T-boss 410

I had it apart last week. I cleaned it up inside, and reassembled it. I checked it to ensure it was functioning properly. I can take is apart again, though. I'm not sure I understand how this starter works, but it's always engaged with the drive gear. The gear reduction unit is inside the side cover of the engine, on the right side. There's a clutch inside that will only turn one way. At first I thought that maybe something had fallen apart inside the cover when I removed the starter, but there's nothing to fall apart. The only other thing I can think of is that for some reason the starter clutch stopped working. The clutch is behind the generator, and doesn't look like it's too easy to get to. With only 14.6 hours on it, I wouldn't think the starter clutch went bad suddenly. Could it somehow be operating in reverse of the correct way it's supposed to turn?

With these, there's no bendix. it's a clutch type. it basically engages a gear that will only turn one way. I can access the gear, which is only turning one way. I can't get in there too close. Too much between me and the clutch case. From what I gather, it's a starter and magneto sort of setup.

Well, replaced the solenoid, reinstalled the starter, and it is free wheeling. I don't understand. It was good when I pulled it, but now it's like the starter clutch is bad. I tried to turn it with a screwdriver, and it only turns one way. WTF am I doing wrong (besides owning a Massimo)? I just thought I would say that before Joe does, lol!

I was going to replace the solenoid, and as far as the cable from the battery to the solenoid, i can make one myself. However, the cable from the solenoid to the starter runs through the frame in a sheath, and I don't think it's gonna budge in that sheath very easily.

If I put the battery back in the UTV, I won't have access to the solenoid. It's located right behind the battery.

Sure am. What do you want me to do?

So you don't see anything wrong with the resistance in the cables?

Sorry, I am just checking for resistance. But yes, there is a loss of about 1 volt from the solenoid to the starter. The battery is at 12.5v, and at the starter it's 11.5v.

OK, here's what I am getting on the short cable from the battery to the solenoid: 1.8 ohms. The cable from the solenoid to the starter is 1.1 ohms. What does that mean for me?

Hey, good news! Looks like you dodged a bullet.

I appreciate the help. I'll be checking it out tomorrow!

Am I correct in assuming that it is most likely a battery cable or the solenoid?

Well, you have to depress the brake pedal to start it. I assume that is the safety switch you're talking about.

Well, that switch is a real bear to get to. At this point I am hoping for a battery cable or the solenoid.

Doesn't the ignition switch just trigger the solenoid?

So what numbers do I expect when testing the resistance? The lower the better? What is unacceptable? Thanks for the help!

So there shouldn't be any loss of voltage from the battery to the solenoid, or from the solenoid to the starter?

Anyone?

OK folks, I tested the wires at the starter, and I am getting 11.5 v. So I am assuming that the solenoid is good? Disassembled the starter, and cleaned and inspected the brushes. They look good to me. I sprayed the whole thing with electric cleaner, put a bit of oil on the shaft at both ends, and reassembled it. Tested it to be sure it was functional, and that's where I stand now. Any ideas? This has me a lot confused. Thanks

Could it be the drive belt?

Thanks, I appreciate it.

Did you ever get a copy of the T-boss 410 manual? Also, what would be the difference between the Buck 400 and the T-boss 410? Thanks

Checked it thoroughly. No stickers or stamping to identify the manufacturer. Only numbers are 201811, on the rear of the housing. I googled it, but came up with nothing.

That sounds good. Sparks ain't my friend! I will disassemble the starter tomorrow and see if I can find anything out of the ordinary. I have a set of wires with alligator clips. I'll use those. I really appreciate all your help, folks.

Well, I can't sit in the seat. Had to remove the seat to access the starter. I figured if I kept everything insulated I would keep the sparks to a minimum. I don't have a service manual. Didn't want to pay $75.00, especially after seeing some posts from others who have purchased it and advised it wasn't worth the cost. The leads that I have with my multimeter are not heavy wire. They won't burn through, will they?