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post #11 of 42 (permalink) Old 09-30-2018, 12:47 PM Thread Starter
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Sorry for the super late reply guys but, yes got the starting issue resolved. it was the fuel pump relay that was going bad/did go bad. I replaced it, got new battery and she fired right up. but it does have a weird grinding noise when I used the electric start. I thought it might be reduction gears, pulled them and checked they all look great. Any other ideas?
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post #12 of 42 (permalink) Old 09-30-2018, 01:40 PM
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Sorry for the super late reply guys but, yes got the starting issue resolved. it was the fuel pump relay that was going bad/did go bad. I replaced it, got new battery and she fired right up. but it does have a weird grinding noise when I used the electric start. I thought it might be reduction gears, pulled them and checked they all look great. Any other ideas?
one or two things ( and thanks for the late reply..lol ) your starter needs some attention ?, or..the cover that fits over the starter transfer gears is binding on the gears ?. I had this happen awhile back, not sure why ?, unless the cases wore down, and then started to bind the gears when I tightened the cover down ?. if its the cover ?, buy some gasket making paper, it comes in 32 and 64 thickness, got it at a auto parts store, bumper to bumper I think the name was ?, but you should be able to get it from any auto parts store. remove the cover, trace out a new gasket, use a hole puncher tool set from harbor freight , install, and see if the cover is still binding the gears ?.

'89 trx350D foreman 4x4...'85 vf700c magna, '03 trx450fm foreman 4x4 , 2015 Yamaha waverunner fx cruiser ho, '08 vt750c2 shadow spirit
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post #13 of 42 (permalink) Old 09-30-2018, 01:42 PM
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you can test the cover gasket by simply backing the starter cover bolts out, tapping the cover off just a little , then using the starter, if the noise goes away ?, then yes..its the gasket !!.

'89 trx350D foreman 4x4...'85 vf700c magna, '03 trx450fm foreman 4x4 , 2015 Yamaha waverunner fx cruiser ho, '08 vt750c2 shadow spirit
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post #14 of 42 (permalink) Old 09-30-2018, 03:33 PM Thread Starter
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I did test the starter alone and it did not make any noise when everything was off I will back it off a hair and check the gasket theory. Than ks for the help
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post #15 of 42 (permalink) Old 09-30-2018, 09:55 PM
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I did test the starter alone and it did not make any noise when everything was off I will back it off a hair and check the gasket theory. Than ks for the help
yw, keep us posted !.

'89 trx350D foreman 4x4...'85 vf700c magna, '03 trx450fm foreman 4x4 , 2015 Yamaha waverunner fx cruiser ho, '08 vt750c2 shadow spirit
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post #16 of 42 (permalink) Old 10-01-2018, 12:37 AM Thread Starter
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So tried what ya said about just backing off a hair and seeing if it made the noise and it did. I pulled the cover and looked closer. To me it looks like the shaft on the bottom gear is what is lose inside the outer housing. Maybe a little wallered out, so tried the opposite instead of adding gaskets tried taking it away all together. But guess its too tight and wont turn now, so will try something else tomorrow.
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post #17 of 42 (permalink) Old 10-01-2018, 01:56 AM
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So tried what ya said about just backing off a hair and seeing if it made the noise and it did. I pulled the cover and looked closer. To me it looks like the shaft on the bottom gear is what is lose inside the outer housing. Maybe a little wallered out, so tried the opposite instead of adding gaskets tried taking it away all together. But guess its too tight and wont turn now, so will try something else tomorrow.
if the cover is bad where the shaft rides ?, you will need a new cover. or..its posb the one-way bearing, which is the starter one-way bearing, it could be going out ?. I would try another starter cover first :-).

'89 trx350D foreman 4x4...'85 vf700c magna, '03 trx450fm foreman 4x4 , 2015 Yamaha waverunner fx cruiser ho, '08 vt750c2 shadow spirit
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post #18 of 42 (permalink) Old 04-23-2019, 07:45 PM Thread Starter
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So update-- Still having the grinding issue when you try and start it. Have done the gasket trick both ways adding too and taking away and still grinding no matter what. I pulled up the OEM schematic, even though it does not show a shim in there seems like there should be. Took a pic of my outter housing and its eating away at it. Not sure how to add pictures in here.
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post #19 of 42 (permalink) Old 04-23-2019, 07:47 PM Thread Starter
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PicturesOk figured out the picture deal
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post #20 of 42 (permalink) Old 04-24-2019, 02:39 AM
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It looks like those reduction gears are installed/stacked in the wrong order? See the attachment.
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