3 knackered starter motors in six weeks
Turbo Mini Forums

I may have been really unlucky that three starters have all failed recently on my new turbo build.

1. Brand new brise pre engaged starter. This was shit from word go. Every time the engine fired there would be a slight crunching noise as it seemed slow to disengage from the flywheel. Shimmed it a bit, was slightly better. It also did not sound too smooth either when cranking . After 100 miles things took a turn for the worse after a hot start the starter refused to stop spinning after the ignition key was released. Sent that back to brise

2. Powerlite race unit from minispares. Also no good from the moment i fitted it. After cranking a few seconds it would give out a cough and pack up. Would have to release the ign key and try again. Did not sound smooth when cranking. 100 miles and the solonoid went down, all i got was clicking noise, starter would not turn

3. Another powerlite unit fitted, sounded really smooth and quiet. No problems for 100miles and suddenly i get a loud rattling from the starter after the engine has fired.

My flywheel is a MED lightweight verto and i have checked through holes in the wok to make sure the ring gear is correct and it looks the correct profile.

So i have three kinda different failures here, just bad luck? Any thoughts

check the number of teeth on the starter and flywheel,

I think if your using a pre engaged tooth profile on a verto flywheelm they can jam.

How many teeth on the pinions? I think it should be 11 for the pre-engaged ones.

Also is the ignition advance a little much cranking causing it to kick back?

Edited by minimole23 on 19th Sep, 2015.

A long time ago, the starter motor on my brothers Fiat Panda failed. We fitted a reconditioned 'exchange' replacement. within a week, that one had also failed, we hadn't even taken the 'exchange' unit back. Feeling a bit pissed about it, we took both back and the guy pulled them apart there and then infront of us. They were both smashed to fuck inside. Turns out the ignition switch was fucked and energising the motor randomly as you drove up the road.

I agree with Joe though, but just check the switch is ok.

inertia setup 107 tooth ring gear 9 tooth starter,

pre engaged setup 129 tooth ring gear, starter 11??

you "can get away with" using the 107 tooth ring with the pre engages starter, but its likly you'll need to space the stater back a bit so it disengages.

inertia setup 107 tooth ring gear 9 tooth starter,

pre engaged setup 129 tooth ring gear, starter 11??

you "can get away with" using the 107 tooth ring with the pre engages starter, but its likly you'll need to space the stater back a bit so it disengages.

Checked my trigger feed to the starter and it is only there when i turn the key.

Removed powerlight starter number 3. Pinion has 11 teeth and looks like this



It looks to me like the pinion is stuck in its "start the engine position". Which would explain all the noise after the engine fires up. Should the pinion be further back inside the casing normally?

Also recieved a brand new brise unit today to replace the first starter that broke. This ones got ten teeth.
Sounds very smooth and no problems yet........

Could be worse, I once had a starter that was turning the wrong way!

Took me a while to work that one out.

Fastest 998 mini in the world? 13.05 1/4 mile 106mph

ten teeth eleven teeth ? the fly wheel is supost to have a set number and the correct start has a matching ratio of teeth i did not think you could have different ratios ?? you know besides a "high tourqe" unit thats got a planetary reduction box in it as far as changeing the ration on the fly wheel/starter id say ur asking for trouble

The ratio of teeth doesnt really matter so long as the pitch and mesh are correct