[RW442]

Cleaned battery and starter solenoid connections charged battery starter turns but bendix shaft won’t engage flywheel to start any help on what I need to replace would be greatly appreciated I have search zl forum and not sure on correct parts to buy to repair also cleaned both pinion gears on shaft disassembled starter checked brushes all looks good.

 

[660catman]

So the starter works but pinion is not engaging on starter ring gear? Is it turning the starter motor shaft?

 

[RW442]

starter pinion gear turns but shaft is not starter pinion gear is turning the first gear on shaft but pinion gear at flywheel is not turning I see that on the the end of the shaft at flywheel there is a spiral cut on shaft which I think is supposed to send pinion out towards flywheel not sure if at the other end of shaft something is broken outer aluminum sleeve for shaft turns free but the shaft itself doesn’t turn. Looking at parts diagram didn’t help much as I don’t see a roll pin on shaft. It looks like there is a Allen screw next to starter mounting bolt not sure if that holds shaft or a bushing for shaft. Thanks in advance for the help.

 

[660catman]

There’s a secondary gear #12 probably hidden behind the bracket. This goes on the shaft so splines on that gear or shaft itself may be stripped. Shaft has to turn when starter is turning

OEM Parts Lookup

Country Cat. Everything Arctic Cat! Large inventory of Arctic Cat and E-Z-GO parts, clothing and accessories in stock. The world's largest Arctic Cat dealer. Snowmobiles, ATV’s, Prowlers, Wildcats and E-Z-GO Golf Carts in stock ready to ride today. We also feature a large selection of Klim, 509...

www.countrycat.com

 

[RW442]

Thanks I will pull it apart and check i will let you how I make out

 

[ejowrench]

Thanks I will pull it apart and check i will let you how I make out

Does the gear go out to mesh with flywheel [on clutch] and the shaft spins, but not the flywheel and pinion gear? Kinda hard to explain, but my Pantera pinion gear [that meshes with flywheel] is a two piece affair with a rubber spacer that separates the two. I think Arctic Cat does this to soften the engagement or to reduce noise, or both. . Anyway, the rubber breaks/ shears apart and now you have a pinion gear that stays put against the flywheel in the engaged mode, and the shaft spins, but engine won't turn over.
I think you have to buy the whole shaft to get gear, either mine was discontinued, or way to much money. If memory serves me correct, I drilled two or three holes and put sheet metal screws into rubber, making this two piece affair 'one'. This may sound crude [because it is!], but it still works [this was like 3 seasons ago].

 

[ejowrench]

Does the gear go out to mesh with flywheel [on clutch] and the shaft spins, but not the flywheel and pinion gear? Kinda hard to explain, but my Pantera pinion gear [that meshes with flywheel] is a two piece affair with a rubber spacer that separates the two. I think Arctic Cat does this to soften the engagement or to reduce noise, or both. . Anyway, the rubber breaks/ shears apart and now you have a pinion gear that stays put against the flywheel in the engaged mode, and the shaft spins, but engine won't turn over.
I think you have to buy the whole shaft to get gear, either mine was discontinued, or way to much money. If memory serves me correct, I drilled two or three holes and put sheet metal screws into rubber, making this two piece affair 'one'. This may sound crude [because it is!], but it still works [this was like 3 seasons ago].

The pinion gear and Inner splines on this gear are bonded to a rubber spacer. The rubber spacer shears apart and now the inner spline of gear spins on the gear. The screws I used 'bond' these parts back together again. Hard to explain, but if you remove the clutch, then remove the gear from shaft [I think a circlip holds the gear on shaft], you will see this and it will be easier to understand what I am talking about. Again, this is on my Pantera, but I think you have the same set-up.

 

[ejowrench]

The pinion gear and Inner splines on this gear are bonded to a rubber spacer. The rubber spacer shears apart and now the inner spline of gear spins on the gear. The screws I used 'bond' these parts back together again. Hard to explain, but if you remove the clutch, then remove the gear from shaft [I think a circlip holds the gear on shaft], you will see this and it will be easier to understand what I am talking about. Again, this is on my Pantera, but I think you have the same set-up.

Yup, on my Pantera, you have to buy whole shaft, $250 if it was still available [it is not]. However, the listing 660catman gave you shows an updated pinion #32 part # 0637-265 for your sled. [Gee, I wonder if it will interchange with my Pantera?

Or, maybe you have a different set-up on your sled then mine, and everything I said above is worthless. Oh well, I try! lol.

 

[RW442]

Setup is the same as the Pantera with rubber piece on the end by the flywheel so it won’t engage flywheel at all when starter was removed I can turn gear that it engages on shaft but shaft will not turn to engage flywheel that’s why I thought there was something broken at the starter end of the shaft if I pull on rubber piece and pull that gear will engage flywheel so the rubber is what puts tension on the shaft to engage flywheelallowing that gear to engage flywheel I can see the spiral cut on shaft .

 

[ejowrench]

Setup is the same as the Pantera with rubber piece on the end by the flywheel so it won’t engage flywheel at all when starter was removed I can turn gear that it engages on shaft but shaft will not turn to engage flywheel that’s why I thought there was something broken at the starter end of the shaft if I pull on rubber piece and pull that gear will engage flywheel so the rubber is what puts tension on the shaft to engage flywheelallowing that gear to engage flywheel I can see the spiral cut on shaft .

Follow 660cat mans advise.

 

[RW442]

Don’t have a clutch removal tool will have to try to remove shaft assembly without pulling clutch not sure it can be done though

 

[gotsno]

Here's a diagram if it helps.

 

[ejowrench]

Don’t have a clutch removal tool will have to try to remove shaft assembly without pulling clutch not sure it can be done though

So diagram #18 above [shaft] is not moving when starter spins?

 

[RW442]

That is correct haven’t tried to remove it yet will let you. All know once I get it out and apart Catman said it coulee be stripped or shaft is broken have been trying to find new shaft or even good used one but no luck so far would like to have parts ready before disassembly even if I had to replace everything at least it will be repaired sled has very low mileage around 1500 miles.