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  1. #1

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    Nov 2013
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    Kawasaki JS440 Starting/Starter Motor Issues

    Hi guys,

    I'm having some issues with my starter motor.

    Originally the starter was completely dead, no sign of even trying to turn over.
    So naturally I took it out and disassembled it, which revealed a lot of rust and stuff in there, was basically all clogged up in there.
    After fully cleaning it up and rebuilding, I was happy to find that it worked great and then even happier when I started the jet ski a few times!

    Some time passed and just recently I pulled the jetski out to start it up. But now, with a fully charged car battery it can barely turn the engine over with the spark plugs in.
    To add to that it would randomly stop turning over and just make a clicking sound as shown in the video below (Note: video is with spark plugs out).


    I took the starter motor out again and by hooking it up to a battery on the bench it seems to spin very well, as you can see in the video below.


    Now, the things I've tried to fix this include:
    - Cleaned up all ground/connections
    - Starter motor positive cable insulation was cut open and wires were rusty, so I re-made it with a new cable
    - Checked there is nothing seizing, eg. driveshaft, but all turns freely by hand
    - Dodgy positive battery terminal changed out with a proper new one
    - Electronic box ground cable was almost cut through, so I re-made it with a new cable

    Could anyone please help me figure our why my starter motor wont turn engine over properly and why it randomly stops turning over?

    Thanks,
    Damian


  2. #2
    CJ's gpr's Avatar
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    Maybe time for a new starter. They're like 50 bucks on ebay. Even if you get it to start again I wouldnt take the chance

  3. #3
    steve45's Avatar
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    Did you clean the copper bars on the commutator? Do the brushes move freely in their guides? Sounds like you may have a bad winding on the armature, or at least a dirty brush contact.

  4. #4

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    Quote Originally Posted by steve45 View Post
    Did you clean the copper bars on the commutator? Do the brushes move freely in their guides? Sounds like you may have a bad winding on the armature, or at least a dirty brush contact.
    Thanks for your input Steve.
    Yes, I lightly sanded copper bars on commutator and the brushes did move freely in their guides when I checked.

    Anyone else have any ideas before I go buy a new starter motor?
    Bit worried that it's not the starter motor, don't want to spend all that money to find that it's something else.

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