[doug80638]

X2

[John H]

You know...in all my years the only time I ever found warn starter drive gears is when one had not been disengaging and had not spun itself into parts because of the running over about 2500 RPMs. They just are not used enough to wear...break teeth because of kick-back, yes, but not warn. They only stay engaged for two reasons normally. One- the oneway won't release for some reason..but it most be here because it hasn't destroyed the starter and drive gears.. and two-the solenoid stays engaged (which would be a high draw on the system)...and that can happen because of a couple of reasons- one..and it happens more often then any other, the amp load across the contacts exceeds it's limits, heats, starts arcing and partly welds the contacts.. or two- the coil stay energized because of a bad key switch or a harness problem. I would say that if they are changing the starter and drive gears out, then I would also want the solenoid and key switch at least tested if not also replaced.  Just thinking out loud here.

I'm in a holding pattern for 2 reasons, parts and tech availability.  It's on their schedule for August 15th.  thats assuming parts have arrived.  If they get a cancellation and a large enough block of time they will work on it sooner.  It's funny, I brought it there because they could diagnose in 24-48 hrs.  wish I had know actual work was so far out. I told the service manager to let me know if they want the machine for their used inventory. 

[John H]

Finally fixed and back in my hands.  I was able to put quite a few miles on this past weekend.  The dealer changed out the starter, the double gear and the single reduction gear a wire they thought was possibly burned and tapped and re-seatted the frame grounds. it's charging and working well.  thanks for al the help and suggestions.  I just wanted to circle back with the resolution in case others have any similar issues.  I do know I check the frame grounds and all were tight and under 1 bolt.  they moved that over about 1" and added a new location.  I'm not sure why and was not able to talk to a tech, it was just in the service notes. I added a ground wire from the battery negative to the voltage regulator mounting bolt in the beginning of this process and it did not help anything so it's odd to me that they needed to move grounds but the money is spent and the buggy is working. 

Thanks all
John

[NMKawierider]

Well..at least they got it. Thanks for letting us know the outcome.