96 Sportster - One Tick on Starter

[david4598]

I have a 96 Sportster with a single 717 engine. I'm trying to get it ready for the season and cleaned the carbs and replaced the battery. When I go to start, I get one loud tick (not a tick, tick, tick). I searched the forum for similar issues, but couldn't find any help. Attached should be a video link showing what's happening. I would appreciate any suggestions.

http://youtu.be/IRM8hcc_9nk

 

[david4598]

Jumping the Starter Solenoid replicated the one loud tick. I held the screwdriver there for a second and produced a small flame, but still only one click.

 

[Coastiejoe]

One loud clunk is normally the bendix hitting the flywheel.

Pull the plugs and turn the engine over by hand to make sure it is not seized. Could be full if oil due to a bad crank seal. Then try it again via the starter with the plugs out.

 

[david4598]

Thanks for the suggestion. I pulled the plugs and they're not wet, but show signs of corrosion. I put penetration oil into each cylinder

I referred to the shop manual to spin the PTO by hand, but I'm not sure I'm doing this correctly. What I think is the PTO won't turn by hand and its difficult to get a Pipe wrench on it without damaging the zerg fitting. I can turn a stainless coupling on the driveshaft. Should I continue to try and free the PTO with a pipe wrench as shown in the attached?

 

[LouDoo]

If you pulled the spark plug and you can't turn the motor over by hand, you either have a seized motor or a seized pump. The next step would be to pull the pump to see which is seized. Corrosion on the spark plugs usually means water in the engine, I'm suspecting the worse but hoping for the best.

Lou

 

[david4598]

I pulled the pump and the impeller spins but the PTO still will not turn. This means my engine is seized?

Further searching on the forum has led me to spray PB Blaster into each cylinder. I plan to let this soak, try to turn PTO, and spray again over the next 1-2 days. Is this the best course of action?

 

[LouDoo]

I guess at this point, it can't hurt. There's one other thing to check, make sure the starter bendix is not jammed at the flywheel.

Lou

 

[Coastiejoe]

If you can't turn it over by hand then pull the starter and then see if you can turn it over by hand.

 

[david4598]

Ok, I'll pull the starter next. Just to confirm, I need to pull the big purple exhaust header to get the starter out, correct?

 

[LouDoo]

I can't say for sure on a boat, because I've never done one, but you don't need to remove the tuned pipe on a ski to remove the starter. You will need a long extension and a long wobble extension works even better.

Lou

 

[IDoSeaDoo]

replace the 717 with a 4tec :thumbsup:

 

[david4598]

The tuned pipe and the starter are now off the boat. I think the 717 requires pulling off the tuned pipe to reach the starter and the 787 requires pulling the air intake box to reach the starter.

The bad news is that the PTO still does not turn after an overnight in PB Plaster and with the starter off...

I'm also realizing that I should have posted this in the boat section all along. Can this be moved, or should I start a new thread there?

 

[Coastiejoe]

We can move it if you want. But sounds like you have your answer. Looks like the engine is coming out. If you want it moved let us know. It start a new post about how to pull the engine and what not,,,

 

[A B Able Truck]

Last hope - wishful thinking;
Loosen the hose clamps (if applicable) on the driveshaft carrier rubber to verify the driveshaft bearing isn't your problem.
** If driveshaft wasn't pulled with the pump **

 

[Bonmotwang]

Something I just did: I was not able to turn the PTO by hand because it is hard to get myself in the boat and put enough force on the smooth flywheel.
I got a strap tool from my buddy. Wrapped it around the flywheel, just with a small push, the PTO started moving. After that I can move the PTO by hand easily.
Not sure if this is your case, but make sure you got enough torque to try.


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[IDoSeaDoo]

Last hope - wishful thinking;
Loosen the hose clamps (if applicable) on the driveshaft carrier rubber to verify the driveshaft bearing isn't your problem.
** If driveshaft wasn't pulled with the pump **

Driveshaft bearing? The 2 strokes don't have one, unlike the 4tec's. The driveshaft just plugs into the solid PTO flywheel and the impeller. Closest bearings on either end are inside the pump and around the crankshaft.

If you have to get a strap around the PTO to turn it, it's not a good sign. I suggest pulling the head off to inspect the condition of the cylinders. If you've got a bunch of rust in there and don't decide to rebuild, don't leave dock without a backup trolling motor and large enough battery to get you home. The head pulls off easily, just 12 bolts and you're free. There are no gaskets to tear or replace, so it's not a big deal at all.

 

[A B Able Truck]

Driveshaft bearing? The 2 strokes don't have one, unlike the 4tec's. The driveshaft just plugs into the solid PTO flywheel and the impeller. Closest bearings on either end are inside the pump and around the crankshaft.

If you have to get a strap around the PTO to turn it, it's not a good sign. I suggest pulling the head off to inspect the condition of the cylinders. If you've got a bunch of rust in there and don't decide to rebuild, don't leave dock without a backup trolling motor and large enough battery to get you home. The head pulls off easily, just 12 bolts and you're free. There are no gaskets to tear or replace, so it's not a big deal at all.

So it has a carbon ring instead of a carrier bearing?? Do they seize to the shafts?? I'm on a learning curve - thinking about buying a Yamaha jet boat that needs work.

 

[Coastiejoe]

So it has a carbon ring instead of a carrier bearing?? Do they seize to the shafts?? I'm on a learning curve - thinking about buying a Yamaha jet boat that needs work.

Carbon rings don't really touch the shaft. They pretty much float on/around the shaft. The rubber bellows that is pressed against the carbon seal is what actually does the work.

 

[DeejaysGTI]

I got the scare of a lifetime when winterizing my 96 gtx. I hit the starter button too quick after letting go and the bendix got stuck on the flywheel. I was certain it somehow seized. Loosened the starter a little. Wiggled it. Tightened back up. Starter turned no problem. Pto should move easy peasy with no plugs installed.

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[IDoSeaDoo]

I've had my '92 GTS with the 587 (smaller cousin of the 720) turn into a 500lb canoe when the starter stuck. The pto was indeed seized like a rock. I had to only loosen the mounting bolts enough to pry it back a little. Didn't even have to remove it, just give it a little space to retract. If I were you, I'd remove it though, inspect it and grease up the bendix, gear and flywheel if you can get to it.