North&Wing&S,LSA&Maintenance&Manual&
Model:&Sport&X2&582&
Issue 3.2
Printed: July 16 2017
Page 96
Two different starters are used depending upon whether a clutch is used in the drive system or
not. The standard Rotax configuration is “without” a drive clutch. In this case the starter is
integral to the Rotax E-box drive system. For engines with a clutch installed, a GPL
aftermarket starter in installed on the electrical end of the engine adjacent to the manual pull
started instead of at the PTO end of the engine.
Before replacing the starter, confirm that the starter is the problem by eliminating the Master
switch, the battery, the starter solenoid, and the wiring as the source of the problem. This is
most easily done by using a loop-type amp meter around the heavy (#6) red wire between the
Hot Box and the starter terminal.
1.
!
With the amp meter loop in position around the heavy red wire, turn the Master switch
to the “Start” position and note the amp reading.
2.
!
As the Master switch is turned to the Start position, a click from the starter solenoid
inside the Hot Box and/or the starter itself should be audible. If at the same time, the
amp meter indicates at least 12 amps and the starter itself does NOT turn, then the
starter is faulty or jammed and must be removed.
3.
!
Note! if the starter turns, but the engine does not turn, the starter ring gear or the starter
drive gear has most likely been stripped and must be replaced. In this case, the amp
meter will read a low value since there is no electrical load on the starter. Skip to the
replacement procedure outlined below to replace the gear ring or drive gear.
4.
!
If the amp meter indicates near zero, then it is necessary to determine if the problem is
in the current supply circuit or in the starter. This is easily done by measuring the
voltage applied to the starter terminal when the Master switch is turned to the start
position.
5.
!
Repeat Step 2 above only this time measuring voltage at the starter terminal. If the
voltage is near zero, then the problem is between the battery and the starter. This could
be wiring breaks, the Master switch, the battery, or the starter solenoid. Further
diagnosis is best done measuring the voltage at each successive point moving upstream
from the starter toward the battery until 12 volts is finally detected when the Master
switch is turned to the Start position. At that point, the last device showing zero
voltage at the out is the faulty item, and it should be replaced.
6.
!
If the voltage is 12 volts at the starter terminal, then the problem is most likely the
starter itself, and it should be replaced.
Replacing the Rotax starter on the E-Box:
1.
!
Disconnect the ground wire from the battery and secure a safe distance from contact
with the battery.
2.
!
Disconnect the positive red wire coming out of the Hot Box from the starter terminal.
3.
!
Remove the bolts holding the starter in the E-Box housing and lift starter out of
housing.
4.
!
Inspect the ring gear by looking through the starter mounting opening.
5.
!
If problem is with the gear in the housing or the Sprag clutch internal to the gear box, it
will be necessary to have these parts replaced by a Rotax repair center.
6.
!
If only the drive gear on the starter is stripped, it can be replaced with a new gear
ordered from any Rotax parts supply dealer.
7.
!
If the problem is the starter itself, install new starter in reverse order.
