Hey guys I need help. My 2nd DS650 (2005) has been giving me some difficulties. A little while the starter was making some grinding noises. I pulled the starter and noted that the teeth were worn pretty bad. The gear that the starter connects with was missing a few teeth (see pics). I purchased a new gear and a used starter off Ebay. I put it together this afternoon. Turned it over before trying to start it (run switch off). It sounds like a chainsaw, very loud and grinding. Didn't turn it over long because I didn't want to damage the new $150.00 gear i just installed.

Any Ideas

 

I would check to see if the starter is spinning the correct way.

 

Is that possible for it to turn the wrong way? The old starter i took out made noise as well, the same as the used one I bought and installed.

 

If someone took the starter apart and rotated it 180 deg. and put it back together it will spin the other direction spinning your motor the wrong direction will make it sound funny. If it is making the same sound as your other one it probably isn't the problem

 

Check for metal parts in oil! Starter on turns one direction unless you rev. polarity.!call 503-320-9688 Gary

 

Gary will give you a call when I get home. I am in camp for another week.

 

Guys I am still fighting the same problem. Took it all apart again today and everything seems to be in the right place (washers and spacers). But it still grinds like a blender. The starter teeth seem to mesh nice and I checked the end play in the starter where it going into the case as Eric suggested and it seemed tight. Also tried the starter with out the gears and it's whisper quite. This one is really stumping me. I have attached a couple of pics to show that everything looks right. I also have a video so you can here the noise. This is with 1 spark plug out as well.

Here a link to the Video I uploaded on youtube.


I am starting to think it might be a Spraug Clutch issue, but am still in need of help before i order $400.00 worth of parts.

 

It was the Spraug Clutch. When I pulled it apart it was stuck, wouldn't turn at all. Bought a new one (aftermarket) off ebay and installed it today only to find out I didnt mark the flywheel when I pulled it off. I am thinking it makes a differance where the trigger is compared to the key on the crank.
The manual doesn't really help on this point, anybody have a fly wheel and spraug clutch off sitting on the bench that could snap a picture ?

 

Finally after a year and a half I got it running. To anyone else out there replacing a spraug clutch make sure you make it with a sharpie before you unbolt the center hub from the outside ring. I didn't and it took me some time to figure out how it bolted back together. I have attached a pic for some reference for anybody else doing the same job.

 

I'm getting ready to do one, thanks for the tip.