I have a Honda EU3000si inverter that seems to have a starter motor issue. The motor leads receive 12v through the relay but not even an attempt to turn the generator over. The unit does start and run when the rope pull is used. The starter motor read +20K ohms which seems very high for a starter motor.
I need to find out how to remove and replace the starter motor...hopefully w/o removing the entire starter assembly as this appears to be a really big job due to the frame and recoil assembly...and there is no manual to look at to help.
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Order a new recoil spring from your suppier. It comes wound up. Remove the old part first usually four screws on the outside. Make sure the rope is fully wound then insert the new spring and reassamble. If it becomes unwound by mistake its a labourious job to rewind but can be done.
Are you sure you have the right length rope??? If you are sure the rope length is correct you may have wound the recoil spring too tight causing it to run out of travel. You want the recoil spring just tight enough to pull the rope all the way in. Wayne
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Hi, Nicholas you turn on the ignition switch press the starter button and all you get is the dreaded "CLICK" or "CLUNK" now before testing any electrical component in the Starter System it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage, the battery is faulty and must be replaced. AGM type batteries fall into this scenario more so than lead-acid batteries. Depending on battery voltage starter relays and starter solenoids can make the same noise when you hit the starter button. You can easily determine which one is at fault by the following two simple tests:
STARTER RELAY- place your thumb and index finger on the starter relay and press the starter button, if you feel the click then the relay is faulty and needs to be replaced.
STARTER SOLENOID- bridge the positive and negative poles of the solenoid with a small screwdriver if you get a loud clunk then the solenoid needs to be rebuilt or replaced as necessary. If the engine turns over then replace the starter relay otherwise the usual suspects for a faulty starter solenoid are:
1. Battery terminals have loose or corroded connections.
2. Battery cables faulty due corroded or broken internal wiring at the cable connector especially the "NEGATIVE" cable which needs to be checked at "BOTH" ends.
3. Battery voltage, must be 12.5 volts or better, voltage from the battery to the main circuit breaker to the ignition switch to the security/ignition fuse to the TSM/TSSM module to the engine stop/run switch to the starter button to the starter relay to the green wire that connects to the starter solenoid must not drop more than 1/2 volt of battery voltage.
4. Disconnect spark plug cables, with a voltmeter connected to the battery, the ignition switch in the on position, the kill switch in the run position, the starter button depressed, starter engagement should not bring voltage below 9.6 volts DC. If the voltage is below 9.6 the battery is faulty and must be replaced. I "HIGHLY" recommend a maintenance free AGM battery typically they have more amperage for cranking.
5. Faulty starter relay, check continuity.
6. Faulty starter solenoid, check contact plate and shoes for excessive electrical erosion/etching, refurbish as necessary or invert contact plate and use the virgin backside. Check contact shoes for being loose. Replace solenoid if the negative function is still a final outcome.
7. Faulty starter, bench test starter with a 12-volt battery if negative function check, decontaminate and undercut armature commutator segments as necessary, check segments with an ohmmeter probe each one and the segment next to it for shorts. Have the armature tested with a growler and field coils, and brush plate with an ohm-meter for opens, shorts or grounds. Replace brushes if less than .438" It is generally cheaper to overhaul/refurbish a starter motor than buying a new one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day. Bike won start grinding clicking sound How to diagnose and recognise starter motor problems Honda CB500T Manual https://www.partsfish.com/page/oem-parts-for-honda Honda CB500X Service Manual
not sure how similar it is but I had a supra of the same year with the same issues. It ended up being a bad connection where the chassis harness met the engine harness. I bypassed this section and the issue was resolved.
turn on ignition. Use a starter power pack or a decent 12V battery with jump leads this bypasses the starter circuit, connect the neutral lead to earth on the bike and touch the live to the starter motor live terminal, this will spin the starter motor and inturn the engine if the starter motor is in good condition. If this works you are into starter circuit see my last post!
are you referring to the starter relay on the firewall? the voltage should drop to 0 when measuring across the signal path because the connection is made, essentially making it a piece of wire and there is no difference in potential between the two points. is there 12v to the starter motor? is the starter solenoid (located on the starter) receiving 12v? check fuses and fusible links. disconnect hot leads from the starter. remove the starter, and supply 12v directly to the motor. does the pinon gear extend and spin? starter.
If there is NOT 12VDC - first check the cables - they may be frayed or damaged or improperly connected at battery or starter.
If there is 12V, and no click when trying to start - the solenoid is faulty. You can JUST replace the solenoid, but its worth your time and effort to replace the unit as a whole. (you have to remove the starter anyway).
If there is 12V, and a click when trying to start - the starter is faulty - Replace starter.
If there is 12V, and click and whine (like a motor spinning) when trying to start - starter gear has been stripped or broken off. - Replace starter.
If no 12V the starter relay is bad.
If relay is good - your problem lies in the ignition module, or key tumbler.
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