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Any Ideas on this Starter Issue?

Posted: Sat Mar 14, 2020 4:07 pm
by VladTheBad
I've been trying to troubleshoot this starter issue and was hoping there were some ideas out there. Each time I press the electric starter I get a satisfying "clunk" from the solenoid moving, but the starter doesn't always turn. It's as if something is binding or keeping the solenoid from making its full travel and making electrical contact at the end of its stroke.

I've already dismounted and disassembled the starter once, and of course the problem does not replicate off the bike. I did notice that there is a metal gasket/shim where the solenoid mounts to the starter, and thought that removing this might engage the starter sooner in its travel. Do these come in different thicknesses?


Re: Any Ideas on this Starter Issue?

Posted: Sat Mar 14, 2020 4:19 pm
by Tomcatfixer
Dead spot in your starter windings? On a 2019, it sounds like a warranty item, to me. :wink:

Re: Any Ideas on this Starter Issue?

Posted: Sat Mar 14, 2020 8:17 pm
by RC20
I worked with a guy who rebuilt starters for diesel engines, well he said he did. Put in more than one that failed.

FedEx vehicle shop came the conclusion that rebuilt starters sucked, they would only install new one after too many failures.

You have that solenoid that has to pull in and move the works and make contact for the main windings. It seems simple and can work just peach keen fine outside, then you put it on and nada.

Long way of saying, Chad is right, something is wrong, I doubt a flat spot but it does not matter, something mucked up just enough no spinney and likely a new one needed regardless of cause.

Re: Any Ideas on this Starter Issue?

Posted: Sat Mar 14, 2020 11:34 pm
by rivers
Insure your batt ground cable is clean and tight at both ends.

Re: Any Ideas on this Starter Issue?

Posted: Sun Mar 15, 2020 5:08 am
by wooden nickel
Actually it is best to check both ends of the ground cable and the positive cable that goes to the starter.
When my old starter died, it started to melt the positive post on the battery. Awhile after I installed the new starter, it gave hit or miss starting until I tracked down the offending positive post terminal bolt.

Re: Any Ideas on this Starter Issue?

Posted: Sun Mar 15, 2020 5:08 am
by wooden nickel
Dratted double post.

Re: Any Ideas on this Starter Issue?

Posted: Sun Mar 15, 2020 6:06 pm
by Long Travel
I have a similar intermittent starting issue on my 2019 Sahara. It was an April delivery model in Australia. It’s not a big issue, it just sometimes takes two or three presses of the starter button and it fires up.

I believe it’s an issue with a change in the wiring on 2019 models. It may be something to do with an intermittent voltage drop, but I don't understand how that can happen. Apparently there is a relatively simple modification at the fuse box that can fix it. I suggest talking to your dealer about this.
Cheers, Steve

Re: Any Ideas on this Starter Issue?

Posted: Sun Mar 15, 2020 6:38 pm
by tubarick
CHECK MY POST. WIRING HARNESS PROBLEM, NOT THE STARTER.

Re: Any Ideas on this Starter Issue?

Posted: Sun Mar 15, 2020 6:57 pm
by sbaker
tubarick wrote:
Sun Mar 15, 2020 6:38 pm
CHECK MY POST. WIRING HARNESS PROBLEM, NOT THE STARTER.
If you want us to check the post.. please post a link to your post........ Search is not coming up with your post.

Re: Any Ideas on this Starter Issue?

Posted: Mon Mar 16, 2020 5:49 am
by Lee Pape
sbaker wrote:
Sun Mar 15, 2020 6:57 pm
tubarick wrote:
Sun Mar 15, 2020 6:38 pm
CHECK MY POST. WIRING HARNESS PROBLEM, NOT THE STARTER.
If you want us to check the post.. please post a link to your post........ Search is not coming up with your post.
viewtopic.php?f=23&t=56421
This is the link for those that need it.

Re: Any Ideas on this Starter Issue?

Posted: Mon Mar 16, 2020 8:40 am
by tubarick
Sorry. I don't know how to use these features.

Re: Any Ideas on this Starter Issue?

Posted: Wed Mar 18, 2020 6:37 am
by VladTheBad
Thanks for the wiring harness tip in the other post!