I have a '22 Uforce 1000 with a brand new engine and starter. Everything worked just fine for the first few cranks. Now it just spins without engaging the engine. Buggy hasn't left the garage since getting it back with new engine. I'm having a hard time thinking the starter is bad already, but I've already checked all connections and voltage. Everything seems to be working properly. Has anybody had this issue before?

[2015 Z Force 800 53/Trail EPS]

In most cases where the starter spins but the engine doesn't its because the oneway spragg has failed or...the rotor it locks to is spinning on the crank shaft because it wasn't torqued properly. Broken teeth are also known to happen and do the same thing. Time to open it up and take a look.

By opening it up, you are referring to pulling the cover to see all the gears(Drive, middle and double)? That was going to be my next step before just buying another starter. Thanks for the reply.

I pulled the starter and checked it on a battery. The starter works fine hooked up to the battery. Looked in what I could hole the starter goes in at the dual gear it meshes with. What I could see of it, the teeth look good in that small sample size. Reached in to see if I could turn the gear. I could easily turn the gear with just my finger. I shouldn't be able to turn that gear with my finger. I've contacted Nflow, as this is where I bought this new engine that has 4 miles on it!

I'm finally putting this buggy back together after several delays. The issue ended up being the one-way bearing was bad. When I pulled the magneto, the one bolt holding that assembly to the crank rod was just finger tight. The service manual says it should be torqued to 70 N-m. Now that I'm putting it back together, once I torque it up correctly. I can no longer turn the gear on the one-way bearing in the free direction by hand. Since this wasn't torqued correctly to begin with, I don't know if this is correct or not. Should I be able to turn the gear on one-way bearing by hand in the free spin direction (Clockwise when looking at it) once torqued?

[2015 Z Force 800 53/Trail EPS]

Yes, obviously. if it doesn't free-spin it will rotate the starter motor while running. There may be a problem with the rotor's hub as in it may be cracked or stretched and is going on too far...or something missing. If you..and anyone in it's past.. used anything other then the correct puller for removing that rotor it is likely now warped and will need replaced. 

I figured that much, as it didn't make sense for it not to. I was able to pop that hub off with just pulling with my hands. The question I have now is on the tightening sleeve for the magneto. The service manual and attached parts diagram show it to be one piece. When I took mine apart, there was a washer with the sleeve. Looking at the diagram, the sleeve seems to have a flange on one side. The sleeve on my engine doesn't have that flange. Since the parts diagram and service manual doesn't mention a washer. Should it be on there or was this just a Chinese way of using what they have on hand?

[2015 Z Force 800 53/Trail EPS]

Should never have been able to pull it off by hand so that says something is wrong. As for parts, I have not seen anything but what's shown in the parts diagram. Yours being different says someone's been in there before.

Yeah, I just had this new motor installed from NFlow by a local shop. The magneto, stator and override clutch came off my old engine to complete the NFlow engine. The bolt like I said was just finger tight, so I believe the magneto was able to loosen up on crank shaft. I think my best option is to order the correct sleeve and see if that is the issue. What they put on there could be pushing the magneto hub too far onto the crank shaft. Which is causing the gear to jam up and not able to turn.

[2015 Z Force 800 53/Trail EPS]

Yeah, I just had this new motor installed from NFlow by a local shop. The magneto, stator and override clutch came off my old engine to complete the NFlow engine. The bolt like I said was just finger tight, so I believe the magneto was able to loosen up on crank shaft. I think my best option is to order the correct sleeve and see if that is the issue. What they put on there could be pushing the magneto hub too far onto the crank shaft. Which is causing the gear to jam up and not able to turn.

Sounds good. I have a sneaky suspicion because it was run loose on the other engine that the hub is stretched or damaged in a way that will require replacement. If it were mine it would just get a new one....although paying 450 bucks is absurd. Gota be one out there for half that.