starter Problems

KKV270 · Post by **KKV270** » Mon Sep 15, 2014 4:05 pm

Hi.

my system is a 12volt system with the 130 teeth flywheel.
The 12volt starter I got (refurbished) had the bendix to the 109 teeth flywheel, so I simply replaced the bendix with my previoius one.

The starter rotates perfect (faster than my old one) off the car. On mounting, I had to fit into position by tightening the bolt and nut as it wouldn't sit in as easy as the other....(a very small part that is) hence the drag in roattion.

I removed to investigate. Why I suspect the bushing, 1- It was a recent fit....who knows, it might have entered squif at the end point as the new starter armarture tip seems slightly longer than the old one and there is an evident friction mark at the tip only.
The old starter worked well with the bushing replacement...but as I said, it had a shorter tip.

Nothing else sounds out of the normal.

One thing though, my bendix bushing cracked off leaving a small piece inside....that is why I asked for specific measurements so as to get replacements soon.

-Battery was tested and came clean.
-My alternator charges at 12volts...
-Old starter failed the ground test. Seems the armarture gave in after the previous series of problems.

KKV270 · Post by **KKV270** » Wed Sep 17, 2014 9:10 am

Blue

Make me understand what you mean about using a self supporting starter from an automatic drive. My system is 12volts. What makes it self supporting? Is it that it doesn't use bushings??? That is my problem. This is such a dissapointing matter. I'm tired of pushing....worst off when in the city centre. It is tainting the beetle face terribly

Blue Baron · Post by **Blue Baron** » Wed Sep 17, 2014 11:06 am

Volkswagen made a self supporting starter that didn't use a bushing, and installed it in all VWs with the automatic transmission. It can be easily identified by its longer length. I know Bosch no longer offers it as a rebuilt replacement item and hasn't for some time.

They can still be found used in the U.S., but I have no idea whether the Beetle with the automatic transmission (or "autostick") was ever offered in Kenya. I suspect not.

Your other option is what's called a high torque stater, which is mainly sold for cars with high performance engines. It also doesn't use a starter bushing. I have one installed in my '56 and it works great, though is a bit noisy, like the old Chrysler starters. The drawback is price. It's an expensive item.

My best advice is to simply find the right starter bushing. As I said, there is a special bushing to mate the 12 volt starter to the 6 volt bellhousing. I have one in my blue '66.

darzoom · Post by **darzoom** » Wed Sep 17, 2014 12:11 pm

have a machine shop make the bushing. Just measure the two parts and they can turn one down for you. THe chanches of finding a self supporting starter are probally slim there. the bushing is made of bronze and you should be able to find a piece of that at a machine shop. Do a google search on VW STarter BUshing Replacemnt and you can find for as cheap as $2 us online. Not sure about shipping but it is an option.

KKV270 · Post by **KKV270** » Wed Sep 17, 2014 1:34 pm

Thank.

Blue, I have had a look at the self supporting starter.... wow!! what a fortune.
Darzoom, thanks. I guess I will settle for the bushings I have locally and get a shop to shave it off slightly as it is the outer diameter that seems too large. Challenge is in getting the right measurements.... Not sure how to go about it....anyways,,,,I will get this thing done.

Thanks for the support and waelth of advice.

darzoom · Post by **darzoom** » Thu Sep 18, 2014 8:25 am

You will need a micrometer to get the measure. Or, take the old bushng you removed to the machine shop and they can measure the OD to know what to cut off the new bushing. you can also take the starter so they can measure the shaft that goes in the center. With those two things they should be able to make up a new pushing or cut one down you have. Good luck.

PS: Yes a self supporting starter is quite pricy. We are lucky to be in a place whre we have a readily avaialble parts inventory. I can understand your challenges as I lived in India and it was almost impossible to get some things. Keep up the fight it will be worht it.

KKV270 · Post by **KKV270** » Thu Sep 18, 2014 12:32 pm

Hi.

I'm glad to be back so soon with very goog news.

1. I removed the recently installed bushing and with that revealed some things.
I had installed a bushing into another bushing.... My systems seems to have been a 6 volt. The larger bushing was so worn and with folded ends.

I hence got a bushing made for the 12 volt bushing to enter....

It sure had me all smiles driving off for a lap having cranked my engine....what an accomplishment.

Thank you all for the contributions made. I sure was better prepared for the task with the wealth of information you made available. I wpuldn't have made it thus far without you guys.

John, thank you for this forum.

Blue Baron · Post by **Blue Baron** » Tue Oct 07, 2014 1:29 pm

You're very welcome for my small contribution.

It's nice to know we have a friend in Kenya! Perhaps you can post some pictures of yourself and you car for us.

And yes, there is a science to parts interchangeability with these cars.

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