F.m.l.

[Buckwild12]

Ok here is the situation. I bought a new (rebuilt) motor from Jetmaniac. And I cant tell you how awesome It looks. I go to hook it up (It is my first time doing so by he way) I hook everything up and secure all the lines. it looks great. get ready to start it yesterday and all I get is a CLICK from the starter solenoid. I check all my connections again and CLICK. I check the battery connections and the positive wire from the battery is hot as sheit. I have called Chris and he said everything sounds like its hooked up right. Upon reading a few threads last night I realIzed that I have a 62t MODDED CDI, and the new connection was a 61x. I changed the connector and assembled the motor thinking nothing of the possible compatability issue with what I had in there as the connector on my last motor was spliced the same way. I have attempted the screwdriver trick across the solenoid connection per chris's suggestion to see if the Solenoid from my ebox was bad, as it certainly does not look new. And made a huge spark. everything I touch makes sparks practically. Which makes me think the battery is good. The only other thing I have done is when I connected the lead from the E-box to the top of the starter I attached the lead in between the 2 lock nuts, should that be directly onto the top of the starter? Its my first time. im really pissed that I too big a tard to figure this out and I really really wanna ride this thing this weekend!!!!! ANY AND ALL HELP WOULD BE ENORMOUS. BTW I still have the flywheel/stator/starter/bendix attached to my old seized motor. They are all in good condition. What are my options if I have any.

 

[SuperJETT]

If you jump from the battery cable to the starter cable on the solenoid and the starter doesn't spin, then your problem is at the starter or engine.

Pull the plugs, can you spin the engine by hand?

Pull the starter and use jumper cables to see if it spins. Does it spin by hand?

61x/62t doesn't matter, they're the same electronics.

Use paragraphs...

 

[Buckwild12]

Sorry for the bad grammar ! I didnt realize it would be that long an explanation i just wanted to be as detailed as possible. I am able to spin the motor by hand without plugs in it. I tried before i installed it. Is it possible to remove a starter to test it without pulling the motor, ive never done that before, but im not scared at this point of my wrenching ability. I know that Chris used the engine and said it was working fine, but I am well aware that happens when it sits.

Ill give it a shot when I get home one way or another. Are there any small parts that may come off and get lost if I dont pull the motor out to check it? any installation tips or seals that are needing to be replaced if I start disassembling things? I just need to order them now if so, I know alot of places are not open tomorrow.

 

[5810]

what pipe u running, is the pipe on the motor. if pipe is on, pull the head pipe off and u will have all the room u need to remove the starter. 2 12mm and one 10mm for cable 3 bolts total. Wrenching is fun!!!!!!!!!!!!

 

[SJBrit]

You can pull the starter with the motor in - it's a PITA with a stock pipe but doable, and pretty easy with an aftermarket pipe. Use a little 1211 around the seal when you put it back in - can't be too careful in terms of keeping water out of the flywheel area.

But, if the motor spins by hand then you don't really need to pull the starter. Do what Darin said and run the starter direct from the battery for a definitive answer on whether the starter is good. If it's sparking then you haven't made the connection properly. Touch the cable to the battery briefly but firmly - just a quick tap. You'll know right away if the starter spins. Do it with the plugs out to reduce load.

 

[SJBrit]

what pipe u running, is the pipe on the motor. if pipe is on, pull the head pipe off and u will have all the room u need to remove the starter. 2 12mm and one 10mm for cable 3 bolts total. Wrenching is fun!!!!!!!!!!!!

I wouldn't - then you need new gaskets for the pipe. It's a bit fiddly, but you can get it out with the pipe installed.

 

[SuperJETT]

Also, if you use jumper cables to jump the starter, never tap them on the battery terminals, always connect the battery side and do the final connection on the load side so any sparks are far away from the battery just in case it's off-gassing.

 

[Buckwild12]

Factory B Mod pipe, all attached at the moment. head pipe is on, but I used locktite when I attached it, and I really dont want to go that far with it if I can help it as I dont have a torque wrench at the house.so the bolts are on the back end of the starter and pass through. I have a shop manual around here somewhere. I got the motor pump midshaft aligned perfect so If something has to come out it'll be the manifold but those are a bit of a bitch to get also
some days I feel like you just cant win... unfortunately I dont get off til 6 tonight, but keep the ideas coming im gonna do what it takes to get this started. I justy keep thinking is something absolutely stupid! that I either hooked up wrong or is loose somewhere. fortunately there are only so many parts on these things.

 

[Buckwild12]

Its also a gel cell battery so if its off gassing I have bigger problems but you couldnt have known that.

 

[Buckwild12]

Thanks again everyone, I learned something new and once I get my ski re-assembled ( I ended up having to take off the pipe) this afternoon, it looks like I'll be riding this weekend.

 

[SuperJETT]

So what was it? Glad to hear you found something probably at least.

 

[Buckwild12]

The starte was f'd up, the yellowish sleeve was jammed up in the nose? when I pulled it off, it looked like a yellow mushroom. I have no idea how it got that way. I eventually gave in and pulled the pipe off after wasting 3 hours trying to get it off working around it. im not sure of the technical term for that sleve but it was nice, clean and seated well Ill take a pic of the bad one and post it when I get home.

 

[Buckwild12]

It was nice and clean on the one I put on, the other one was crap I cant type for anything today, I promise I havent been drinking, yet.........