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Discussion Starter #1
Starter will not run,solenoid clicks. Pull rope to rotate the engine a little and the starter runs and engages just fine. Not at all familiar with this starter setup. Sure can use a little education. Just got the bike and haven't gotten a manual yet. I know someone will yell....2004 Honda Recon 250 ES
 

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Hi: I would say your battery is dead -- try boosting the bike.
 
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Discussion Starter #3
Battery is is top shape. It turns iver just fine if the engine is rotated a bit.
I am a small engine mech. But I have never run across this type of start clutch thingie.,
 

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Please refrain from making multiple threads about the same problem. I will remove the other one and everyone can respond in this thread. Thanks!
 

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I had mine do the same, ended being worn down starter brushes.
 
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Discussion Starter #6
As an admin on a small engine forum myself I try not to make multiple threads and could not figure out how to delete the other.
 

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Discussion Starter #7 (Edited)
Maybe I should have asked someone HOW this starter system works. I have never seen one that didn't have a bendix. A low voltage condition wouldn't be helped by turning the engine a few degrees and hitting the key. UNLESSSS....maybe it's stopped at the top of a compression stroke?
 

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As an admin on a small engine forum myself I try not to make multiple threads and could not figure out how to delete the other.
No worries! We all make mistakes. Thats why were here!
 

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take the starter off and try putting power to it. I suspect it's junk but I'm not real sure why rotating the engine a little with the pull start makes a difference.

These don't use a bendix, I guess because everything is sealed. The starter is in constant mesh with the flywheel, usually by the way of another gear or two to increase the torque of the starter motor and decrease the speed. The starter gear on the flywheel will have a one way bearing on it. So when you go to turn it over with the starter it will turn over, but when the engine is running it's allowed to free wheel.
 

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Discussion Starter #10
Thanks Mac. I was able to download the IPL and figured out what is what. I now suspect the starter is weak and hanging on the compression stroke. I'm gonna plug in my leakdown equipment and see if I can vary the conditions. If drawing off a little pressure fixes it...I'll know it is the starter.
 

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I believe this part will fix you up 31201-ks5-901
 

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Those Chinese ones aren’t even that bad, make more noise than OEM but seem to be pretty robust. I typically see rebuilt oem starters not last as long as the China replacements. Seems like the commutator bars just end up damaged and they chew up new brushes fairly quick. Typically anyway.


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Discussion Starter #14
Pulled her in the shop today...a smack with the butt end of a maglight turns her over. It looks like the new starter won't be here till next week and I have five days off. Might pull the brush plate and chuck the armature up in the lathe. Thanks guys.:angel
 

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Not sure about your starter but I've bought some really good aftermarket brush kits from local Napa store for several makes of ATV starters for less than $20. Some were around $12.

The kits I'm referring to had the brushes in a new end cap with the new bushing, etc.

You might research such after you have examined yours.

I had to take the brushes out of one of the aftermarket kits and install them into my OEM cap end cap because the kit end cap. I could have took the kit back to Napa for another but seen that I could make it work Ok.
 

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Discussion Starter #16 (Edited)
Took it apart and yes the one brush was getting thin and the commutator was dirty. Cleaned the armature up on the lathe and called the biggest dealer in town looking for the brush holder. He had the same number that Wilson offered BUT....said that I was the first who ever needed one and it wasn't stocked !! Show how few mechanics there are as opposed to parts changers. But then again, if I can get a new starter for 32 bucks and free shipping compared to 18 with shipping for the holder...well ya know. I used a small file to cut down the slots in the holder and was able to grab a couple hundredths more brush play to get the starter to work for a couple days...
 
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