 

[F_R]

The pinion does not fall down by itself. It is kicked down by the flywheel when the engine starts. Same thing as what you are doing with your hammer and bolt. In other words, it ain't broke.

 

[TVZ]

The pinion does not fall down by itself. It is kicked down by the flywheel when the engine starts. Same thing as what you are doing with your hammer and bolt. In other words, it ain't broke.

Thnx F_R, but mine comes up and engages the flywheel when you turn the key. Then it's supposed to fall back down. But it sometimes becomes jammed, tooth against tooth with the flywheel, and does not go back down. Then when you turn the key to start it, nothing happens. You have to force it down with the hammer to fix it so the engine will turn over.

 

[racerone]

When the pinion is up there something has to TURN to get the pinion back down.

 

[F_R]

Thnx F_R, but mine comes up and engages the flywheel when you turn the key. Then it's supposed to fall back down. But it sometimes becomes jammed, tooth against tooth with the flywheel, and does not go back down. Then when you turn the key to start it, nothing happens. You have to force it down with the hammer to fix it so the engine will turn over.

I repeat, it is not supposed to "fall back down", but it might. When the motor starts running the flywheel kicks it back down. If it won't crank again, there is something else wrong. I have worked on thousands of those motors.

 

[racerone]

^^^^^----Another round of applause for F R-----TVZ----In order for the pinion to go down it must TURN.----The pinion gear is on a helix !!!

 

[TVZ]

I repeat, it is not supposed to "fall back down", but it might. When the motor starts running the flywheel kicks it back down. If it won't crank again, there is something else wrong. I have worked on thousands of those motors.

I think the crux of the matter is that the pinion gets jammed against the flywheel, tooth-to-tooth, so nothing can move until I knock it down with a hammer and a big bolt.

 

[racerone]

Good luck sorting this out.

 

[F_R]

I think the crux of the matter is that the pinion gets jammed against the flywheel, tooth-to-tooth, so nothing can move until I knock it down with a hammer and a big bolt.

OK, I think I am beginning to understand what you are trying to tell us. Are you saying the pinion comes up and the ENDS of the teeth jam against the ENDS of the flywheel teeth? Not that they mesh and stay meshed? If that is what you mean, the problem is the pinion teeth or flywheel teeth (or both) are battered and worn on their ends. More than likely the flywheel teeth, since it only happens occasionally, according to you. Take a good look at the flywheel teeth in the area it is prone to jam, and compare with the rest of the way around. I must say, the condition is fairly rare, but I have seen it.

 

[TVZ]

OK, I think I am beginning to understand what you are trying to tell us. Are you saying the pinion comes up and the ENDS of the teeth jam against the ENDS of the flywheel teeth? Not that they mesh and stay meshed? If that is what you mean, the problem is the pinion teeth or flywheel teeth (or both) are battered and worn on their ends. More than likely the flywheel teeth, since it only happens occasionally, according to you. Take a good look at the flywheel teeth in the area it is prone to jam, and compare with the rest of the way around. I must say, the condition is fairly rare, but I have seen it.

Yes, the tops of the teeth sometimes get stuck together rather than pinion teeth meshing into the valleys of the flywheel. Actually, the flywheel teeth all look pretty good. The pinion gear is a bit more worn (as seen in the photo). I bought that pinion gear last year because the old one was more worn. The one I bought was used--all I could find.

I lubed it up good w/ grease and WD-40, so hopefully that will help...

 

[F_R]

Well at least I understand the problem. The flywheel teeth are probably only worn in a couple of areas around the ring---where the engine usually stops between compression strokes.

 

[racerone]

I think you can separate that ring and reposition it by 60 degrees.