My starter took a dump

[BubbleHead]

Well today was fun. I started my bike and everything was well and good. Rode it some for a way and then to to the gas station and it was then that the day turned sour. I shut it down, got gas and went to start it again and bang that loud starter noise that I've had in the past and this time nothing but wingwingwingwing sound. I called Fiber to see if he knew maybe what to do, he made some good suggestions but to no avail. So my son-in-law's brother came to tow me home. By the luck of the Gods I have an outstanding friend Tom that is an incredibly excellent mechanic and Master Tech. I called him to see if he had any suggestions, he gave me some but to no avail BUT when I was waiting for the tow, here Tom comes on his own like the great guy he is. He left a birthday party he was at and out of the goodness of his huge heart, he followed us to my house and helped me get the primary case off and low and behold, the starter jack shaft had sheared in half.:angry: :bang: See pictures below.

Now, anyone else ever had this issue? If so, did Big Dog cover it under the warranty? I would think so since I still have 10 months of warranty time left. What I'm most worried about is that the dealer will only replace the starter and not try and find what was causing the banging in the first place. I DON'T WANT THIS TO HAPPEN AGAIN, if you all know what I mean.:bang:

Does anyone have an illustration of how the starter goes in to or out of the primary case. It's a 2007 Chopper with a 117.

Now on Monday I have to call the closest Stealer, get an appointment and wait for weeks proably to get it fixed knowing them.

 

[Fibersnake]

Damn BBD,

Not was I was expecting to see but it does explain the whirl sounds. Have no idea what would cause it to break like that, how does the strater gear ring look on the clutch? Is there damage to the teeth?

It is good to hear that you wear able to get it trailered home. I wish I could have helped you out better. Do keep us informed of what the dealer and BDM finds out and the actions they take to correct.

Should not be an issue for the warranty. Can not imagine them even having any thought of not covering it. Very important to also find out what is the root cause to get that addressed also.

If you have some documentation and information where you had it looked at before for ther knocking sound. May be very good to pass that onto BDM also. I do seem to recall that you had posted on here previously when it was occuring but not positive.

Have you check to make sure the engine spin over freely after you took the starter out. May want to check it by removing the spark plugs and disconnecting the battery wires and then get the appropriate socket and turn the engine through a few revolutions to make sure nothing is binding up.

Wishing you a quick repair and return to riding as well with solid information on the root cause. Hopefully it was just a bad jack shaft and not some much more serious.

 

[BubbleHead]

Tim, yes I did post about this banging issue before. No I have never had it to a dealer yet since I've owned it. Never had to since I do all my own regular maintanence. No Tom and I checked the Starter ring gear and everything in the primary case . everything looks perfect. No wobble or apparent looseness on the clutch carrier or clutch pack so the big nut behind all that is apparently tight. Chain is good and the adj shoe isn't as worn as I thought it was. It didn't scar up the inner or outer primary any at all. Tom doesn't believe the engine is in any way hurt. or locked up any. I will post more details as this situation develops, count on that. Thanks again for being there for me Brother. Much much appreciated!

 

[reddog]

YES MY SECOND

 

[BubbleHead]

RedDog, did you have the starter banging issue before it broke? Did your jackshaft break like mine? If so, did they fix the reason it was happening?

 

[Chopper Dave]

BBD.....Ray can shed some light on this......he has gone through a few starters......
I think BDM will take care of ya....
http://www.bigdogbiker.com/forums/drive-train/125-broke-hard-starter.html

 

[Fibersnake]

Tim, yes I did post about this banging issue before. No I have never had it to a dealer yet since I've owned it. Never had to since I do all my own regular maintanence. No Tom and I checked the Starter ring gear and everything in the primary case . everything looks perfect. No wobble or apparent looseness on the clutch carrier or clutch pack so the big nut behind all that is apparently tight. Chain is good and the adj shoe isn't as worn as I thought it was. It didn't scar up the inner or outer primary any at all. Tom doesn't believe the engine is in any way hurt. or locked up any. I will post more details as this situation develops, count on that. Thanks again for being there for me Brother. Much much appreciated!

Not a problem and wish I could have helped more. It is good to hear that there is no apparent other damage. Strange for sure and would be interesting to see what the cuase was if one is found.

Been a strange week though. JUst got off the phone with another friend that was out riding with some others today and one of his partners took a dump over near Harpers Ferry due to gravel. She is now in the Hagerstown Hospital getting stiches in her knee and it appears that they are going to bring the bike to the house to secure.

 

[woodbutcher]

BBD, mine is another one that does the occasional hard bang, seemingly when the battery is low on charge. i have a new interstate 310 in the garage ready to go in probably tomorrow. hopefully there hasn't been any damage to the shaft yet. i guess i will find out if it was the battery causing the bang

 

[BubbleHead]

Thanks Wood, let me know if the battery change-out stops the starter bang. Maybe that is my cause for this and the dealer will replace that if it is. If not I'll get a new one myself if that proves to be the issue.

 

[Gas Man]

Was that just hangin around in the primary?

I'm guessing it was at least touchin the clutch basket. If not you could have push started the bike...

But if it wasn't secured in some fashion the damage could be INTENSE if it got loose in the primary.

 

[BubbleHead]

YEA GAS, IT WAS ROLLING AROUND IN THE PRIMARY. I'M GLAD I DIDN'T GET IT PUSH STARTED. YOUR RIGHT, IT WOULD HAVE BEEN MASSIVE DAMAGE IF IT DID START. I'M TOO OLD TO PUSH IT UP MUCH OF AN INCLINE THESE DAYS. I'M CALLING THE STEALER TODAY AND MAKE ARRANGEMENTS TO GET IT TOWED AND FIXED. I'M THINKING I'M GOING TO BE DOWN FOR A WHILE.

 

[Chopper Dave]

hopefully they can have your scoot ready in a few days...unless they have to wait and order a new starter......

 

[reddog]

RedDog, did you have the starter banging issue before it broke? Did your jackshaft break like mine? If so, did they fix the reason it was happening?

YES JUST LIKE YOU SAID REPLACED STARTER RING TOO:flag:

 

[Raywood]

Hey BBD, i'm on about 9 or 10 starters (actually forgot now!) but never broke the shaft. BD will cover without question I'm sure. Just make sure they check your starter ring closely.
As for the banging sound when you hit the start button, I've had that a couple times and don't know exactly what causes it. Sometimes I think it's mis-alignment but then it doesn't happen again for a long time. Must just be the starter not meshing with the starter ring correctly.

Hope you're back on the road soon. :2thumbs:

 

[BubbleHead]

Hey BBD, i'm on about 9 or 10 starters (actually forgot now!) but never broke the shaft. BD will cover without question I'm sure. Just make sure they check your starter ring closely.
As for the banging sound when you hit the start button, I've had that a couple times and don't know exactly what causes it. Sometimes I think it's mis-alignment but then it doesn't happen again for a long time. Must just be the starter not meshing with the starter ring correctly.

Hope you're back on the road soon. :2thumbs:

THANKS RAY! I REALLY WANT THEM TO FIND THE REAL REASON THIS HAPPENED SO IT DOESN'T HAPPEN AGAIN. I DON'T NEED TO LOOSE CONFIDENCE IN MY DOG LEAVING ME SOMEWHERE. BY THE WAY I LOVE HOW YOU KEEP CHANGING YOUR AVITAR, EVEN WHEN I THINK IT CAN'T GET BETTER , IT DOES. YOUR ONE LUCKY MAN:2thumbs: :flag:

 

[Raywood]

BY THE WAY I LOVE HOW YOU KEEP CHANGING YOUR AVITAR, EVEN WHEN I THINK IT CAN'T GET BETTER , IT DOES. YOUR ONE LUCKY MAN:2thumbs: :flag:

Hey, thanks Bro!! Practicing for the 09 Calender!

:flag:

 

[BubbleHead]

RAY IN MY EYES YOU ALREADY WON THE TOP SPOT IN THE CALENDER, HOW CAN YOU NOT HAVE THAT WITH YOUR MODEL? I'M JUST ENVIOUS BRO, DON'T MIND ME

 

[bruce]

hey sorry to hear about your starter, I have had a very hard banging noise on start up after the bike is hot. If I have been riding and say stop for gas, it would happen and I would also have no speedo if I drove off - i would have to shut down and restart so the speedo would work. this went on for about a year and when they replaced my clutch found starter gear and ring gear to clutch house was messed up, so they replace both, I was told it was from not being aligned properly. I did not have banging any more, until the new clutch went up (only about 1 month old), now it is banging again. A weak battery can also cause it, but most of us ride regularly so this should not be the problem. I am seriously thinking about going to a open primary which I have been told would solve the starter and clutch problems plus looks cool. did you change you carb. jet and if you did remember everytime you change a jet you have to reset the idle adjustment screw. If you need help let me no.

bruce

 

[BubbleHead]

Thanks B. Yes my speedo would quit till I shut it off and reintialized it. I'm hoping that the guys at Brooklyn cycles will find the cause and fix it for good. No I have left the carb alone since you adjusted it. That seems to be ok for now. How long did it take them to fix yours when you had the banging issued resolved?

 

[woodbutcher]

BBD, put the NEW battery in this morning and cranked right up. went for a ride of about 25 miles and stopped for gas. went to start it back up and no bang---------------- no nothin'. gonna pull the NEW battery out and put the old battery back in, and make a trip to my local friendly interstate battery dealer. :angry: :angry: :angry: :angry: :angry: :bang: :bang: :bang: :bang: :bang:

tried jumping it off, nothing. excellent stranger helped me push it off and after 3-4 tries, got it cranked. thank you excellent stranger!!!! hard as hell to push-start a bike that heavy on flat ground.