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Old 12 April 2009, 10:27   #1
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Engine struggling to turn over

So i've re-built my engine and connected up all the electrics again in exactly (as far as I can tell) the same way they were before.

When I came to start it, it initially seemed to turn over fine but then it died off drastically to a point where there just didn't seem to be any umph left in the battery to turn it over. Charged the battery up over night, did the same thing this morning. Tried another fully charged battery that is used to start our tractor and it did the same thing. Somewhere there is something sapping out all the power from the battery before it can get to the starter motor.

The starter motor and solenoid seem to work as I ran the starter with it pulled away from the flywheel. I can also turn the flywheel freely by hand so its not a mechanical restriction.

Any ideas? I'm not too hot on electrics and so far my dad's a bit stumped too
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Old 12 April 2009, 11:16   #2
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Bad contact somewhere.Look for a hot one. Either that or starter brushes are in need of replacement.
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Old 12 April 2009, 16:57   #3
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Are there any particular contacts I should check? I have checked the obvious ones and they seem ok (battery, starter motor and solenoid).

Can I replace the brushes in my starter motor myself or does it mean a new motor (=expensive I assume)? The motor seems to run fine when it can spin freely and it seems weird its never given me any problems before or shown any signs of degrading and now decides to just give up after being taken off and put back on again.

One thing that might be worth mentioning was that when I first tried to start it the other day it cranked over fine and actually started on the second attempt. It then stalled after a few seconds from what I assume was lack of fuel (I don't think it had been pumped through properly) and when I tried to then crank it again it got worse and worse until after about 3 or 4 cranks it could barely move at all.
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Old 12 April 2009, 17:16   #4
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Start at the battery +ve and work your way through the heavy duty terminals. One will be hot. It'll be that one. It's unlikely you'll be able to see it without trying to start it and a multimeter won't test it as it'll only be breaking down under heavy load.
It's also still possible even though it's spinning up when off that your starter motor is the problem. If the brushes are worn out it'll notice under load 1st.
I assume your battery is ok?
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Old 12 April 2009, 17:44   #5
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we've tried 3 different batteries including a big one which is used to start our tractor (proper big tractor, not a sit on lawn mower!) so short of buying a brand new one we've pretty much ruled out the battery being the problem.

So its looking like it could be the brushes. Can I change these or will it be a new starter motor?
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Old 12 April 2009, 18:25   #6
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Originally Posted by slimtim View Post

So its looking like it could be the brushes. Can I change these or will it be a new starter motor?
Take it somewhere that reconditions them-it'll be a lot cheaper. You may be lucky and be able to replace the brushes yourself, but I doubt it and unless you've done it before it's not an easy job to strip and reassemble without damaging it.
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Old 13 April 2009, 03:01   #7
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Originally Posted by slimtim View Post
One thing that might be worth mentioning was that when I first tried to start it the other day it cranked over fine and actually started on the second attempt. It then stalled after a few seconds from what I assume was lack of fuel (I don't think it had been pumped through properly) and when I tried to then crank it again it got worse and worse until after about 3 or 4 cranks it could barely move at all.
Tim, i'm no expert - so feel free to ignore this suggestion especially if someone who is says im talking pish. Starter works OK without load, starter did work OK with a load, starter no longer working as expected with the load... ...could it be the load is too high? e.g. the engine is not turning over smoothly, assuming its 2 stroke, no fuel=no oil which might (will) be bad.

Just a thought before you start spending money on the starter.
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Old 13 April 2009, 03:20   #8
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Tim, i'm no expert - so feel free to ignore this suggestion especially if someone who is says im talking pish. Starter works OK without load, starter did work OK with a load, starter no longer working as expected with the load... ...could it be the load is too high? e.g. the engine is not turning over smoothly, assuming its 2 stroke, no fuel=no oil which might (will) be bad.

Just a thought before you start spending money on the starter.
There'll be enough residual oil in the engine to turn it over. It'd have to be nearly seized before a healthy starter couldn't turn it.

The starter should give good kick in your hand when it starts to spin if you try it off the engine. If it is,look at the starter solenoid instead.
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Old 13 April 2009, 04:37   #9
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Polwart, I have considered this but I can turn it over by hand with only the resistance of the air compression so it should be fine. I going to check each contact today and clean them even if they look ok and then take a look at the starter, I think the bottom comes off it giving access to the brushes.

Today is a perfect rib day
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Old 13 April 2009, 04:42   #10
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Polwart, I have considered this but I can turn it over by hand with only the resistance of the air compression so it should be fine.


Quote:
Today is a perfect rib day
the good news is that this means your engine troubles are completely fixable - and you will be back in action just as soon as the weather changes to being rain/sleet/hail and F9+
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