454 mercruiser borg warner TR2 starter issues
 

I've got a problem with my starter on my sterndrive. Everytime I start the engine, the starter stays engaged. I'm stumped. I took all the wires off of the starter expect the main power. I jumped the main power to the selonoid terminal, it pulled in and still stayed in. So the power is either bypassing in the starter solenoid, or the bendex is stuck on the flywheel holding it in. I replaced the starter solenoid with a new one, so I don't think it is the problem. But I have never heard of the flywheel holding the starter in. to give a bit of back ground. The boat is new to me. It's a 1977 fiberform 28ft cabin cruiser. Has a 454 borg warner TR2 drive. It's early 80'ish. Hasn't run for four years. I've rebuilt the leg and everything up to the gimbel housing. I've put a new fuel pump and rebuilt the carb. Trying to fire it up and now this is happening.

I would check the ignition switch. It may be sending power to the starter anytime the switch is in the on position.

What Patriyacht said, and check the slave solenoid mounted on the engine. The wire you're checking for power is the yellow with red tracer I believe.

no, i thought about that too. I tool all the wires off of the starter. The only wire going to the starter was the main power. With a piece of wire, I jumped the power from the main power wire to the S terminal. Still stayed in. Either bypassing inside of the solenoid, or bedex is stuck out. don't know

So the engine does start, right? And the starter keeps spinning with the engine? If this is the case take the starter off and bench test it. Sounds to me like the starter drive is hanging up and not retracting when it should be. Is this a top mount or bottom mount starter?

no the engine has not started yet. It's a top mounted starter. I did a bench test on the starter when I had it out. Everything was fine. There is a bit of play between the bendex and the armature and between the armature and the bushing in the housing. So maybe the conbined play is allowing the bendex to jam with th flywheel...? I've got a rebuild kit on the way so we'll see after the kit is in. I've got another problem now. But I will start another thread for that one.

my guess is the starter bendix is the problem,i would replace the starter.

I used to see this problem in my rebuild shop alot back in the day. The gap between the drive gear and the snap ring assy to is too wide. The easiest way to fix is to tweak the shift lever so it moves the drive further forward.

Bench test by holding drive with a pair of channel locks and "lock test" the starter. The solenoid should release when you removed voltage from the "s" term on the solenoid