Only Start if Engine Manually Turned Over

Energy One
MKTLAWYER

MKTLAWYER

Member
I have an '06 K-9 and had it in the shop to fix the starter but they gave up (a HD Shop) and returned it. I checked posts here and narrowed it down to make sure it was not weak battery/poor connections. New battery installed, I cleaned all connections today, I checked voltages per trouble shooting guides, service manual addresses electrical starter issues but not mechanical ones (bendix?).

Bike will make a real short attempt to turn over when starting, but then just stops before it fully cranks motor over (typically starts instantly if engine turns over). If I turn motor over manually (rocking it in 6th gear or turn rear tire while up on jack) then try to start, starter will turn motor over and it fires right up.

I thought it must be worn bendix. I turned back here and read so many more starter posts with so many different starter problems, that I'm lost and paranoid. I am unsure if I should pull solenoid, pull whole starter, fix bendix wire boot, see if there's oil in starter, pull of the primary cover and tighten a jackbolt or just find another shop to take it to and pray.

Does anyone know what my next logical step should be or should I just start on the drive side and work my way in (fix wire boot, pull solenoid, check plunger, check electrical brushes, etc,?????)? Or just ride it and rock it in 6th gear before needing to start it up (embarrassing) every time? Or pull starter and send to DOC? Please let me know. Thanks in advance.

Mark
 
BWG56

BWG56

Guru
Are your compression releases working? Pull the green solenoid wire off the starter and hit the run/start button, you should hear them clicking or put your finger on them to see if you can feel them engage.
 
MKTLAWYER

MKTLAWYER

Member
Yep, I should'a mentioned I checked the CRs too. Right after poor connection/low voltage, it seemed to be the next usual suspect with the short turn over, but no. The CRs are working fine. Thanks though.
 
chubs

chubs

Guru
Sounds like it's time for a new starter if everything else checks out good! Did the dealership actually pull that started apart and look at it, or just shake their heads and say "Gee we can't figure it out" ??
 
MKTLAWYER

MKTLAWYER

Member
chubs said:
Sounds like it's time for a new starter if everything else checks out good! Did the dealership actually pull that started apart and look at it, or just shake their heads and say "Gee we can't figure it out" ??
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I'd say the later . . .
 
MKTLAWYER

MKTLAWYER

Member
Lotta ground up brass in there and the end of the plunger smooth silver part was pretty rough and burred up? But it pushed in and was a pretty snug fit still.
 
pauldeepsea

pauldeepsea

Guru
MKTLAWYER said:
Lotta ground up brass in there and the end of the plunger smooth silver part was pretty rough and burred up? But it pushed in and was a pretty snug fit still.
Click to expand...
Clean up the contacts, I used a very fine piece of sandpaper before I ended up replacing the starter
 
pauldeepsea

pauldeepsea

Guru
MKTLAWYER said:
I have an '06 K-9 and had it in the shop to fix the starter but they gave up (a HD Shop) and returned it. I checked posts here and narrowed it down to make sure it was not weak battery/poor connections. New battery installed, I cleaned all connections today, I checked voltages per trouble shooting guides, service manual addresses electrical starter issues but not mechanical ones (bendix?).

Bike will make a real short attempt to turn over when starting, but then just stops before it fully cranks motor over (typically starts instantly if engine turns over). If I turn motor over manually (rocking it in 6th gear or turn rear tire while up on jack) then try to start, starter will turn motor over and it fires right up.

I thought it must be worn bendix. I turned back here and read so many more starter posts with so many different starter problems, that I'm lost and paranoid. I am unsure if I should pull solenoid, pull whole starter, fix bendix wire boot, see if there's oil in starter, pull of the primary cover and tighten a jackbolt or just find another shop to take it to and pray.

Does anyone know what my next logical step should be or should I just start on the drive side and work my way in (fix wire boot, pull solenoid, check plunger, check electrical brushes, etc,?????)? Or just ride it and rock it in 6th gear before needing to start it up (embarrassing) every time? Or pull starter and send to DOC? Please let me know. Thanks in advance.

Mark
Click to expand...
I would pull the outer primary and inspect the bendix, may have some broken / worn teeth that are not engaging
 
Srodden

Srodden

Well-Known Member
MKTLAWYER said:
I have an '06 K-9 and had it in the shop to fix the starter but they gave up (a HD Shop) and returned it. I checked posts here and narrowed it down to make sure it was not weak battery/poor connections. New battery installed, I cleaned all connections today, I checked voltages per trouble shooting guides, service manual addresses electrical starter issues but not mechanical ones (bendix?).

Bike will make a real short attempt to turn over when starting, but then just stops before it fully cranks motor over (typically starts instantly if engine turns over). If I turn motor over manually (rocking it in 6th gear or turn rear tire while up on jack) then try to start, starter will turn motor over and it fires right up.

I thought it must be worn bendix. I turned back here and read so many more starter posts with so many different starter problems, that I'm lost and paranoid. I am unsure if I should pull solenoid, pull whole starter, fix bendix wire boot, see if there's oil in starter, pull of the primary cover and tighten a jackbolt or just find another shop to take it to and pray.

Does anyone know what my next logical step should be or should I just start on the drive side and work my way in (fix wire boot, pull solenoid, check plunger, check electrical brushes, etc,?????)? Or just ride it and rock it in 6th gear before needing to start it up (embarrassing) every time? Or pull starter and send to DOC? Please let me know. Thanks in advance.

Mark
Click to expand...
I have pulled my starter to clean it despite not having any issues. Not hard to do !
 
zigmars

zigmars

Member
Starter collector connections is burnt off,it runs instead of 2kw maybe half of that,it is possible to see if you know where to look at- just where the copper contacts meet the fat wires, have to replace starter or just rotor if you can see no connection, use magnify lense,other you can check is bearing and bushing play for rotor, no bendix or solenoid problems here.
 
zigmars

zigmars

Member
Forgot to mention about free movement of brushes ,if one of them stock,same story.. lots of power draw no torque.
Actually the starter is Japan made and the parts fit from Japanese cars.brush set is Cargo number for brush frame is 132873 or Valeo 69-8202...cost here 12 usd
 
Th3InfamousI

Th3InfamousI

Administrator
Staff member
zigmars said:
Forgot to mention about free movement of brushes ,if one of them stock,same story.. lots of power draw no torque.
Actually the starter is Japan made and the parts fit from Japanese cars.brush set is Cargo number for brush frame is 132873 or Valeo 69-8202...cost here 12 usd
Click to expand...
That sure looks right man! Nice find.

Another cross reference is 028510-0640

Curtis sells them for about $12 too! But I like having the part numbers just in case!

Sent from my 2PS64 using Tapatalk
 
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