I have an older 2-stroke Mercury 200hp that runs perfectly most of the time. But starting last fall, for some reason, the bendix gear on the starter will randomly stay in the “up” position and engaged to the flywheel even once the engine turns over. This causes the starter to overheat and burnout if the engine runs for too long, obviously.
To try and fix the problem, I replaced the batteries and the battery cables/terminals, thinking that I had a low voltage issue. But now I have been through 2 new starters that have ultimately ended with the same exact problems.
I’m starting to think my solenoid might be faulty, and might be sending voltage to the starter even after the key switch is released. Has anyone experienced anything like this, or have any suggestions on what else to fix/investigate/replace?
SOUNDS LIKE YOU’RE ON THE RIGHT TRACK BUT WITH IT HAPPENING WITH DIFFERENT (NEW STARTERS ) I WOULD > 1. CHECK FOR SECURE STARTER TO MOTOR MOUNT AND ALIGNMENT…
2. BURR OR DAMAGE TO MOTOR FLYWHEEL… CHECK EACH TOOTH AND POLISH WITH FINE GRIT
EMORY CLOTH …
3. HEAVEN FORBID SOMEHOW THE CRANKSHAFT BENT ( HAVE YOU ANY KNOWLEDGE OF EVER HITTING ANYTHING UNDER POWER???
HOPE THIS HELPS ;;; GOOD LUCK
George McDonald
US Navy Seabees,Retired,
MAD, Charleston Chapter
[http://www.militaryappreciationday.org
When you see “Old Glory” waving in the breeze, know that it is the dying breaths of our fallen hero’s that makes it wave.
author unknown
I’ve run a number of mercury two strokes overthe years everything from 225 EFI to60hp. I’ve had minor issues with the gear staying up but lubrication has taken care of that. Another thought get some starter shims for a Chevy and cut them to fit or something aluminum try to give it five or ten thousand play.
I am fragile.
Not like a flower.
But like a bomb.
I am fragile.
Not like a flower.
But like a bomb.
Ok those are good tips, I’ll check the teeth on the starter gear and the flywheel to double check it’s not a “mechanical issue” causing the binding. Haven’t struck anything underwater to my knowledge
Since you have changed out starters and still having the issue I wouldn’t be concerned with a bad Bendix/starter but rather some sharp/worn teeth on flywheel. I’d do as George suggested and polish flywheel gears You may need to get a small round file if badly worn and if that is the case I’d start sourcing a Flywheel. I’ve always put a small amount of Heavy grease on the teeth.
USE A STICKY HEAVY GREASE AND LIGHTLY COAT THE INSIDE OF EVERY TOOTH ON THE FLYWHEEL… USE A SMALL ACID OR ARTIST BRUSH TO GET INTO THE GEAR MESH ; THE DIA OF THE FLYWHEEL DOSEN’T ALWAYS STOP AT THE SAME SPOT THAT THE STARTER GEAR ENGAUGES WITH ; COAT THE STARTER GEAR THE SAME WAY… A LITTLE BIT WILL DO IT ; NO NEED TO GOB ON THE GREASE AND MAKE A MESS WITH SLINGING GREASE</font id=“green”> GOOD LUCK AND POST YOUR RESULTS…
George McDonald
US Navy Seabees,Retired,
MAD, Charleston Chapter
[http://www.militaryappreciationday.org
When you see “Old Glory” waving in the breeze, know that it is the dying breaths of our fallen hero’s that makes it wave.
author unknown
I had the same concern, so I had the key switch replaced, and the issue still ended up happening again. So now I’m wondering if I need to run new wires from the switch to the engine. And maybe new wires from the kill switch to the engine as well while I’m at it
NOT TO CONTINUE AN ARGUMENT CAUSE I LEARN SOMETHING NEW EVERY DAY,SO I DOUBT NOTHING , BUT MY MONEY IS STILL ON A STICKING CAUSE ;IE; BURR,LUBE, FLYWHEEL,ALIGNMENT AND SO ON ::: PLEASE KEEP US INFORMED WHEN ISSUE IS FOUND:+1:
George McDonald
US Navy Seabees,Retired,
MAD, Charleston Chapter
[http://www.militaryappreciationday.org
When you see “Old Glory” waving in the breeze, know that it is the dying breaths of our fallen hero’s that makes it wave.
author unknown
I’ve had a 94,150-a pair of 96 -175 , a pair of 2001- 225s & a 2001- 60
Every one of the motors would occasionally not disengaged the starter if it wasn’t lubricated. And thay would usually make a weird whining noise when they disengaged. And not long after that they would hang up. I put everything on the worm gear from WD, 3-in-1 white lithium. What I found that would last the longest was air tool oil.
If you think it’s a solenoid or wiring problem. Disconnect the power from the starter Hook a test light to the wire.and just sit there and play with the switch for a while. And a shim is always an option… I’m far from a professional mechanic. But I’ve always managed to take care of my own motors without taking it someone.
The new four strokes whole different story. I’m lost as a blind queer at a weenie roast.
I sure miss my old two strokes.
Yeah lubrication and double checking the teeth are definitely on the list. And good point, I’ll check the wiring from the switch to the starter before worrying about pulling all new wires.
Trying to avoid any shims for now, because the motor ran for 19 without ever once having this problem. So it doesn’t seem like the alignment should just suddenly have gone out of whack
Motor Update: So we ended up finding that the starter was still in good shape, and the solenoid and key switch all were working properly as well. Turns out, half of the stator wires had melted, and so did the wires going to the trigger.
So we replaced the stator and the trigger assembly, and she’s been working fine so far. Talked to multiple mechanics, and no one has a good explanation for what caused the components to melt the way they did. Go figure
Thanks for the input on here, glad to be back on the water. Tight lines
