Hey guys, my dad's ol 03 Rubicon 500 will not start with the electric start, It's not the battery, because that battery is only 3 or 4 months old, and has been on a battery tender since it was new, on occasion it will start with the electric when it is good and warm, but lately it has been starting less and less often, it acts like the starter isn't spinning fast enough, or it isn't getting spark, but I think it has to be getting good spark, because it fires up with the pull rope, without even pulling the cord all the way out, could it be the brushes in the starter motor getting a little corroded?

Any ideas and opinions are welcome
Thanks again

 

have you tried using another similar battery??

 

If the starter doesn't sound fast enough it is probably the brushes & the commutator bars getting dirty ..

 

I haven't tried a new battery, but I have tried it directly off the battery tender, and I checked the battery had 12.9 volts and still wouldn't go,

Honda Mech, would the brushes and bars be cleanable, or would I better off with a rebuild kit, or would I have to get a whole new starter

Thanks again

 

Ok I got it tore apart, and the brushes are 12mm, and the book says the service limit is 9mm, and the new brushed are 12.5mm, so the brushes are fine, what should I use to clean the bars and stuff?

 

Ok, I cleaned the starter all out, and it still did the same thing, I did some checking, and I have good voltage at the starter, but I have no spark with the electric start, but I have a good healthy spark with the pull rope, what should I be looking into next?? the pulse generator coil, ignition coil?

thanks again for your help

 

i know on my 01' rubicon its very tough to start when in gear with the front brake pulled in, if i click it to netural it fires right up. so maybe there is some sort of switch that's sticking where it "thinks" its in gear? I would not expect major componit failures and would lean toward the switch on the front brake or gear possition ****.

 

well, I thought about that, but it starts just fine with the pole rope

 

Bump, any ideas Honda Mech. I won't be on till sunday, we are goin riding

 

I rebuilt the starter on my 300 with brushes out of a junk starter I found in a junkyard... Just clean all parts with carb cleaner and you should be good to go =)