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Weak starter 1996 115hp

Z

zing

Member
Johnson 115hp 1996 J115SXEDR
I've got a weak starter took it apart and cleaned some black dust out, did not test continuity, put some 3in1 oil on the spindle. The bendix has given me problems in the past, I hit it with some liquid wrench to clean it up and then some 3in1 oil. This motor is a pain to work on as there is a timing / flywheel cover that has to be removed, reassembly requires a link/sync. You cannot even see the bendix when it's assembled and cannot crank it with the bendix in place without putting the cover back on. The regulator has been replaced a couple times and it's still giving no tach and shows charging at 16V while running - could that have fried the starter? starter runs fast and quiet with no gears attached.

Battery cable connections cleaned and Tight on both ends, no wingnuts. I'm beginning to think the cables are bad and might be causing the 16v charging or blowing the regulator due to high resistance.

I've got a few Questions:
  1. How do you tell if the brushes are bad in the starter?
  2. How do I bypass the solenoid to test the starter?
  3. Possibly bad battery cables from console to engine. Can I put a short set of car cables on a battery near the engine to test and still use the key to turn it over?
  4. Will a resitance test using regular ohm scale work to test a battery cable? Should see no resistance correct?
  5. Can I just have the starter tested at an autoparts store like advanceauto?
Jim
 
The " bosch " starters are easy to check.-------Take it apart again.---------Check OHMS from commutator to the shaft.---Should read infinity.---------I replace these brushes all the time $5.00 a set ( Made in the Orient )--------16 volts at charging does not damage a starter, these starters can not tolerate long periods of cranking and are easily burned out.---------------If you are running in salty water than there is a good chance your battery cables are corroded internally .---See any green stuff around the ends???
 
To test the starter itself.....

Run good known jumper cables from a good known battery directly to the electric starter terminal stud and a good ground.
 
Thanks guys,
Green stuff, yes. What size cable should I be using for a 15' run?

The lugs on the end of the cable are the open type, that do not cover the end of the cable. What's the best way to make new cables, ends, soldered, types of connectors?

Should that shaft have any lubrication at the bushing and top seal, if so what type, lithium grease or just 3in1 oil?
 
I took out the positive cable and it's difficult to bend in the middle 5 feet, cable is 18' long. that would be the low point of the cable and it's definitely crunchy. I'll replace all the battery cables and put new brushes in the starter.

Thanks for the info.
 
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