DD2 Starting Issues

Christopher Nieves · Posted: Thu Feb 28, 2013 11:30 am Post subject: DD2 Starting Issues

Hey all,

Currently I am having issues with my DD2 engine. It just got rebuilt to rotax spec and i just hooked everything up after getting all the parts I finally hooked it up and put the gas into it yesterday and everything. I started it up yesterday and it worked perfectly for a couple of minutes. I brought it outside (had to turn vertical threw the door which caused fuel to leak out of somewhere) and started it out outside. It worked for a few minutes so I sat in it and put it in first. After a few seconds (which sounded like I did not give it enough gas) it cut out. I started it up again and it had a lot of issues then just shut up. So I started it again and now it wont even start chugging.

By Chugging I mean no starting sound at all. I flip it to the off switch, put it in the middle, and it beeps, and try to click it to the other side and it does absolutely nothing. I just checked all the grounds and wiring and they seem to be functional (I don't have a volt meter to truly verify so it was from a purely eye based position). I asked the guy I got it from and he said I may have cold seized it, but the started is cold when I try and switch it on. BTW the battery is full.

Update: I used a multimeter to check the battery (12.95 V) and checked the starter wire which was also getting high voltage. So the starter is getting voltage, but not actually moving?
Any ideas?

Thanks,
Chris Nieves

Joe Ricard · Posted: Thu Feb 28, 2013 12:23 pm Post subject:

Pull the sprark plug and put your thumb over the hole. hit the starter and you will feel a bunch of compression blowing your thumb off the hole. If not then yea you cold siezed it and time for new upper.

If you have a compression tester it should be 150 PSI or higher.
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Christopher Nieves · Posted: Thu Feb 28, 2013 1:13 pm Post subject:

It's not starting at all, like theres no electricity going even to the starter it seems. There is electricity to the rotax gauge though. It it really a cold seize?

Brian Degulis · Posted: Thu Feb 28, 2013 6:11 pm Post subject:

Proubably not it's more likely to be a starter/wiring issue. Since you've got not exposed clutch to turn I'd pull the starter off to get to the gear and go in with a screw driver and see if the engine turns. I bet it does and you got a simple problem.

Brian

Christopher Nieves · Posted: Thu Feb 28, 2013 6:19 pm Post subject:

You think the starter is stuck? I just started to take off the two bottom pieces of the seat so I can get to the starter and take it off tomorrow when I get home from school.

Brian Degulis · Posted: Thu Feb 28, 2013 6:36 pm Post subject:

Not necassarly stuck maybe just bad. The first thing you want to figure out is does the engine turn. If it does (I'm betting it will) then you know you have a small problem in the starter circuit. It will be easy to figure that out.

Brian

Christopher Nieves · Posted: Fri Mar 01, 2013 7:19 am Post subject:

So if the engine does turn after I pull the starter and move the gear around then the circuit for the starter is being weird right?

If the engine doesn't turn after I pull the starter then its cold seized?

I'll pull it when I am done with school today and see whats happening to it.

Thanks for the help so far everyone.

Brian Degulis · Posted: Fri Mar 01, 2013 8:11 am Post subject:

Yes pull the starter and confirm the engine is not seized. If not then look to wiring battery starter problem.

Brian

Josh Michalosky · Advertiser Joined: 01 Oct 2007 Posts: 87

One of the lead wires inside the starter may have broken the solder joint and the starter just isn't engaging. Its a common problem with the starters on the rotax/leopard.
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Christopher Nieves · Posted: Sat Mar 02, 2013 7:26 am Post subject:

Unfortunately whoever put on the starter left me with 2 stripped screws, so i'm still trying to pull the starter.

Nick Weil · Posted: Mon Mar 04, 2013 6:47 am Post subject:

Did you buy the kart used? If so, do you now who owned it prior? I own SpeedQuest here in Central Florida and we are extremely knowledgable about DD-2's. Knowing where your kart came from may shed some light as well.

I would say you probably have a bad connection in the starter motor. If that is the case a new starter is over $200, but we offer a rebuild/replacement service for around $100. If your motor was just rebuilt, who rebuilt it? They should have noticed or reported stripped starter bolts and replaced them when rebuilding it...
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2004 Team USA Rotax Worlds Finals DD-2 Driver

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Christopher Nieves · Posted: Fri Mar 08, 2013 6:11 pm Post subject:

i finally got the screws off, i have pictures of everything, but not sure whats wrong. If anyone could help I have pictures of everything. it was rebuilt by RJV Enterprises in MA. I looked up if trhe starter was replaced, but the only thing on the receipt is some kind of starter repair kit and starter support. I would love to bring it to a shop, but have no way of getting it there because I only have a coupe.[/img]

update:
I am assuming that all the gear oil was suppose to come out as well? wasn't sure. Anyway, when I pulled the starter the coils were just hanging there (I figured the coils were suppose to be in the square shape holders for them. Other than that I put that back together. Not sure where that spring was suppose to go, but I have that. The bearing in loose moving around the shaft of the starter and it rotates. I'm a college kid so I understand what I am looking at, but not how it goes back together and such. Not sure what I can do next. I put the starter back into it so that the chamber didn't get air into it btw.

jeff grose · Posted: Fri Mar 08, 2013 6:31 pm Post subject:

SERVICE CALL NICK Very Happy

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Christopher Nieves · Posted: Tue Mar 12, 2013 7:07 am Post subject:

Anyone have any idea where my next step is?

Chris Rock · Joined: 15 Aug 2002 Posts: 339

This should help with reasembly of your starter
From the Leopard owners manual (same starter on a rotax)
Start at page 36

click here >>>>>>>brush replacement

It's actually pretty easy to do once you make the two little U shaped wire pieces