OMC Johnson/Evinrude Pull Start Pinion Gear

thingiverse

This is the pinion gear for the pull start mechanism on Johnson, Evinrude, and Gale outboard boat motors. It should fit most older models between 6 and 8 horsepower (and possibly some others). I designed the modified piece for our 1960s 6hp Johnson motor and the original piece for our 1980s 7.5hp motor. The reason I have two different part ones is that I made a modified gear to fit our 1960s motor because one of the bushings had worn out causing the whole assembly to be loose and the gear to slip. I fixed this by making the gear a little bit bigger. The original part one should fit in most cases, but if your bushing has worn out as mine did or if your pull start mechanism is really loose, you may want to print the modified version. Once you have decided which part one to print off, you will also need to print off part two. You will need to glue part two into the notch on the bottom of part one (I used super glue). Once the two parts are glued together, you can clip the spring onto the part and attach the gear. As for strength, I have used one of these parts for a month or two and I was able to get a couple hundred pulls out of it before the first tooth snapped (although it was still functioning). I think it is possible that this was a fluke, so I'll have to do some more testing.