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Tourer
Joined: Sep 2016
Posts: 375
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From: Illinois
So here’s my theory after checking every other possible thing that could be wrong. I put new brushes in the starter but I only changed the brushes that were attached to the terminal that sticks out the side of the starter the cable is attached to. I did not change the field coil brushes. This may result in a starter that is just not putting out enough power, Because the Bendix gear will spin, but as soon as it hits the ring on the outside of the clutch shell, it stops. So that tells me power from the starter is being transferred from the starter, through the gear case and up to the shaft and finally the pinion/bendix gear. But I think it just does not have enough power to turn the motor. So the only thing I can think of is replacing the field coil brushes. I will give that a shot when I get around to it and let you guys know how turns out. Sure has been interesting
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From: Honah Lee
Make sure the insulator between the fields on the communtator has a recess. Sould be at a minimum, a 1/64 below top. The brass on a starter could easily be worn below. (Use a extra fine short piece of hacksaw blade to carefully lower insulator)
If this is not done, the brushes are held off the communtator a little more then a brush width greatly reducing motor power besides bouncing the brushes causing a fireball of arching.
If this is not done, the brushes are held off the communtator a little more then a brush width greatly reducing motor power besides bouncing the brushes causing a fireball of arching.
Last edited by Jackie Paper; Jun 13, 2018 at 07:12 AM.
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Tourer
Joined: Sep 2016
Posts: 375
Likes: 15
From: Illinois
When I kick start it, the clutch basket travels ccw (counter-clockwise). Ok, so the bendix gear free spins cw and locks ccw. In looking at this with the primary off, I would have to say that In order for the bendix gear to push the clutch shell ccw, it would have to lock cw. Is this even possible? Did they sell me the wrong bendix gear? This is nuts!
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Joined: Nov 2009
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From: Farmington ,MS
I have seen the long though bolts rub into the coils inside starter...the starter would work...but had no power.
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Joined: Mar 2010
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From: Honah Lee
If like an 04 starter, the gear drive is a spur clutch. It is drive always. What happens is if the gas motor start and you do not let go of start button, or heaven forbids, the starter solenoid welds in (happens) the spinning primary spins the starter gear fwd which runs the drive roller pins up a ramp where they freewheel with a loud click hum. This prevents blowing the windings out of the armature and locking all up. So make sure it lock on the way it turns your gear. Once running, then the big gear runs away (out runs) from it.
Last edited by Jackie Paper; Jun 13, 2018 at 10:20 AM.
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