mikeexplorer

Magnets are probably glued in, I would not try to remove them, probably would crack.

Hey it worked

What does this starter go to? (type of machine) Depending on the battery size you probably wouldn't see a large drop in voltage. I do see in your picture that the brushes do have a spring mechanism in the arm. So they would be contacting properly. There is a high resistance somewhere. The only thing I can think of is to assemble the motor, attach the meter to the leads with clamps if possible (if not strip a section of wire and wrap it around the meter leads so you don't have to hold it. ) Set meter to low ohm reading. Rotate the shaft SLOWLY I mean one full rotation should take you 30-60 seconds. see if you get jumps in ohm readings. It will jump around a bit but when done slowly, you will not get an inductive EMF backlash voltage reading. (from the magnets) It is possible the brushes are not maintaining contact as it rotates. I would feel the shaft with the commutator and feel for any bumps, that would deflect the brush for a moment and lose contact. Another test is with the starter assembled, connect one lead to either connection, the other to the frame, set meter to 100k range and slowly rotate the shaft. You were getting a static reading of about 10K which isn't good. If it changes a lot that could mean the power is bypassing the windings and the armature is no good. What is the highest DC amp range your meter can do? I would re-check the windings. Put a meter lead on one commutator point, the other lead to the one next to it. do this all around the armature. Ohm readings should be the same. At 0.1 ohms, that starter could pull 120 amps from the battery under full load.

Best way to clean commutator is with very fine sandpaper, or a fiberglass brush. I guess your meter's lowest OHM setting is 0.1 ohms. Not a big deal in this case. You have no open windings, which is good. What is NOT good is the frame reading. Segment to frame should read in the megaohms. The armature is ground faulted. Now this is only a 12 volt motor so there is no shock hazard. This most likely happened if the motor was run hard and the windings overheated, or it got wet inside several times. So have you looked at the permanent magnets in the case? Is any of them cracked? Loose? If the motor was subjected to overheating that will decrease the Gauss factor of the magnets (make them weaker) You say it spins well unloaded, but does not loaded, does this mean when it is installed or did you try to put a load on the shaft (grab it GENTLY) Did you do this test with the existing wiring of whatever this came out of? Do you have a battery jump box to try? (connect it to the motor and see if it runs under load) You could be losing current in the wiring.

You would unlikely see the broken wire. What you need to do is take your meter and remove the armature. test ohm reading from one copper point to another and go around the whole thing. The ohm reading should be consistent from one to the next one. The brush holders are weird, I don't see any springs that would hold the brush against the commutator. If it is an older starter, the brushes could be worn down and the rebuild kit would be the way to go.

Came with the quad so it has been used for things other then plowing Those springs work, many times I could have been thrown if it wasn't for them I have always had good luck with WARN winches. I do take them apart and service them every few years.

My plow has two large springs so if it hits something solid, it will fold down and skip over the bump.

12 years old, it was due No it has a metal bottom edge that can be replaced I know what you are talking about but it wouldn't be practical. Most winters the plow doesn't get used much. This year looks to be an exception. The winch is older so the cable wasn't 100% to begin with. For now I am going to spool out a foot or two and cut it, then re-attach with cable clamps. In the spring I am going to service the winch fully and will take the cable off. If it looks crappy overall, I will just replace it.

No work today and the ski area was delayed opening so I did the final round of plowing before heading out. Guess I worked the plow a bit hard, just as I was finishing ... SNAP! broke the winch cable.

Scranton area got about 12 inches, More north (where I ski) got about 16 inches. My plow I bought back in 2008 and still works.

Everything was closed. It did allow the quad to charge the battery back up after heavy use of the winch. I do keep it on a battery tender in the shed.

Ha Ha, did a third round but getting dark. PA went to a state of emergency so it is now legal to take ATV's and snowmobiles on the roads so I dropped the plow and went for a little joyride around town. Don't have work tomorrow either, bummer

Naw, got stiffed

Quad and plow are going to get a workout today!

Those can be heavy but hey it was a free score. The one you are posing on, we have a few of those at work and they are neat in how they can be unfolded several ways. Great for tight spots.

You can go to a place like countrycat and compare part numbers between the machines. I would bet that the parts won't match, the 2008 366 was a Kymco machine (I owned the 2010 model 366) The 400 back then had Suzuki motors. (I had a 2007 400 model)

OHSA rule, I got a ladder from work that is perfectly good but the stickers are faded.

What year 400?

I have a friend with one who has issues with his. Main wire was gauged too small and burned up leaving him stranded on the trail. Around 2,500 miles he had the motor replaced. I don't know the details of the issue but both times it was done under warranty.

I was referring to the Mag light. At work I have one of those cheaper rechargeable lights that clip to a hat since we have to wear bump caps. Doesn't have a laser pointer, but it works great to keep my hands free.

Welcome

They are durable and last long, dropped mine many times and still works.

Skiing yes, plowing, no. Been warm and raining here

Agreed, nice picture. (both look good) As you can see, all the weight of the machine is forward of the axle which is not good. That will put it very tongue heavy. You can even see how the vehicle is squatting due to the weight.

The new year brings me to a step into retirement. I went from working 40 hours a week down to 32. (work 4 days /week) Still a few years away from 65 so this still considers me full time so I still get benefits from work, but now I have every Friday off which saves on vacation time. (Now I can book more ATV / Camping trips )