Starter Issue?

My brother has a 2002 Merc 2 stroke that won't start. When he turns the key the starter will turn, but the pinion doesn't extend out to engage the flywheel. Also, the dashboard mounted voltage meter goes down to zero when the key is turned. Does this more likely point to a problem with the starter, or something with the electrical system? We're not sure what to look at first. Appreciate any suggestions. Thanks guys.

[Jimmy Jig]

Lube the shaft with the pinion.

Sorry, forgot to mention we already tried that.

[yarcraft91]

Your dashboard voltmeter may not be connected to the battery (by design) when the key is turned to Start. Put a voltmeter directly on the battery. Report the voltage while the starter motor is turning.

FWIW, if your dashboard voltmeter has a "0" reading, it's different than any analog dash voltmeter I've seen. Most don't read below 8 volts.

[dbal]

Sounds like a battery, the starter has to spin fast enough for the drive (bendix) to engage. I'd check the battery.

[yarcraft91]

Originally Posted by cast10k

Sorry, forgot to mention we already tried that.

SHould have asked the first time- how did you lube the pinion shaft? Did you pull the starter off the motor and thoroughly clean the pinion shaft before lubing it?

[REW]

Before doing anything else, run your tow vehicle up next to the motor in the driveway, and run a set of jumper cables from your tow vehicle battery directly to the starter on your motor with the cowl off.

With the jumper connected directly to the starter, does the starter work correctly, or do you just get a big spark.

If you just get a big spark, it sounds like you have a shorted starter that needs to be rebuilt or replaced.

If the starter now works correctly you need to either fix, clean or replace any bad connections between your battery and starter - or if all of those are all right - replace the battery.

Good luck
REW

Thanks guys. No we didn't fully remove the starter to clean it, might have to give that a try.

REW - does it matter where we put the cables on the starter? Just anywhere that they'll stay firmly clamped and not touch eachother?

[REW]

Clamp the negative wire from your jumper cable to any good bare metal on your motor main case.

Clamp the positive wire to the main heavy nut/bolt that feeds the starter.

REW

[yarcraft91]

OK- saga of my starter problems on a Johnson 120 2-stroke. Maybe the same will work for you.

Starter motor would spin, but not engage the flywheel. Lubing the pinion shaft was ineffective and manually moving the Bendix I could feel it was binding on the shaft.. I removed the starter, clamped it (gently, between two pieces of wood) in a vise, with the Bendix/drive gear down. Then, spent some time with mineral spirits, cleaning the pinion shaft while working the Bendix back and forth by hand. When all the cruddy old grease was gone, I left it in the vise to dry (you don't want solvent to run into the starter), then lubed the pinion shaft with GE silicone grease. Starter has worked perfectly ever since.