Starter Shaft wear.

[kingquad14]

I have a 1993 King Quad LT-F4WDXP. I have had to replace the starter 3 times and each time the end of the shaft where the splines are cut in is all worn down. Getting ready to do it again any ideas on how to solve this problem? Is the a starter gear in the crankcase that is worn or broken. It make a grinding sound while cranking after a week or so.

[oxidized_black]

try messaging this member ... Tim-ANC's ATV Page » QUADCRAZY ATV Community

[Tim-ANC]

First, here is my post about these:

http://www.quadcrazy.com/atvforum/suzuki-atv-forum/13672-91-98-king-quad-starters.html

Since, the machine I was changing these on has fully failed to start electrically. I talked to the local mechanic. He said the shaft the starter idle gear rides on breaks out of the recess it sits in. He has a fix for it at $500.

Pull the starter and look in the hole. Feel if the gear spins or wobbles. Otherwise you would have to pull the left hand crank case to investigate. I would first try to find a starter with good splines and see how that holds up.

For me, I just used to pull starting it. Not worth it for me to tear into it at this point. Winter project maybe.

[kingquad14]

Pulled the cover and the starter idler gear.

Gear was frozen on the pin.

Turned the big idler gear and hear noise.

Guess Ill put new bearings on the rotor and new starter idler gear.

Thanks

[Tim-ANC]

The rotor should only turn one way and not the other. There is a one way bearing behind this. I hope that is ok. Otherwise you have to pull the rotor and need a special tool to pull that big nut.

[kingquad14]

Took a week to get the tool. Local dealers did not have one. Came in yesterday.

Going to pull it off today. Yep, only turns one way and does not sound too good when spinning it by hand.

[Tim-ANC]

You're on the right track. Seems like that one way clutch bearing gave out. Our maybe a piece of debris in it. Good news the starter gear shaft did not break anything in the case. Did you pull the crank case cover with engine in frame?

[kingquad14]

Yes pulled the cover with engine in the frame. All the bearings were good. The Pin shaft was stuck in the starter idler gear. Popped it out and it was bent thus making the gear run in an ovular rotation not a circular rotation.

Just went up and ordered a gear, pin shaft and spacer as well as all new gaskets. Think it will be whipped when we get it back together. Thx.

[Tim-ANC]

Impressive. Pulling the left crank case cover in frame is a chore and delicate process. I like your theory about the eccentric rotation on the gear.