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2002 90hp johnson 2 stroke..starter not engaging flywheel

J

joek

Member
I have a johnson 2002 90 hp 2 strokethat I have just put in a new starter,starter solenoid and battery...and am still having the same problem...the starter spins but does not engage the flywheel...does anybody have any suggestions I could try to correct or identify my problem..battery fully charged,starter spinsfreely....any help greatly appreciated...thanks joe
 
Seeing as how you installed a new starter... I assume a brand new starter, not a used or rebuilt one... I am ruling out a possible defective starter and/or a greased sticking bendix drive. Never grease the bendix as that collects dirt and grime that leads to sticking.

Normally caused by either a loose or a tight but dirty connection somewhere in the starter circuit or a cable that is failing/corroding internally.

Remove and clean thoroughly all cables/wires associated with the starter circuit, including the battery terminals themselves and the ground at the powerhead. Be sure to also clean the component that the cables/wires attach to.

If after performing the above process, the starter still turns slow, feel the cables with your hands for hot spots that would reveal that the cable is failing internally.
 
starter spins rapidly....it just wont engage the flywheel....is there some sort of gear under the fly wheel cover that is suppose to pop up or down then disengage after it starts?
 
The only gear should be the one attached to the starter bendix unit. Is that starter gear spinning counterclockwise and trying to rise up the shaft? If not something is wrong with the starter or the polarity.
 
The electric starter spins the bendix gear assembly. The bendix gear sits upon a sloped spindle where centrifugal force causes it to rise into the flywheel teeth. Possibly someone has either greased or applied oil to the bendix which has caused it to stick in place. Remove whatever is necessary in order to observe the bendix gear.

If it is indeed sticking... clean the debris away with WD40.
 
what and where is is the starter gear clutch located...someone mentioned that that could be the issue on this model and year motor...having to remove flywheel possibly..replies back appreciated thanks joe
 
The bendix gear is of course metal. The gear itself being the teeth. Just beneath the teeth (all one unit), the metal sort of has a bulged effect. Within this bulge is the clutch.

If the clutch fails, the gear engages the flywheel teeth properly and just sits there while the starter armature shaft spins wildly within it.
 
does the starter even have the clutch and gear on it?if so you should be able to take your fingers (with no voltage on the starter motor please) and check the freedom for it to go up and down on the shaft..i do nor know if the starter will turn backwards with reversed polarity...i never tried it....you should at least see some movement of the gear on starter motor...while you are at it take a multimeter and set it to the 20volt dc scale...place the positive(red) lead on the terminal on the motor...this should be a heavy wire and you might have to move a rubber cap to get to the lug...please pay attention to the polarity...please get back to us on the voltage reading...
 
will get reading soon as it stops raining up here and able to get back to working on boat...thanks...will let you know..joe
 
with bench testing should the armature pop up more than a 1/4" if that...maybe I do have faulty aftermarket starter...not a Johnson..gear on shaft spins rapidly...
 
Test the starter alone with a battery jumper cable set. Connect the battery with the correct + & - . see if the starter gear jumps UP.

Then reverse the battery cables on the battery. The motor should spin in the reverse direction. Did the stsrter gear finally jump all the way UP now ?

If yes...........The starter is made incorrectly. Send it back for a good one.
 
Was the complete starter replaced including the geared down shaft with the bendix.-------Sounds to me that you need to look at why bendix is stuck.
 
you will not read a voltage drop without drawing current...please take the readings when the starter is turning...or trying to turn...
 
no starter did not pop up either way...my starter seems to fit direct into a gear assembly on flywheel from what I can dedect.....on top of the that gear is a smaller gear ...only accessible by removing flywheel assembly...any more in put appreciated..b4 I call a marine mechanic ...$$$$...thanks
 
problem solved...when dealer installed new motor...spliced pos...and neg..lead to battery....did not run new leads direct to battery...positive crimp ons with nut and bolt and electrical tape failed....corroded....respliced and soldered with correct butt connecter for the heavy copper wires...worhs perfectly...would not recommend granby allpower for new outboard installations...thanks everyone for your time and inpt...joe
 
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