BBC Starter bolts for mini starters
 

I have modified 365 mag engines from 1990 (gen 4) with 10.25 compression ratio. Prev owner had installed mini starters. Port eng cranks normally. Starboard eng starter works but sometimes makes a nasty sound.

Pulled eng and bell housing so I could see what's going on. Flywheel teeth look good but I can see wear on only the half of the teeth closest to starter.

Using a jump starter and a momentary switch connected only to the solenoid coil, I see the starter gear engages the flywheel teeth but doesn't always fully engage. Usually only engages abt 1/2 way. When I release the switch the gear does not retract away from the flywheel (eng not turning). I had to loosen the starter bolts a couple of turns for the starter gear to retract away from flywheel. When I connect the jump starter so eng spins, the starter gear occasiaonally disengages but only when eng spins backwards a bit due to compression.

After removing starter, I removed the starter motor from the planatary gears. Can't figure out how to get the planatary gears completely out. They come out about 1 inch but the linkage from the solenoid is stopping them from coming out any further. Don't see a way to remove the solenoid from the starter or disconnect the solenoid linkage. All the grease inside the planatory gears was dried up, so I cleaned it up the best I could and applied wheel bearing grease to the planatory gears and bendix. It bench tests great.

When went to re-install the starter, I noticed the starter would move around a bit as I was tightening the starter bolts. Pulled both bolts back out and discovered they are both slightly bent. Hit 4 auto parts stores but none had the same bolts I removed. Need to order some bolts but not sure what to order since these are not the original starters.
Don't see a manuf name on the starters or any info for that matter.

From what I have gathered this morning, these mini starters may have a different diameter bolts holes than original so I may need bolts with "stepped knurling". That is knurling of one diameter to fit the block bolt holes and a slightly larger knurling for the part that engages the starter to keep everything centered. Does this sound right? If so, where can I get these stepped knurling bolts?

My phone is acting up so I couldn't get any pics. I'll try to find my old digital camera and see if I can get it to work.

Thx!

YOu don`t want full engagement on the teeth. if I recall about 1/4" or half the teeth.. any more and the starter wont disengage and you`ll burn it out . Ask me how I know.
I had shims from IMI to get it right .
I also drilled a hole in the bellhousing to see the engagement .
No stater I ever used had any special bolts so without a pic can`t help ya there .


Chevy Starter Tuning - Super Chevy Magazine

https://cimg6.ibsrv.net/gimg/www.off...245b050875.jpg

Went back out to the shop and looked at the starter again. It has markings on the end cap that were painted over. It says" Delco Remy 9000762 9g25 SAE J1171 marine"

Looked at the bolts again, this time with calibers. The length measures 4.83" from top of head and 4.34" from under head.
One of the bolts is slightly loose in either starter hole, the other bolt is tight in both holes so one bolt is definitely worn.

Measured knurling diameter and it is indeed stepped.
The part of the knurling in block is 0.3785"
The part of the knurling that's in starter is 0.3985" on the tight bolt and 0.3970" on the loose bolt.

Now that I think about it, the knurling would almost have to be stepped since the block part of the knurling has to pass thru the starter when installing the bolt. I had always assumed the knurling was the same diameter for the block and starter, but this makes more sense.

I doubled checked the installed length and verified I'm 1/8" away from bottoming out the bolts in the block.

Both bolts are definitely bent. I ordered a set of ARP 430-3514 bolts. I'll install those and re-evaluate the alignment.

Thx for the link, I'll try and digest that this evening. Good to know starter gear isn't supposed to slid all the way across the flywheel teeth when engaged.

Okay, it’s a GM model PG200 late model style ‘mini’ starter. So, you should get bolts fir that.

Here is it’s info from Delco Remy themselves:
9000762 PG200 New Starter | Product Details | Delco Remy

This may be bolts your looking fir. Double check:
GM 22348064
4.33 long
$3 each

Thx guys. Ever had one of these starters apart? I got the motor off but can't figure out how to get the plantary gears all the way out. Appears the lever from the solenoid is holding everything in. Doesn't look like the solenoid can be removed.
https://cimg5.ibsrv.net/gimg/www.off...5884bcad2e.jpg
https://cimg6.ibsrv.net/gimg/www.off...2bf703528d.jpg
https://cimg7.ibsrv.net/gimg/www.off...d713b5b3fc.jpg

I never had one apart.
Here is s microfiche parts breakdown:
Genuine Mercury & Mercruiser parts. Starter Motor, 8 Inch (PG 200) 3.25 Inch Diameter End Cap

Thx. That helps a lot. Item 14 fell out. Didn't see 13 but it's probably inside 12. Looks like item 13 is the key to getting it apart.

Good news: Got it apart and it looks OK. Bad news: Had a large snap ring vaporize on me. Heard it hit the roll-away, then gone....Spent an hour looking for the damn thing. Grrrrrrrrrrrr..
There's a spring inside the drive housing along with the lever from the solenoid, a couple of retainers and one large snap ring. None show up on the parts breakdown for some reason. Maybe it's considered part of the drive housing??