Progress.....the 1.6 ran!! but I have starter problems

[chris71920]

Well, I had the 1.6 running earlier, albeit a bit briefly

Firstly I made the rookie mistake of having the dizzy 180 degrees out but found out pretty quickly. Kept turning it over and over and eventually it fired up

I have no throttle cable mounted yet so was doing it by hand using the choke for now, but Ive made a bracket, just needs a bit of fettling to clear various things but that should be sorted in the morning

Also, initially the starter worked perfectly then after a few more turn-overs it was making some dodgy noises when cranking, and I could hear it "winding down" once I'd let go of the key until eventually it wasnt meshing at all with the flywheel and was just spinning over. The starter is pretty tight up against the block despite being a "skinny" one but would JUST fit with a little shove.

It was also very tight to remove despite revolving when the mounting bolts were out......so my theory is that because its so tight its not quite sitting right and therefore not meshing correctly. In which case I will take a little bit of metal off of the offending area tomorrow. Does this sound likely?

All teeth are still on both it and the flywheel btw

[chris71920]

Ive just read that loosening the gearbox to engine bolts and rotating the top of the box towards the driver's side a couple of mm will cure this, anyone had experience of this?

[ScottieJ]

I cant imagine that you'll be able rotate the gearbox enough to make much of a difference. I'd go for a careful bit of grinding. What make/model skinny starter is it?

[chris71920]

It may be possible on mine as Ive not used the conversion plate so have drilled the top holes through to 12mm and nut and bolted the bottom ones (sounds a bit pikey when written but hey....)

Its literally a mm or 2 to "fettle" in 1 area, not the crazy grinding of block and starter with huge angle grinder method lol

Its a D6RA-13, theres pics up in the "starter" thread

[dan_2k_uk]

I did it without the adaptor plate and my "skinny" starter cleared it by loads?

Dan

[chris71920]

See the pics in this thread http://suzukiclubuk.co.uk/forum1/viewto ... 13/t,5084/

Mine is ever so slightly different to the one posted further up in that the housing is the same all the way round, where as the previous one only has the bolt areas protruding.

In my 2nd pic, its the bottom face thats causing the issue. Is this likely to be the cause of it not meshing correctly??

[dan_2k_uk]

Possibly. Would have thought that if it bolts up all the way home against the gearbox then it woild be correctly lined up. I do know of some people having to rotate the box slightly like you have said.

Dan

[ferris]

Seems strange that it was engaging initially and now needs moving.

I would check all the connections are clean and tight. I had a loose connection on my starter and it would spin, but not engage with the fly wheel.

[chris71920]

I can't get it to engage! Been trying, haven't tried moving the box yet. I can hear the solenoid firing so it must be moving the gear out....I'll keep at it, as obviously it was working initially!

All connections are tight though

[chris71920]

Getting frustrated now, even took starter apart and found the spindle to be a bit sticky so cleaned it all up and regreased it in the hope that the solenoid wasn't pulling right down but still the same :(

It's annoying as it was working fine for a good 10 or so cranks initially yesterday!!