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2005 Suzuki LTZ 400 Starter Problem


joescarzz
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Starter is turning but the gear to turn the crankshaft spins freely. It does not turn the engine over. Is there a shear pin or do we have deeper problem?

It sounds like the starter motor spins, but the pinion gear is not engaging. You may have a sticking pinion gear due to dirt. Maybe pul it out and see. Worst case scenario, your starter is bad. I have heard of starters not fully engaging when the battery is weak. Try adding a booster back to your battery or charger with a 12v engine start..just to check and make sure.

I've moved your thread into the mechanical section.

Welcome to the community!

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  • 3 weeks later...

I have not worked on a Suzuki before but have alot of mech experience. The starter appears to engauging. And spinning strong. I put a new battery on it. The gear that the starter engauges spins freely in either direction. I am getting ready to pull the clutch cover off and see why the gear spins freely. That is unless yall can keep me from heading in the wrong direction.

Joe.

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The best thing to do is to actually watch what is happening, you can pull the clutch cover like you said, or remove the starter and watch the starter gear as you activate it. What you will probably see in either case is that the gear is spinning, but not moving forward. You may be able to remedy that problem by taking the starter completely apart. Then clean and lubricate where necessary.

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The design of the starter does not appear to have a sliding starter gear. It appears to stay in in the same location at all times. When I have had the starter off to test and then reinstalled, it has to mesh with the gear in the bottom of the starter houseing location in the side cover. The gear in the bottom of the starter houseing location spins freely in both directions. The starter is turning this gear when the clutch is is activated and the starter button is depressed. Has anyone been into this particular model ATV starter gear drive?

Joe.

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  • 2 months later...

it is the flywheel key. it has sheared in half.

it can happen...

you need to use a rattle gun and removed the nut holding on the flywheel.

you will see a sliver of metal that is a diffrent color than the rest of the shaft.

push it out with a screwdriver and remove the other half from the groove in the flywheel.

you will have to buy another key way, it is cheap.

then install the fly wheel as per fitting instructions.

some LTZ400 when modyfyed Cam shafts break this very often, and need to have some locktight added to the shafts taper "where it contacts in to the flywheel" and do up a little tighter than standard.

I guess that you have fixed it already, since you posted your question in march. But maybe this will help the next guy.

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  • 4 years later...

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