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Honda BF90A squealing starter

I

iftia

Member
Toward the end of the season here in Massachusetts, my starter started to squeal 9 out of 10 times when I started it. Was quoted over $600 to replace it so I removed it to rebuild. Was told that it probably just needed lubrication after 12 years of service.
I have a couple concerns:
  • The manual (from the model years just before my 2001) calls for a Yamaha sealant that is in evidence at the joints to keep the salt at bay. I can't find the sealant online or at the chandlery. Any recommendations? RTV Silicone?
  • The manual recommended replacing parts such as e-clips and snap rings which I intend to do.
  • there is a rusted gear below the drive gear that has me worried about getting destroyed trying to remove it. Any suggestions?
My local motor re-builder won't touch it same with the auto starter re-builders. Am I flirting with disaster?
 
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Well, first let me say I have never torn one of these down but, from looking at the parts explosion, (link provided below) I would not hesitate to take a shot. It sounds as if you may have a bad or sticking overrunning clutch (item #14) and that could have done some irreparable damage to the gear set and/or pinion. The only way to know is to go in and take a peek. Does your flywheel gear teeth show any damage?

http://www.boats.net/parts/search/Honda/Outboard Engine/2002/BF90A2 LRTA /STARTER MOTOR/parts.html

I could be wrong but it doesn't look all that complicated and should be something a capable (you sound capable) person should be able to tackle as long as you take your time and don't force anything.

Note that there are a couple of differing part numbers depending on where your outboard is in the serial sequence so pay attention to that when ordering parts.

Even if you do the work, it looks as if the parts can add up money wise if too much needs to be replaced so you will have to make a decision there. But, if you can go in and lube every thing up and replace those stoppers, oring seals and put a new set of brushes in, you could be WAY ahead of the game.

Let us know what happens and...

Good luck!
 
Thanks for the encouragement. Photo attached. The teeth all look in reasonable shape. I still need to find a sealant for reassembly.
 

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One of the most reliable sealants available, that I have used with much success, is RIGHT STUFF. I have made oil pan , timing cover, intake manifold, waterpump and various other types of gaskets with it and they WILL NOT LEAK!

I smear it on precut gaskets and Orings as "insurance" in cases where I am unsure if the joint will hold or, if it's a job that I absolutely do not want to revisit like an intake on a V6 that can take nearly a day to do over.

RIGHT STUFF will not seal raw gasoline though so don't attempt to seal fuel senders, tanks, carbs or anything else that will have liquid gasoline contacting the sealer. It handles the vapors just fine. It would be my choice for this job.
 
I got some Right Stuff at my local auto parts store. Now to find which version of BF90A I am dealing with. Serial number 4400166. How do I insure that I'm taking parts off the correct model micro fiche? Honda Mrine isn't very helpful. They want me to contact my local dealer...
 
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