Just acquired an 86 Trailboss 250, no manual yet. The starter spins, but the bendix does not throw out. To remove the Bendix, I need to remove the flywheel right? Is the flywheel hard to remove? On the outer side of the flywheel is that collar about 1/2" thick and 1-1/2" in diameter - Is this collar attach to the flywheel or does it come off first? Thanks for the help.

 

The flywheel (as a whole) does need to come off. You will notice 3 small threaded holes near the crankshaft nut of the flywheel. These are tapped 6X1.0mm. If you have access to a automobile harmonic balancer puller and a source for long 6mm bolts (you will have to put washers on the heads to fit the balance puller) you can pop the flywheel right off. You can make your own long bolts using grade 5 or 8 1/4-20 bolts and a 6X1.0mm die to cut the threads into the shoulder of the long bolts (cut the majority of the threads off before using the die to cut threads into the shoulder)

 

OK - Out to look for a puller .... The Bendix appears to be all there .. Could it just need cleaning or do these things do bad?

 

I just replaced the bendix on our 96 trailboss, rented a steering wheel puller to pull the flywheel with from the local auto parts store.


As you tighten the puller lightly tap the flywheel with a hammer and it will pop off.

 

Got the flywheel off with ease .... The Bendix is all there, thinking about soaking it carb cleaner to remove the varnish and just clean it up. Other that cleaning it real good, is there need to ever repalce it?
About the starter - How is one suppose to get the the one screw located just behind the cluch cover - it appears I will have to remove the clutch, belt, and inside cover - just to get the to screw to remove the starter ... Is this right? Thanks..

 

Heres the latest .... Cleaned the bendix up real good and re-installed it (looks like new now). Now when I hit the starter the Bendix gear slides out to engage the flywheel but only for about a second - the gear retracts back away from the flywheel while the starter/Bendix is still spinning. Any ideas?

 

Check your starter motor, if the brushes are bad or if there is dirt inside it, it wont have enough spin to keep the bendix engaged. I had that happen to me I bought a new bendix and found out it was the starter. you can buy a rebuild kit on ebay. Also check your bendix, there is a little metal spring, almost like a rubber band around the weights. They rust and break off, but usually the bendix stays engaged when that breaks. Good luck.

 

Yep - Pulling the starter sounds like the thing to do next. Look up in the thread about my starter issues. I tried pulling it the other night but could not get to 1 screw. Can someone with a manual for this 86 Trailboss 250 look and see what needs to be removed to get the starter off. It appears that the clutch and inside clutch cover needs to come off just to get to this 1 screw. I hope not. Thanks.

 

With a little patience, you can get the hard to get to bolt out with a 10mm wrench. Getting it back in will be an ordeal also. The easiest way is to remove the clutches and cover, but again - it can be done with out removing them if you have the patience.

 

Got the starter off, the brushes look brand new and the inside is very clean. Tested the ohms on the commutators (like book reads) and all test within tolerance.
I gotta think the starter is OK. Now back to the Bendix. Again - it looks great from the outside as well. Took it apart and can see that little spring band inside is intact. The gear slides smoothly and I see no other problems, Should I spring for a new Bendix?