Jerry, Mark, Nils or Other Guru

[Franko]

I am having all kinds of trouble getting the PTO housing to mate with the engine housing. I can get the starter into the hole in the PTO and the oil pump rotor into the slot in the engine housing. But there is still about a 1/8 inch gap that I cannot get rid of. Any tips?

Plus, I noticed that I appear to be missing a washer on the starter. I have a flat metal washer and two spring washers against that sliding ring. The shop manual shows an additional flange washer. This washer was NOT on there when I removed the PTO cover. I was careful when pulling the PTO cover off because Mark warned me about these washers. Here is a pic from the manual and the washer I am missing:

[Green Hulk]

Frank, all i had was two spring washers and a flat washer on mine.

Like i told you on the phone yesterday, i had the same issue when reinstalling my PTO housing. My problem was the big gear that the starter drives wasn't seated properly. I am certain this is your problem. Wish i would have taken a pic when i had it apart.

[Franko]

Jerry, the starter appears to be properly seated (pushed back with gear teeth engaged). I can turn the crank with the drive shaft and the starter turns as well.

Is the manual just wrong about that flange washer?

[Green Hulk]

frank, make sure this gear is seated properly. It can be very decieving.

[Green Hulk]

Wow Frank, i just realised you put me in the same category as Mark and Nils im not even close to those guys, but thanks for the complement

[Franko]

Yeah, I know what is wrong now. The starter gear should not be engaged with the flywheel right now. Mine is, so I need to shove it back even further. But that washer is a mystery. Without it, the bendix can move and result in the gears engaging while the ski is in operation. I think mine was left off from manufacture. I think this because I KNOW it didn't fall off when I removed the PTO cover. Secondly, the tips of the starter teeth are worn like it has been coming into contact with the flywheel. Jerry, were the tips of your starter gear worn?

[Green Hulk]

yep, the tips were a little worn. i think thats normal.

[Franko]

Looks like you have to buy an entire starter to get that washer! The parts list shows the flat washer and the spring washers, but doesn't show the flange washer as a separate piece.

[Green Hulk]

I think if it wasn't in there to begin with you dont need it. I didnt have it either Frank

[Franko]

I'm kind of leaning toward not worrying about it. But it has me spooked a little.