generator starter motor fail

[sardine]

I've got a Chinese knockoff 6 kva Diesel geny, Yamnar L100 clone engine, the starter motor won't always engage with the flywheel gear ring, unless its exactly lined up the motor gear just hits the ring gear and spins, I've fitted a new solenoid, but its still doing it. If it engages it turns it over OK, so I can't see much wrong with the motor itself. It looks to me the push forward is not strong enough to get the two gears meshed, but its a new solenoid, and new battery.

All I can think of so far is grind the motor gear teeth to a better lead in angle.

Any ideas ?

 

[the snooper]

have you installed the new solenoid same way round as the old one and was the solenoid connected the right way round in the first place? did it work when you first got it? the solenoid has 2 coils 1 pull it into the ring gear and the other to hold it the once its in if you have the connection from motor to solenoid 180 degrees out it wont work as it should
also cant remember exactly but don't these have a clutch assembly on the gear ? if so check for cracks in the cast as they slip when cracked
check also that the gear turns slightly as it moves forward

 

[rtbcomp]

Is the pinion the right way round? They normally have a lead on the teeth to guide it into the starter ring.

 

[Rig Pig]

Check the ring gear for burrs, it's probably slightly chewed.

 

[sardine]

The only thing I can see is the clutch is stiff to turn in the free direction. I presume its a Sprag clutch or similar.

The motor to solenoid connection only fits one terminal
The gear turns as it moves forward
Pinion only fits one way
I have de burred all the teeth
Had the motor apart and can't find any damage

 

[the snooper]

The only thing I can see is the clutch is stiff to turn in the free direction. I presume its a Sprag clutch or similar.

The motor to solenoid connection only fits one terminal
The gear turns as it moves forward
Pinion only fits one way
I have de burred all the teeth
Had the motor apart and can't find any damage

but isnt it possible to fit the solenoid 180 degrees out

 

[wristpin]

Have had a similar problem caused by voltage drop between key switch and the solenoid. Check out whether you have that issue by touching a patch lead straight from the live to the actuating terminal.

 

[MattF]

patch lead or a long thick screw driver

I've got visions of a spot welded screwdriver now.

 

[piman]

Hello Sardine,

I assume this is a pre engaged starter, and if so, it shouldn't start the motor until the pinion gear engages with the ring gear, so something wrong somewhere?

Alec

 

[CKJDJK]

Is there a screw and lock nut on the fork pivot for the pinion throw. It could be eccentric and be adjusted to allow the pinion to fully engage before applying the power to the motor. If you disconnect the solenoid output to the motor and operate the solenoid you will see just how much throw you have.

 

[sardine]

but isnt it possible to fit the solenoid 180 degrees out

No it only fits in one position o clock.

 

[the snooper]

what condition are the bushes (not brushes) in, I had to replace one on mine as it was all over the place

 

[sardine]

The pinion clutch is very stiff, service manual says it should be free, I'm guessing that is the problem. Chinese clones don't sell the part separate so its a whole new starter motor. Only £50, but then something else will go !

Even free Chinese junk costs you in the end !

Anyone scrapping a Yanmar clone generator ?

 

[the snooper]

The pinion clutch is very stiff, service manual says it should be free, I'm guessing that is the problem. Chinese clones don't sell the part separate so its a whole new starter motor. Only £50, but then something else will go !

Even free Chinese junk costs you in the end !

Anyone scrapping a Yanmar clone generator ?

chuck a load of oil in the clutch and see if it frees off

 

[Justme]

I have three real L100 powered gennies.

The cheap £50 starters dont last long if you are using it a lot.

Get a real L100 starter.

Or take yours in to a reconditioners.
Will cost about the same as a cheap new one.