Starter DD50

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solid808
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Starter DD50

Post by solid808 »

question? I can kick start my dd50 with no problems, but when I electric start it, it only works sometimes... It works fine whenever it wants to. Starter motor works perfectly fine its just that gear by the pulley sounds like its not engaging it sounds like. what can I do to fix this?
2006 SYM DD50
72 Corsa
Mini Stroked
26mm Polini carb
Stage 6 intake manifold
Sparrow Exhaust
Polini Ruckus Variator
Malossi Fly Clutch w/ blue
1500 contra
Lightened mag
7.4-1 gears
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Rip_City_Spree
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Re: starter

Post by Rip_City_Spree »

I don't know anything bout your dd50 but on my elite I had to problem and took my variator assembly off and reinstalled think it wasn't lining up properly. Do you have a bendix gear? Check that but hard for things to break in there. Was told sometimes the belt isn't all the way on and throws everything out of whack
01 Elite SR
polini corsa
Polini 26mm Carb
Naraku intake
Naraku sport variator
Currently 5g rollers
zx trans
Arrow
red contra with yellow clutch springs.
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solid808
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starter question

Post by solid808 »

is there a trick to making the bendix gear engage? I can hear my starter but I think that gear is not engaging to start my motor.. I know its in the correct spot
2006 SYM DD50
72 Corsa
Mini Stroked
26mm Polini carb
Stage 6 intake manifold
Sparrow Exhaust
Polini Ruckus Variator
Malossi Fly Clutch w/ blue
1500 contra
Lightened mag
7.4-1 gears
solid808
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Posts: 109
Joined: Sun Feb 08, 2015 10:36 pm
Location: Honolulu

Re: starter

Post by solid808 »

I pulled out the bendix gear looked at it.. I think it looks fine.. put it in and just my starter spins and that bendix gear doesnt even contact the starter... How do I fix this..
2006 SYM DD50
72 Corsa
Mini Stroked
26mm Polini carb
Stage 6 intake manifold
Sparrow Exhaust
Polini Ruckus Variator
Malossi Fly Clutch w/ blue
1500 contra
Lightened mag
7.4-1 gears
User avatar
Wheelman-111
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Re: starter

Post by Wheelman-111 »

Greetings:

Was the belt drive modified? Check the belt width; 15.5mm is stock. 18 or so means someone installed a ZX drive. To do that, the outer sheave of the front pulley is moved outboard by a couple of mm. A different Bendix may be available, but my solution was a shim washer installed on the bearing surface - that little pin that juts out on the engine side. This moves the Bendix assembly outboard a mm or two - just enough for the big teeth on the Bendix to engage with those on the outer sheave. If either sets of teeth are "rounded off" from incomplete contact, the Bendix won't engage to spin the crank. Replacement of both may be necessary, but try shimming it out first.
Wheelman-111
Most of my money is spent on scooterparts. The rest is just wasted.
"ISO": '03 Vespa ET4 Malossi187 74MPH
Flash 9: 2001 Elite SR Contesta 72 ZX Tran, 9:1 Gears, Stock Airbox/Carb/Pipe 58.8 MPH
Punkin: 2010 Vespa/Malossi S78, 61MPH
solid808
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Re: starter

Post by solid808 »

Wheelman-111 wrote:Greetings:

Was the belt drive modified? Check the belt width; 15.5mm is stock. 18 or so means someone installed a ZX drive. To do that, the outer sheave of the front pulley is moved outboard by a couple of mm. A different Bendix may be available, but my solution was a shim washer installed on the bearing surface - that little pin that juts out on the engine side. This moves the Bendix assembly outboard a mm or two - just enough for the big teeth on the Bendix to engage with those on the outer sheave. If either sets of teeth are "rounded off" from incomplete contact, the Bendix won't engage to spin the crank. Replacement of both may be necessary, but try shimming it out first.
thanks I think thats my problem.. where would you get those flat shims from? I know you cant just buy washers and put it in lol
2006 SYM DD50
72 Corsa
Mini Stroked
26mm Polini carb
Stage 6 intake manifold
Sparrow Exhaust
Polini Ruckus Variator
Malossi Fly Clutch w/ blue
1500 contra
Lightened mag
7.4-1 gears
User avatar
Wheelman-111
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Joined: Wed Oct 22, 2008 5:09 pm
Location: Deepinnaharta, Texas

Re: Starter DD50

Post by Wheelman-111 »

Greetings:

Believe it or not, between Lowe's and Home Depot's stash of 17mm washers, I found a pretty good collection of shim washer candidates. You want the outer diameter to match that of the pulley boss if possible. VT Cycles at one time carried really thin ones for stacking perfection.
Wheelman-111
Most of my money is spent on scooterparts. The rest is just wasted.
"ISO": '03 Vespa ET4 Malossi187 74MPH
Flash 9: 2001 Elite SR Contesta 72 ZX Tran, 9:1 Gears, Stock Airbox/Carb/Pipe 58.8 MPH
Punkin: 2010 Vespa/Malossi S78, 61MPH
solid808
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Re: Starter DD50

Post by solid808 »

Wheelman-111 wrote:Greetings:

Believe it or not, between Lowe's and Home Depot's stash of 17mm washers, I found a pretty good collection of shim washer candidates. You want the outer diameter to match that of the pulley boss if possible. VT Cycles at one time carried really thin ones for stacking perfection.
Ok I put the washer on and now feels like my starter cant spin my bendix.... do you think I need a stronger starter?
2006 SYM DD50
72 Corsa
Mini Stroked
26mm Polini carb
Stage 6 intake manifold
Sparrow Exhaust
Polini Ruckus Variator
Malossi Fly Clutch w/ blue
1500 contra
Lightened mag
7.4-1 gears
User avatar
Wheelman-111
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Re: Starter DD50

Post by Wheelman-111 »

Greetings:

Maybe a newer battery, but it's not uncommon for the starter to engage and then "hang up" as it attempts to overcome the increased compression of some kits. Mine does that occasionally, especially on a cold start. Kicker comes in handy...
Wheelman-111
Most of my money is spent on scooterparts. The rest is just wasted.
"ISO": '03 Vespa ET4 Malossi187 74MPH
Flash 9: 2001 Elite SR Contesta 72 ZX Tran, 9:1 Gears, Stock Airbox/Carb/Pipe 58.8 MPH
Punkin: 2010 Vespa/Malossi S78, 61MPH
solid808
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Joined: Sun Feb 08, 2015 10:36 pm
Location: Honolulu

Re: Starter DD50

Post by solid808 »

Wheelman-111 wrote:Greetings:

Maybe a newer battery, but it's not uncommon for the starter to engage and then "hang up" as it attempts to overcome the increased compression of some kits. Mine does that occasionally, especially on a cold start. Kicker comes in handy...
I bought a charger and will see what happens.. Thank you for the help...
2006 SYM DD50
72 Corsa
Mini Stroked
26mm Polini carb
Stage 6 intake manifold
Sparrow Exhaust
Polini Ruckus Variator
Malossi Fly Clutch w/ blue
1500 contra
Lightened mag
7.4-1 gears
User avatar
Wheelman-111
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Joined: Wed Oct 22, 2008 5:09 pm
Location: Deepinnaharta, Texas

Re: Starter DD50

Post by Wheelman-111 »

Greetings:

I have found battery lifespan seldom exceeds 3 years in ferocious Deepinnaharta heat. Fully-charged, it should work a few times, but loses its oomph quickly. Replace or keep the kickstart lubricated.
Wheelman-111
Most of my money is spent on scooterparts. The rest is just wasted.
"ISO": '03 Vespa ET4 Malossi187 74MPH
Flash 9: 2001 Elite SR Contesta 72 ZX Tran, 9:1 Gears, Stock Airbox/Carb/Pipe 58.8 MPH
Punkin: 2010 Vespa/Malossi S78, 61MPH
solid808
Spree
Spree
Posts: 109
Joined: Sun Feb 08, 2015 10:36 pm
Location: Honolulu

Re: Starter DD50

Post by solid808 »

Wheelman-111 wrote:Greetings:

I have found battery lifespan seldom exceeds 3 years in ferocious Deepinnaharta heat. Fully-charged, it should work a few times, but loses its oomph quickly. Replace or keep the kickstart lubricated.
eliminated that the battery is low lol.... It seems like the bendix gears dont want to shoot out and contact drive face... So I ordered one and will see if that works... process of elimnation huh hahha
2006 SYM DD50
72 Corsa
Mini Stroked
26mm Polini carb
Stage 6 intake manifold
Sparrow Exhaust
Polini Ruckus Variator
Malossi Fly Clutch w/ blue
1500 contra
Lightened mag
7.4-1 gears
solid808
Spree
Spree
Posts: 109
Joined: Sun Feb 08, 2015 10:36 pm
Location: Honolulu

Re: Starter DD50

Post by solid808 »

Changed my bendix gear and all of the sudden. Presto my starter works again. Thanks again
2006 SYM DD50
72 Corsa
Mini Stroked
26mm Polini carb
Stage 6 intake manifold
Sparrow Exhaust
Polini Ruckus Variator
Malossi Fly Clutch w/ blue
1500 contra
Lightened mag
7.4-1 gears
veedubh20
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Re: Starter DD50

Post by veedubh20 »

dd50/ elite (dio motor) is very famous do cracked on the block where pinion gear mount on. dont need a starter!, just go kick start.
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