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Well, I know nothing apparently but your problem will be the bendix. That is the unit behind the black cover with two screws, just in front of the starter ring gear. Depending on what type of chain lubricant you use depends on the degree of contamination. Take off the cover and spray the bendix unit with copious amounts of brake cleaner. Put a cloth underneath as you will probably find quite a mess pouring out. Let it dry and just give it a puff of WD40 to keep off the rust. They are designed to run dry but it is worth just putting a smear of grease on the dog gear as the gear wears quite badly in general use. The new clutch is no different to the old one regarding engagement of the bendix. What happens in an ideal world is that the starter motor spins the bendix and the dog gear is thrown out into the clutch ring gear and then begins to turn over the engine. If the bendix is sticky with chain libe, it will not get the initial throw out into the ring gear and it starts to slip on the back of the plate, resulting in that horrible noise. The other fault can be a failing battery that has not got the initial power to throw the bendix into engagement and results in the same noise. Chassis mounted batteries can cause the plates to get damaged. The battery has quite enough power to run a kart all day but cannot deliver enough power to do all the processes of starting. Check the battery connector if you still use slide on connectors, as they tend to spread and can give a high resitance under load.
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Rotax starter problem by 'mattkart' (08 Sep 2010 @ 19:49)
