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'83 mercury 40 hp starter problem

E

equinton

New member
just completed the rebuild of our '83, 40 hp merc outboard. can turn crank with wrench on flywheel. Starter will engage but will not turn the flywheel. works fine on the bench and solenoid seems ok. turned the motor fine before we rebuilt it. Seems like it lacks torque to turn the rebuilt motor. would a repair kit help?
 
First thing to do is check your battery and cables. Cables may show continuity, but not be able to carry the needed amperage. Use a pair of jumper cables to make a direct connection between a fully charged battery and the main starter positive lug. Then connect battery negative to engine ground. Also, make sure the starter housing is grounded well to the engine block.
 
equinton said:
just completed the rebuild of our '83, 40 hp merc outboard. can turn crank with wrench on flywheel. Starter will engage but will not turn the flywheel. works fine on the bench and solenoid seems ok. turned the motor fine before we rebuilt it. Seems like it lacks torque to turn the rebuilt motor. would a repair kit help?
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added info: Bendix gear engages the flywheel but won't turn it. Starter shaft keeps spinning in the Bendix gear. gets very hot quickly.
 
Recheck your grounds,Do posts 2,3,4.could be internal corrosion in cables,Is battery fully charged?Know how to use dvm?Whats getting very hot,cables, starter,solenoid?
 
thanks for your advice. starter is getting good current. problem is Bendix gear will engage the flywheel but will not turn it. starter shaft continues to spin and the Bendix gear gets hot in a few seconds. does not appear to be an electrical problem. cables are good, batt fully charged. basically, the Bendix gear shoots up the shaft, engages the flywheel ring but will not turn the flywheel, yet the starter shaft continues to spin and heats the Bendix gear.
 
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