Click/Clunk - No Crank

[E350]

1993 550x with reed engine.
Interstate Battery, 12.79 DCV

Starter switch causes (the starter solenoid?) to click/clunk, but no cranking by the starter whatsoever - not even an attempt to spin the engine. No humming, no sound, no nothing.

12.79 DCV at the starter solenoid-in post.

0 DCV at the starter solenoid-out post without handlebar starter switch depressed.

12.65 at the starter solenoid-out post with the handlebar starter switch depressed.

When I try to jump the wire from the battery at its connection with the staring solenoid directly to the post where solenoid is sending current to the starter. Nothing. Nadda. Not even a spark.

(You know how you are normally a little scared to touch the screwdriver from the solenoid-in post to the solenoid-out post? Well there is simply nothing no spark when touching, nothing.)

I can push the pistons down freely in the spark plug holes with a screwdriver.

I really don't want to pull the fuel tank and then the engine if I don't have to.

I do not know how to "load test" a battery. Should I pull a different known-good battery from another ski and try it before moving forward?

 

[fastgtfairlane]

It sounds like your starter is going bad or has already failed. I used to take them apart and basically clean the commutator which is what the brushes contact send the power with some fine sand paper. They're pretty easy to go through.

 

[WFO Speedracer]

Yep if you are getting 12 V on the output side of the solenoid the starter needs to be repaired or replaced , if you don't want to tackle the starter REBUILD yourself most areas have places that repair starters and alternators , one of them should be able to fix you up , but truefully rebuilding a starter is not that difficult It's just a little fiddly getting it ALL back together , most likely it is just the brushes that need to be replaced , the article below is on a Yamaha starter but most starters are similar, they just use different brush configurations etc.

Super Jet - Save that starter! (Starter rebuild)

My starter finally gave out despite my efforts to prolong its life. I went the route of buying a clean, used, freshwater OEM starter. The seller sent me pictures and a video of that starter working. It arrived, and I installed it, but my ski had no life. This began the frustrating experience of...

www.x-h2o.com

 

[E350]

Thanks @fastgtfairlane and @WFO Speedracer I have rebuilt the Bendix on the Super Jet type starters a couple of times, but never the motor.

I'll be back . . .

 

[E350]

Well, just for giggles, I took the known-good battery out of the FX-1 and put it into the 550sx

and . . .

Same thing, you guys were right. Nothing but a click/clunk. No other sound of the starter trying to turn.

So, I am considering adding this to that jet ski trailer and make it my working trailer since the other ski on the trailer is my wife's old 300/440 superstock with a seized piston (and moving my cherry picker for the 7.3 diesel out to the trailers is a pain). But it is an expense so, I am still considering:

https://www.harborfreight.com/12-ton-capacity-pickup-truck-bed-crane-with-hand-winch-61522.html

https://www.harborfreight.com/custom-modular-5-ft-x-10-ft-utility-trailer-1000-lb-stabilizer-jack-70789.html

 

[WFO Speedracer]

One more thing you can try , even though they say not to, tap on the starter while hitting the start button, if it spins over you will know that the brushes are worn out and most likely that's all it needs , anything that will fit down in there will work , the end of a pipe wrench for example or if you have the room which you most likely don't , a small hammer , remember I said to tap on it , not whale on it .

Sometimes that small tap will make the brushes make contact for just a split second , long enough to make the starter spin over.

When I was much , much younger we rode around in my ex - girlfriends Ford Thunderbird for about a week , banging on the starter with a hammer to get it started , she would crank it , I would slide under the car and bang on the starter with a hammer , true story .

 

[E350]

Well, I should have access to the front of the starter after I remove the fuel tank but before I remove the engine. So I will try to tap the case with a soft face dead blow hammer.

 

[WFO Speedracer]

Anything that will jar the starter and make the brushes contact will work fine.

 

[Baja 252]

It also could have a dead spot on the armature. Remove the lanyard so it won’t start and reach down and turn the driveshaft. Probably have to take spark plugs out to do this. Then try it again and see if it just clicks.
Not a long-term fix, but it might work.

 

[WFO Speedracer]

It also could have a dead spot on the armature. Remove the lanyard so it won’t start and reach down and turn the driveshaft. Probably have to take spark plugs out to do this. Then try it again and see if it just clicks.
Not a long-term fix, but it might work.

Ummm maybe I missing something here but please explain how turning the driveshaft will turn the armature in the starter , I can't wait to hear this one.

The starter is not connected to the flywheel unless the starter is spinning and it throws the bendix forward , if it was and you revved it just once the starter would fly apart as it cannot handle those type of RPM's .

I know because I have seen one with a bendix engaged and stuck do exactly what I just described , it also destroyed the bendix and the stator when the bendix flew apart .

 

[Baja 252]

I was thinking that he might have two issues going on. A weak starter and the bendix teeth jammed / stuck with the flywheel teeth. Turning the engine over by hand could release the bendix and maybe turn the armature a little if it is engaged.
Total 100% long shot, but easy to try.

 

[fastgtfairlane]

Had that happen before.

 

[E350]

I can turn the engine over by hand. Well really by screwdriver down the spark plug holes very easily.