PSA - 115hp Optimax

[Hyco Bass]

While I was cleaning up/ inspecting under the cowl (2013 115HP Optimax, S/N 1B975189), I found very two very small and unique looking pieces of metal laying in the lower cowl, pieces almost identical. I examined and surmised these were the ends of a small c-clip. Pulling from my half-vast knowledge of fasteners I knew that this was a) a bad sign and b) likely an important part. I looked over the engine and could not locate such a fastener, so I went online the mercury site and poured over the exploded parts diagrams. I found only one c-clip shown in the diagrams for under the cowl parts (but no part number for the c-clip as it was part of a subassembly of the starter gear, 880805A1 "gear kit"). Armed with this information I went back out to the engine and found the remainder of the c-clip exactly where it should have been, on top of the starter gear, still holding it in place. I pried the remainder of the clip off and went down to Tractor Supply to hopefully match it up (as there was no aforementioned part number to order from, nor an open Mercury parts store close by). Found a "7/16 external retaining ring" that matched up with the inside diameter. Not an exact part match as the original part is slightly wider/thicker, but it fit and worked. See photo.

Odds of finding the both ends of the c-clip in the bowls of the engine – improbable. Odds of the remainder still holding the starter gear on - equally improbable. Online parts explosion on the Mercury site – my gratitude to Mercury. Finding the problem before “worse” occurred – priceless.

Nagging issues: 1) Root cause of both ears shearing off. 2) Need the Mercury part # for the c-clip so I can replace with O.E.

Snap ring parts.jpg

[FrancoCialone]

Your lucky to have spotted it and replaced the broken clip, EuropeanAM should be able to help you with the OEM part#.

[EuropeanAM]

Very lucky find. Not sold separately... despite checking well over 100 different models that use the 880805A1 Drive Gear. It's used on virtually any Optimax or Verado model with a starter-mounted solenoid that drives the bendix. Also found on some of the 4-strokes as well.

If the one you have fits well... it's better than one that does not fit at all.

[Hyco Bass]

Many thanks for the replies. The C-clip came as a two pack so I have a spare. Will keep an eye on it.