Problem has "started" again

[Dorman]

Hi All

 

Sometime back had a problem with a replacement starter motor damaging the flywheel on the engine. Its a BD5 axial starter with starter pinion which pre-engages by a pair on contacts before coming up to full torque on a Dorman 3AL.

Sent away the starter to a specialist who carried out a full rebuild with proper parts i.e. manufactures contacts etc and set up properly and deburred the flywheel and worked great --------- until yesterday.

Suddenly it started clashing before fully engaging and l am worried that it will start to rebur the flywheel and damage the pinion and we are back to square one again. The clearance hasnt changed between the pinion and flywheel.

 

Does anyone know somebody in the Worcestershire or Warkwickshire areas, we are at Wyre Piddle on the Avon, who is knowledgeble about older vintage engines as l want to seek some advice before sending it back or doing more damage!

 

Simon

Edited June 3, 2013 by Dorman

[Timleech]

I imagine you have a BS5 starter, rather than BD5?

Either there is not enough clearance between starter pinion and ring gear (is it adjustable?), or something is worn or not working as it should in the trigger mechanism which allows the solenoid to pass to the full power position. SirNibble will have more precise knowledge if he's around.

 

If the starter is on straps rather than bolted to a flange, try moving it away from the flywheel by up to 1/8". If the problem persists, it's definitely a starter fault.

 

Tim

[Dorman]

Yes typo it is a BS5

 

Just come back from the boat and checked clearance between pinion and starter ring face and its nearer 6mm! Manual quotes 0.79mm to just over 3mm for "smooth engagement" so probably coming at the starter ring a bit briskly, so not moving it back.

 

Spoke to suppliers of the starter motor and they are coming to have a look.

 

One thing though managed to get a good look at the starter with covers off and somebody turning the key and it appears to be engaging ok but the "clacking" noise seems to be coming from backlash on the pinion shaft and pinion gear as it turns initially on the flywheel it moves back and forward.

Didnt get this on the old one but it had a phosphor bronze pinion, not steel so maybe its just a bit louder in operation?

Anyway no damage to flywheel or pinion teeth since last year so didnt need to do any more deburring.The teeth look ok and within couple of mm from nearest to furthar away ones from the pinion when rotated with no breaks etc--normal wear and tear l guess.

When l stop engine on decompression it seems a bit smoother missing the wear points on TDC helps l guess.

 

Definitely looks as if new starter needs to move forward as slightly different clearance situation. Tempted to have the front casing turned down to try and get it nearer as there is plenty of teeth length on the ring.

 

Simon

[RLWP]

Is that the front casing of the starter?

 

Richard

[Dorman]

Yes the casing of the starter sits in the bell housing and has a turned section to accomodate it about 5-6mm deep.

 

Simon

[RLWP]

I suspect that the suppliers will diagnose something about the front casing and swap it. If you do have to have it machined, I can help

 

Richard

[Dorman]

Thanks Richard

 

I access to a lathe and operator but appreciate your kind offer.

 

Keep you posted.

 

Simon

[Dorman]

Pleased to report moved starter back as suggested and clacking noise disappeared and appears to be working ok--will keep you posted!!

 

Many thanks Tim

 

Fingers crossed

 

Simon

 

Edited to say--just shows you dont always believe the manuals--experience better

Edited June 16, 2013 by Dorman