starter By joe (Read 1,034 times)

[joe]

i installed a new starter,new solenoid
my scooter won't start
i take out starter it spins when i push start button,with starter in i here the solenoid click,it starts with kick starter, plus i have no headlights when engine is running

[Bashan]

Well if the starter turns and so does the engine it must be in the gears and clutch that connect them as you see in this cutaway diagram:

Here is a PDF about these gears:

STARTER GEARS PDF

And here is a link to pulling your flywheel and stator to get to them:

FLYWHEEL STATOR REMOVAL

And last a video on oil pump and starter clutch replacement:

I can just about gaurantee you that your headlight problem is a bad connector. You'll have to trace the wiring and find the faulty connection.

Hope this helps. Rich

[daver]

Joe,
First off, like Rich says, the lights are prob a seperate problem..
I would say there is a 90% chance your just trying to start your bike with a nearly dead battery.. It takes no amps to turn a starter that isn't installed, but soon as it's engaged thats a different deal..
Make sure your battery has a full charge, and if needed jump it from a auto battery.. (DO NOT have the auto running when doing this).. If your still having the same problem, then there is probably something else wrong.. (Ground wires been cleaned and tightened?)
Let us know how its going.. Good luck... Dave

[joe]

i had the battery checked,the guy said nothing wrong with battery
i kick-start it and it starts right up

[Alleyoop]

Joe,
Try this, get a screwdriver or a pair of pliers and turn the key on and and TOUCH both Terminals on your RELAY and see if it turns the Starter. If it spins your staarter then most likely you have a bad Relay. Try swapping the old back in.
Alleyoop

[joe]

i put the old solenoid back in,still nothing
only here the relay click,crossed the 2 terminials,nothing

[Alleyoop]

Joe,
Well to eliminate the battery, try jumping it with your car battery(but don't have the car running). If it kicks it over then your battery is putting out lower than 12.7 volts.
Alleyoop

[damin69]

Hmm this really almost sounds like a blown Fuse or wire connection problem or both. Does it turn over if you short across the Solenoid? If it does I would check the fuse that goes to the solenoid. Lights sound like a fuse or a bad connection at the fuse possibly.

[erictheviking666]

I see you installed a starter and a solenoid, but not a starter clutch (drive). I recently did the same thing and ended replacing the clutch to fix the problem. I had the same issue you have, when you hit the switch the solenoid would click one time and that was it. Check the drive too see if the gears are chewed up, also check the gear on the Variator as well.

[joe]

well,i tried starting my scooter with car battery the starter didn't turn over,,,i checked the gears they are ok,,,whats next

[Bashan]

What do you mean you checked the gears, did you pull everything apart and look at it? The starter clutch could be bad and appear normal on the outside. Did you look at this PDF and the section on clutch disassembly? You've pretty much narrowed it down to this area, the problem has to lie between the starter motor and the crank. Rich

STARTER GEARS PDF

[joe]

my scooter is running,i installed a wire from neg side of battery and grouned the other end to starter,it starts with electric starter and also the head lights work,,,thank you guys so much

[Bashan]

Wow, that's one for the books, we'll all have to check that with your kinds of symptoms. Congradulations on some excellant sleuthing. The list of thinks to check off grows longer with each resolved problem. Good work Joe. Rich

[joe]

i took my scoot for a long ride everything works fine
i'm still puzzled why the wire worked
all lights work fine,i even took all ground wires off and sanded them down real good,,,,still scratching my head

[shanghaid]

Sept 23, 2010 18:47:42 GMT -6 joe said:

i took my scoot for a long ride everything works fine
i'm still puzzled why the wire worked
all lights work fine,i even took all ground wires off and sanded them down real good,,,,still scratching my head

Maybe the ground wire to the frame isn't getting a good enough connection which would explain the lights and starter issue?