1971 Johnson 40HP outboards Service Manual, Page 71Get this manual
fIf the pmlOn does not properly engage the flywheel, the pinion and screw shaft assembly may be worn, distorted, or dirtyLocate cause of binding and correct before completing assemblygThe starter solenoid is sealed unit and is not serviced separatelyTo test the solenoid, apply 12 volts from separate batterySee Figure 7-12The solenoid plunger should give an audible click as it operatesThe solenoid must be replaced as unit if defective 3494
Figure -13Reassembling Starter
REASSEMBLY OF STARTER
aLubricate the armature shaft and drive screw threads each with one drop of SAE No10 oilThis lubrication should be very light as the oil may capture dust and form gum, restricting the operation of the drivebReassemble the starter drive, replacing any part not in good conditionDo not force parts together as all parts are designed for free operation and any binding may cause failure of the drive to functioncTo facilitate reassembly of the starter motor, insert brushes and brush spring in holder, and tie in place with fine wire or stringAssemble brush holder and armature to frame and field assembly, and remove string or wireSee Figure -13dReplace commutator and drive end heads to complete starter motor assemblyeCheck starter motor with no load testWith 10.0 volts applied to the motor terminals, maximum current should be 60.0 amperes and minimum speed should be 8000 rpmSee Figure 7-6