Alright guys, this summer on our yearly trip out to the dunes to Silver Lake on the last day there I was climbing a hill and my DS started to bog out and cut off at the top of the hill...I let it sit for a little bit to cool down and went to start it and it cranked a couple times then there was a loud metal on metal sound and the starter would just spin.

Since I couldn't start with electric start I got her running my pull starting it and it ran as if the plugs were burnt out...but I never heard of anyone having issues with the start...Anyone every have this happen to them, we have a similar thing wrong with our scrambler and you need to open the motor to get the broken gear, could this be the same thing?

Please let me know because if this is the case I am going to pull the motor out of my quad and bring it up to school to tear it down...Someone please help!!

Thank you,

Julian

 

a metal on metal sound is never good, i dunno if id try runnin it until u find the problem, u dont wanna keep tryin to start it and break more ya know, $100 fix is better than a $500 fix [img]i/expressions/face-icon-small-wink.gif[/img]

 

Yeah...It made the simialr sound a couple times before since the begining of time of owning it...just sounds like the starter catches wrong or something...just wondering if anyone had this happen to them...already ruled out its not the starter and not really looking forward to opening it up...

 

Are you running an aftermarket CDI box? If so, what kind?

Could be sprag clutch.

 

No aftermarket CDI box...All stock besides an airfilter with prefilter and a full trinity exhaust system


I have been looking through my Cd service manual and it says:

1- Check gear condition on electric starter.

2- Check condition of starter pinion gear.

Anyone know how to do either or?

 

have you pulled the starter motor to see what the gear looks like?

 

What ever became of this? i just went for a joy ride.. it got above zero! and earlier tryed starting the 01' DS and it back fired [img]i/expressions/face-icon-small-sad.gif[/img] but took off later after i charged the battery up and today there was a good clank like the starter didn't mess up.. and again it started but while warming up i heard metal on metal every once and a while and shut it off. theres aluminum shavings in the oil strainer screen.. and the starters teeth are fine i haven't opened it up yet. any ideas? ASAP its killing me thinking of 1k repairs!!