Unique starter fail, seeking advice

[dANbOT]

update on the 5009 bendix?

[dANbOT]

Well, today things got worse...
The kick start shaft snapped off almost flush with the right side cover. SO now I am making another attempt at fixing my e start. Last time the machine screw broke right away so I made a solid pin from the butt end of a drill bit, and have epoxied it in place. Hopefully this gets me through until I get some parts.

[dANbOT]

Ordered a used kick start shaft from eBay out of a 2013.
I also took a gamble on the smu5009 14/40 bendix. Hoping to hear a successful report from pigpen

[pigpen966]

Sorry, been busy at work. The 5009 works like a champ!!! I actually think this is the PERMANENT fix. Soon as I get some time out in the garage I'll disassemble it and take some pics of how I got it to work.

[dANbOT]

Originally Posted by pigpen966

Sorry, been busy at work. The 5009 works like a champ!!! I actually think this is the PERMANENT fix. Soon as I get some time out in the garage I'll disassemble it and take some pics of how I got it to work.

That is some great news!
Was it just a matter of shimming the starter body to allow for the slightly larger diameter of the 40t?

[pigpen966]

The 40 gear is the same diameter, the problem is it is thicker. I had to remove about 1mm from the motor housing where the top of the bendix shaft sits to get the housing to fit down on the flywheel cover.

[pigpen966]

Sorry it took so long, got a big job going on at work.


Here is the SMU 5009 bendix from DB Electrical $22 and the OEM.



As you can see the 40 tooth drive gear is the same diameter but thicker.
When you drop it in looks like this



I took about 1mm off the bottom of the 5009 shaft with the bench grinder
Also relieved about 1-1.5mm off of the housing to get it to sit down on the flywheel housing




Works like a champ now and the 5009 bendix is a direct swap for $22 bucks.

[Jakobi]

Could you not get someone to machine up a batch of small spacers and fit it between the 2 parts. Would add a tad more to the cost, but save the handy work grinding parts down.

[pscook]

Originally Posted by Jakobi

Could you not get someone to machine up a batch of small spacers and fit it between the 2 parts. Would add a tad more to the cost, but save the handy work grinding parts down.

The starter motor bolts to the PV cover, so you would have to slot the holes in the starter motor bracket as well with the spacer. You might be able to add a spacer between the two parts and then relieve the interface between the starter motor and the upper bendix housing (lower the starter motor inside the bendix housing).

Is the shaft longer overall, or is the shaft the same length with just a thicker gear?

[pigpen966]

Originally Posted by pscook

The starter motor bolts to the PV cover, so you would have to slot the holes in the starter motor bracket as well with the spacer. You might be able to add a spacer between the two parts and then relieve the interface between the starter motor and the upper bendix housing (lower the starter motor inside the bendix housing).

Is the shaft longer overall, or is the shaft the same length with just a thicker gear?

The shaft is actually about 1mm shorter overall but the distance from the top of the drive gear to the keeper on the bottom is longer.