2000 zl 550 electric start quit working

4563 Views 14 Replies 4 Participants Last post by RW442, 2 mo ago

RW442

Discussion Starter · 3 mo ago

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.

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ejowrench

· #6 · 3 mo ago

RW442 said:
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].

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ejowrench

· #7 · 3 mo ago

ejowrench said:
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.

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ejowrench

· #8 · 3 mo ago

ejowrench said:
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.

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ejowrench

· #10 · 3 mo ago

RW442 said:
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.

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ejowrench

· #13 · 3 mo ago

RW442 said:
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?

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