Thanks Mitch, unfortunatly or fortunatly, I just learned that not more than an hour ago.....

I just got back from the rebuilders, towed the boat up there but they wouldn't look at it. They looked at the starter and said, "The drive is still good." They took it back to the back and ran a buffer to the drive gear and it went right back down. So apperanlty I have 2 good starters. The rebuilt one and the new one.

So now I am at the fly wheel as my issue, I went thru and hit all the teeth with a flat file very lightly, just a pass or two. Except the few that had a small bur then I carefully filed the burs off. Came in to eat some lunch, then I'm going to go out and put the old starter back on it, hook the water hose up then commence to starting it and shut it off, over and over many times. If it kicks out again then I'm pulling the engine and replacing the fly wheel. Atleast now I know how to make the drive go back in. I should beable to give an update on the final fix later this evening or tomarrow. Atleast now the end is in sight..... unless the crank is some how bent..... I wil be praying that the fly wheel fixes it one way or the other.

Thanks guys, any tips feel free to share.

 

Wooohooo

Well that seemed to help loads..... but it still kicks out once every 40-50 cranks or so. Not near as often but I learned that when it does, if I stick the ratchet on the crank and turn it just a little it will click then it is engaged. Turn the key and it starts and releases as normal. Returns to 100% functional till it hits that spot in the fly wheel again.

So worst case scenario, if I don't change the fly wheel immediatly I can take my ratchet set and if it kicks out while on the water I can still start it back again with out taking the starter off.

Thanks for the help guys, I am giving positive rep points to everyone that has responded. Thanks again.

 

when out on the lake and it acts up, you can let the wifey sweat for a while, then fix it and be the hero. you can then get permission to remove and rebuild the engine over the winter.

 

Psssh, forget that. I already got permission to buy a new (probably used) one this fall! No more than 6 years old though.

I was ready to just go get one this last weekend, but finance manger (AKA wife) wouldn't grant permission, infact just the opposite.

Her words, "I'm sure it's something minor, your just pissed, wait a day and let yourself cool off, then go fix it. If you can make it last atleast until this fall, then they'll be cheaper and I will have our finances ready for that payment."

 

looks like she really knows you.

 

Yep, after 11 years she has me pretty well figured out.

The problem that had me wanting a new boat was a $3 coil wire that went out while sitting on the trailer at the ramp to put in. At that time the new starter hadn't failed yet.

I guess technically non of the starters had failed since the first rebuild last spring.... I'm just an idiot!!!! Idiot + slow learner = expensive + headaches.