Rotax will not turn over after connecting switches wrong

Chris Bany

I'm putting together my first Rotax -- used Rotax engine package on GP chassis.

And at a risk of revealing to everyone that I'm an idiot..here's the scenario.
After putting together package, charging battery with trickle charger -- I, with the on/off switch in the up position, connected the battery terminals and the starter instantly engaged - I believe it instantly engaged because I wrongly had the larger wires connected to the on/off switch (instead of push button).

I then, like an idiot, tried one large wire, and one small wire on the on/off switch. And one large wire, and one small wire on the push button. The starter again turned over briefly while I had terminals connected to battery.

I then went inside to read the Rotax User Manual a littler closer and connected wires correctly: larger wires to push button, and smaller wires to on/off switch, connected terminals to battery, with on/off switch in up position; I pushed the starter button and nothing - not a sound.

Could I have fried or shorted one of the electrical components? I feel it's more likely this would have occured when I had the one small wire, and one larger wire connected to each of the switches.

Any suggestions or diagnosis ideas would be greatly appreciated.

Chris

Ryan Leger · Joined: 19 Jul 2012 Posts: 133

its fried did the same thing a few years ago but run a volt meter across th elines and see where power is going to and where its not

Chris Bany · Posted: Tue Sep 04, 2012 6:47 am Post subject:

Ryan Leger · Joined: 19 Jul 2012 Posts: 133

my starter went when i did that i ran a volt meter to everything and power was going every where except the starter motor

Chris Bany · Posted: Tue Sep 04, 2012 7:39 am Post subject:

Ryan Leger · Joined: 19 Jul 2012 Posts: 133

i just replaced it there not that much and to be sure that everything was good just felt safer doing it that way

Chris Bany · Posted: Tue Sep 04, 2012 5:11 pm Post subject:

anyone else concur or have other thoughts?

Thanks,
Chris Bany

John Savage · Posted: Tue Sep 04, 2012 8:11 pm Post subject:

My vote is for the starter motor
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Chris McGinley · Posted: Tue Sep 04, 2012 8:17 pm Post subject:

Seems odd that this mis-wiring would damage the starter. I'd be more inclined to think the switches or battery are damaged.

I'd troubleshoot it a bit more - try bypassing the pushbutton switch with a jumper wire that you can quickly disconnect once you prove the starter engages. That will rule out that switch.

If that doesn't work, use a volt meter to see if you're getting power at the plug where the starter connects (when the pushbutton is engaged). If you are getting power, and the starter still does not crank, then the problem is the starter.

The on/off switch is not related to the starter cranking, so try to focus on just getting power to the starter first.

-Chris
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Chris McGinley
Monster Raceworks
Rotax Masters
"Always stay one step ahead of the storm" - JZS
http://www.njkarting.org
http://www.btbsecurity.com

Chris Bany · Posted: Fri Sep 07, 2012 5:39 pm Post subject:

Turned out it was a bad ground. I had ground wires attached to Prospeed Coil relocation mount. And also found rusty colored crud on the starter gears when taking starer out. Could this be from previous owner driving in rain?

Thanks for the help. Hopefully now I can make the OGP race on 22nd.

Joe Ricard · Posted: Tue Sep 11, 2012 3:55 am Post subject:

Is there an electrical diagram of the wiring?

My Rotax did this trick yesterday at the track. Cranked up and made about 10 laps. came in checked things out made some changes. Cranked up and went back out and then it started flaking out. I pulled over and checked battery connections which were good.

Then cranked and it kept dying and sputtering. came back in changed batteries. cranked and then on track sputtered. then no start no crank of starter. had to push back to truck and it never started again. Took it up to the kart shop put new battery on it and still nothing. Packed up and went home. Sad

If I knew where I should have power and what enables power through what I could troubleshoot. Now I will swap part with my son's mini max till it starts working. Which is NOT the right way to fix things.
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Arrow AX-8/ Rotax Sr.

andy graham · Posted: Tue Sep 11, 2012 6:43 am Post subject:

possibly the coil/cdi?

Joe Ricard · Posted: Tue Sep 11, 2012 7:46 am Post subject:

See that makes no sense to me. how is coil CDI related to getting the starter to roll over?

Do I need to forget EVERYTHING I know of how cars work?

Guess that validates my question. If current needs to flow through everything to complete a circuit fine. I've worked on the military's most sophisicated toys. But I had wiring diagrams to follow.
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Arrow AX-8/ Rotax Sr.

Chris McGinley · Posted: Tue Sep 11, 2012 7:53 am Post subject:

I think the coil/cdi recommendation for a starter that won't turn over isn't accurate at all.

For a non-crank situation, check:
1. do you have power at the push-button
if no, check battery and/or wiring harness for damage
if yes, continue
2. do you have power at the starter connector when you push that button
if no, button is bad
if yes, continue
3. is connector clean ... clean it and try again no matter
if still not working, continue
4. check starter ... brushes tend to go bad in these things

That's the troubleshooting I would do for a non-crank issue...
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Chris McGinley
Monster Raceworks
Rotax Masters
"Always stay one step ahead of the storm" - JZS
http://www.njkarting.org
http://www.btbsecurity.com

Joe Ricard · Posted: Tue Sep 11, 2012 8:52 am Post subject:

Now that is someone who has done some troubleshooting before. Thanks.
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Arrow AX-8/ Rotax Sr.