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Starter is stuck to flywheel

#1

K

kkjfjns2014

Hello all, I went out to try and start my 2009 craftsman yts4500 and it turned over 3 times and just suddenly stopped. Now when you try to turn it over it just makes one click and doesn't do anything. Battery is good and charged.

The battery side of the solenoid has 12.6 volts but when you turn the key the starter side only gets 6.4 volts. I took the cover off and noticed the starter bendix was stuck to the flywheel. (Pic attached) I tried tapping it down to no avail. Does anyone have any ideas why this happened or what to do now? Thank you.

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#2

B

bertsmobile1

Time to replace the starter gear
Either loosen off the starter mounting bolts or turn the engine backwards by hand to loosen the starter drive pinion
If you have nbeen smacking it with a hammer then remove the drive pinion & energise the starter motor to check that you have not bent the end of the shaft .


#3

K

kkjfjns2014

bertsmobile1 said:
Time to replace the starter gear
Either loosen off the starter mounting bolts or turn the engine backwards by hand to loosen the starter drive pinion
If you have nbeen smacking it with a hammer then remove the drive pinion & energise the starter motor to check that you have not bent the end of the shaft .
Click to expand...
I took the starter off and stuck power straight to the screw and it didn't turn. I'm assuming that means the starter is bad?


#4

K

kkjfjns2014

kkjfjns2014 said:
I took the starter off and stuck power straight to the screw and it didn't turn. I'm assuming that means the starter is bad?
Click to expand...
bertsmobile1 said:
Time to replace the starter gear
Either loosen off the starter mounting bolts or turn the engine backwards by hand to loosen the starter drive pinion
If you have nbeen smacking it with a hammer then remove the drive pinion & energise the starter motor to check that you have not bent the end of the shaft .
Click to expand...
I mean I was barely tapping it and the motor would not turn either way until I completely removed the starter. I'm assuming the starter shaft is locked up right?


#5

B

bertsmobile1

kkjfjns2014 said:
I took the starter off and stuck power straight to the screw and it didn't turn. I'm assuming that means the starter is bad?
Click to expand...
And a ground cable to the body I hope
Some starters have replacible brushes , some don't and others are hard to find
So if it does not spin, nothing to be lost by pulling it apart to see what went wrong
Good chance that while it was jambed & you were energising the starter you burned out one set of windings .


#6

D

DarkKnyte

If you put 12+ to the screw and 12- to the case and the starter didn't even flinch, then your brushes are most certainly burned up, and depending on your luck, the stator armature may have a short.

Starters are relatively straight forward to disassemble and service. Worst case, you can't put it back together and have to get another starter anyway. If you aren't interested in a project, just order a used one toss yours. Otherwise, take it apart and see what looks broken. Nobody here is going to know exactly why it isn't working. It's all guess work until you get it open and see what's what.


#7

K

kkjfjns2014

DarkKnyte said:
If you put 12+ to the screw and 12- to the case and the starter didn't even flinch, then your brushes are most certainly burned up, and depending on your luck, the stator may have a short.

Starters are relatively straight forward to disassemble and service. Worst case, you can't put it back together and have to get another starter anyway. If you aren't interested in a project, just order a used one toss yours. Otherwise, take it apart and see what looks broken. Nobody here is going to know exactly why it isn't working. It's all guess work until you get it open and see what's what.
Click to expand...
I'll probably just get another one they're only about $50 new. I did ground it while I was testing it. Thank you all for the feedback. Is there a way to test the stator?


#8

D

DarkKnyte

kkjfjns2014 said:
I'll probably just get another one they're only about $50 new. I did ground it while I was testing it. Thank you all for the feedback. Is there a way to test the stator?
Click to expand...

Note: I wrote stator, I meant armature. I had my mind on something else when I was replying.

There's no point in testing the armature. It isn't really serviceable, other than cleaning and refreshing the contacts. You can replace the brushes and clean the armature, but the cost delta between servicing the starter and replacing it is relatively low, it may make more sense for you to just replace it.

DIY: How to Test an Armature of a Motor - YouTubeYouTubehttps://www.youtube.com · 4DIYers


#9

B

bertsmobile1

The $ 50 ones are junk
They are 2 pole starters that draw a lot more electricity and produce less torque


#10

F

Forest#2

Why do you want to test your stator?

Lots of info on-line about how to test.

When asking questions about such you should list the type of engine and it ID info.

You might check with dbelectric for a replacement starter. You need to make a close inspection of all the flywheel teeth on your engine. Your old bendix gear has been going up too high when meshing with the teeth. If just one tooth is bad the whole barrel of apples is will go bad.


#11

K

kkjfjns2014

bertsmobile1 said:
The $ 50 ones are junk
They are 2 pole starters that draw a lot more electricity and produce less torque
Click to expand...
That may be true but I don't have $250 for a kholer brand starter lol.


#12

K

kkjfjns2014

Forest#2 said:
Why do you want to test your stator?

Lots of info on-line about how to test.

When asking questions about such you should list the type of engine and it ID info.

You might check with dbelectric for a replacement starter. You need to make a close inspection of all the flywheel teeth on your engine. Your old bendix gear has been going up too high when meshing with the teeth. If just one tooth is bad the whole barrel of apples is will go bad.
Click to expand...
Someone mentioned it might he shorted out for some reason?

It's a Kholer SV735s 26 hp engine on a craftsman YTS 4500.


#13

StarTech

StarTech

I know that DB Electrical sells the same J&N starters that the Kohler starters are. Currently the 32 098 03-S is their 410-21069 and is currently listed @ $70. (well $69.32)

As for the stator/regulator usually the regulator fails. PN 25 403 37-S

But in this case it appears the starter has failed.


#14

F

Forest#2

bertsmobil is correct about them cheap starter, most are weak and wimpy.

I've had good luck with dbelectric starters but have to pay little more than the China clones but less price than OEM over the counter name brand starters.
If you contact dbelectric give them all your engine info and let them pick your replacement. I sometimes send them a email instead of calling if I'm not in a rush and they usually get back in about 4-5 days.


#15

K

kkjfjns2014

StarTech said:
I know that DB Electrical sells the same J&N starters that the Kohler starters are. Currently the 32 098 03-S is their 410-21069 and is currently listed @ $70. (well $69.32)

As for the stator/regulator usually the regulator fails. PN 25 403 37-S

But in this case it appears the starter has failed.
Click to expand...

Forest#2 said:
bertsmobil is correct about them cheap starter, most are weak and wimpy.

I've had good luck with dbelectric starters but have to pay little more than the China clones but less price than OEM over the counter name brand starters.
If you contact dbelectric give them all your engine info and let them pick your replacement. I sometimes send them a email instead of calling if I'm not in a rush and they usually get back in about 4-5 days.
Click to expand...
I need to mow so I'm in a hurry. Maybe I'll order the dB one and keep the China one for a backup. Thank you.


#16

F

Forest#2

You can find lots of info on-line about how to test the AC output volts of the stator.
You will need a electrical tester. As startech says usually it's the regulator that fails UNLESS someone has been hacking the wiring and sent DC voltage to the stator winding and let the smoke out. (the smoke is already inside electrical stuff just waiting for someone to let it come out) If you are not electrically inclined or have the testers sometimes you can find some regulators for less than $20. Also some auto parts places will check your battery for free No need in replacing other electrical charging parts if you have a bad battery.


#17

F

Forest#2

You say:
I need to mow so I'm in a hurry. Maybe I'll order the dB one and keep the China one for a backup. Thank you.

China as a back-up. Now that is funny. A knee slapper.
Good luck on that one.


#18

K

kkjfjns2014

Forest#2 said:
You say:
I need to mow so I'm in a hurry. Maybe I'll order the dB one and keep the China one for a backup. Thank you.

China as a back-up. Now that is funny. A knee slapper.
Good luck on that one.
Click to expand...
.....aight then.


#19

B

bertsmobile1

You will end up paying a lot more than that
Quality aftermarket staters are available from all of the genuine after market parts wholesalers
Prime line used to have the best priced starters , Rotary, Stens & Oregon all do them.
Why people want to play parts roulette is beyond me
For all you know it might be fine with nothing more than a set of brushes ( unlikely ) but you will not know till you pull it apart .
Not uncommon to have a customer who has replaced a cheap starter 3 or 4 times + a couple of batteries plus a solenoid or two because they "think" that they can not afford a guaranteed quality starter
Even had a couple where I have needed to replace the wiring loom because the excessive current draw melted the insulation and the wires in the loom shorted .
Mind you siting there and cranking for 5 minutes at a time because they have never adjusted the valve lash did not help either .

To be just a little flippant
If you can't afford the starter then buy a goat or a sythe both of them are "free" to use .


#20

K

kkjfjns2014

bertsmobile1 said:
You will end up paying a lot more than that
Quality aftermarket staters are available from all of the genuine after market parts wholesalers
Prime line used to have the best priced starters , Rotary, Stens & Oregon all do them.
Why people want to play parts roulette is beyond me
For all you know it might be fine with nothing more than a set of brushes ( unlikely ) but you will not know till you pull it apart .
Not uncommon to have a customer who has replaced a cheap starter 3 or 4 times + a couple of batteries plus a solenoid or two because they "think" that they can not afford a guaranteed quality starter
Even had a couple where I have needed to replace the wiring loom because the excessive current draw melted the insulation and the wires in the loom shorted .
Mind you siting there and cranking for 5 minutes at a time because they have never adjusted the valve lash did not help either .

To be just a little flippant
If you can't afford the starter then buy a goat or a sythe both of them are "free" to use .
Click to expand...
Ok then.


#21

F

Forest#2

You can also find some good info about checking/repairing Kohlers starters on-line. The brush end has a kit and it user friendly to replace the brush assembly kit.


#22

K

kkjfjns2014

Forest#2 said:
You can also find some good info about checking/repairing Kohlers starters on-line. The brush end has a kit and it user friendly to replace the brush assembly kit.
Click to expand...
I'll check that out thank you


#23

E

EABill

Keep that shaft clean and lubricated so the gear slides up and down freely. I can have the same problem with our 35 year old wheel horse 314-8.


#24

S

skipb

kkjfjns2014 said:
Hello all, I went out to try and start my 2009 craftsman yts4500 and it turned over 3 times and just suddenly stopped. Now when you try to turn it over it just makes one click and doesn't do anything. Battery is good and charged.

The battery side of the solenoid has 12.6 volts but when you turn the key the starter side only gets 6.4 volts. I took the cover off and noticed the starter bendix was stuck to the flywheel. (Pic attached) I tried tapping it down to no avail. Does anyone have any ideas why this happened or what to do now? Thank you.
Click to expand...
Not knowing any info on motor,try pulling spark plug to make sure the cylinder is not loaded with fuel. That will cause compression lock up.


#25

Z

Zedo

kkjfjns2014 said:
Hello all, I went out to try and start my 2009 craftsman yts4500 and it turned over 3 times and just suddenly stopped. Now when you try to turn it over it just makes one click and doesn't do anything. Battery is good and charged.

The battery side of the solenoid has 12.6 volts but when you turn the key the starter side only gets 6.4 volts. I took the cover off and noticed the starter bendix was stuck to the flywheel. (Pic attached) I tried tapping it down to no avail. Does anyone have any ideas why this happened or what to do now? Thank you.
Click to expand...


#26

Z

Zedo

kkjfjns2014 said:
Hello all, I went out to try and start my 2009 craftsman yts4500 and it turned over 3 times and just suddenly stopped. Now when you try to turn it over it just makes one click and doesn't do anything. Battery is good and charged.

The battery side of the solenoid has 12.6 volts but when you turn the key the starter side only gets 6.4 volts. I took the cover off and noticed the starter bendix was stuck to the flywheel. (Pic attached) I tried tapping it down to no avail. Does anyone have any ideas why this happened or what to do now? Thank you.
Click to expand...
Bad starter or not seems like the Bendix is bottoming out, the Bendix shouldn't go that high up on the flywheel. . I would take the starter off place it in a vise or have someone hold it down firmly , it will try to jump on you. Apply 12 volt and see what the starter does.


#27

G

Gord Baker

It is worth taking apart and carefully see if one brush is stuck in its' holder and not contacting armature.
Have a firm grip on the starter when you are testing it!


#28

C

Cajun power

just a suggestion. check your battery again. there is a non zero possibility that the key START switch is borked or even the starter solenoid, and thus full energy is being applied to flywheel starter, thus it remains extended. This would be very rare that this happens, but I would still check to make sure those two devices are not borked and caused the problem to begin with. Of the few times I've seen or read a flywheel starter solenoid to pop out and remain out, is usually related to some other root cause. But then it could just be a flywheel starter that slammed against the flywheel and hit a tooth instead of a groove and has caused the gear bearing or shaft to bend hard...which isn't common,
as others have commented, the cheap flywheel starters are not cheap but are better quality. If cost is a concern, it would a good idea to run through the entire system before installing another one that might fail due to an unknown root cause.

note: I have had pretty good results with cheap flywheel starters. I am not going to say they are as good as the OEM and third party equivalents, but in a pinch and tight budget (or a customer on a budget and knows I cannot warranty the part replacement), I've gone that route. For my own personal commercial equipment ...always top quality Flywheel starters..And that can be serviced...such as the motor...or the brushes as others have commented.

just throwing out some ideas to help.


#29

R

rbrading

Same issue I find in 2024. I expected starter, so I bought a new one, through BadBoy dealer for a Kohler engine. Same thing happened. Put old one back on, same thing again. Note, tapping with hammer did not fix. Took spark plugs out, turned fly wheel, bendex slides back in place off fly wheel. Put plugs back in. Everything works fine now. I bought this 2015 mower a little over a year ago.


#30

G

Gord Baker

A little sticky grease on the bendix shaft will help.


#31

R

Rivets

Please do not use sticky grease on a bendix shaft, it will draw dirt and cause problems. If you want to lube the shaft use powdered graphite only.


#32

R

rbrading

Rivets said:
Please do not use sticky grease on a bendix shaft, it will draw dirt and cause problems. If you want to lube the shaft use powdered graphite only.
Click to expand...
Other forum with same problem. One comment said adjusting valves can clear up due to not dumping compression. If problem happens again I may try that, with some help. Only happened once but I spen $295 on a starter I didn't need.


#33

F

Forest#2

OPoster evaporated?


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