Hello All,
I'm helping out a family friend by working on his Cushman Hawk utility vehicle. It has 14 HP Vanguard V-twin OHV. The original issue was the teeth on the starter were ground off to the point of no engagement. Apparently you can remove the starter while in the vehicle, however, I opted to pull the engine since there were other things to be looked at and it wasn't much of a hassle. I eventually found the right starter gear, installed it to the starter and reinstalled the starter. While I had the engine out, I changed the spark plugs and the spark plug boots on the coils. I adjusted both coil air gaps and all 4 valves. I also changed the oil and filter. After having an issue finding the starter pinion gear with the right number of teeth, I tested out the starter while on the engine to make sure the new gear would turn the engine over fine. With no fuel or spark, obviously the engine didn't start but I let it turn over for about 3 seconds. All was well. Starter engaged and disengaged fine. I put everything back together and put the engine back in the vehicle. As I went to install the drive pulley back onto the crankshaft I had to turn the crankshaft a bit to get everything lined up. I notice the crank would only turn about 60 degrees total. When it came to a stop it was quite abrupt, not like the engine was just building compression. After checking all the clearances of moving parts and removing the coils to make sure they weren't contacting the flywheel, I removed the engine once again to see if I could get a better look. This is the point I'm at now. I can't find a thing wrong. It almost sounds internal to the engine when it makes contact with whatever it is. I pulled the valve covers to double check the valves and also removed the spark plugs. It's crazy because just yesterday the engine turned over without issue. The vehicle gets driven mostly on gravel and there was a fair amount of gravels around the engine. I thought maybe one of those got lodged behind the flywheel but I can't see anything or hear it rolling around. I gave the engine a good shake while on the hoist hoping to dislodge something but no dice. The point at which it stops turning is just about where the flywheel magnet passes each coil. It will only move back and forth between those two points. I'm thinking of pulling the flywheel next, but I was hoping someone had another idea. Anyone had this happen?
Thanks,
Seth
I'm helping out a family friend by working on his Cushman Hawk utility vehicle. It has 14 HP Vanguard V-twin OHV. The original issue was the teeth on the starter were ground off to the point of no engagement. Apparently you can remove the starter while in the vehicle, however, I opted to pull the engine since there were other things to be looked at and it wasn't much of a hassle. I eventually found the right starter gear, installed it to the starter and reinstalled the starter. While I had the engine out, I changed the spark plugs and the spark plug boots on the coils. I adjusted both coil air gaps and all 4 valves. I also changed the oil and filter. After having an issue finding the starter pinion gear with the right number of teeth, I tested out the starter while on the engine to make sure the new gear would turn the engine over fine. With no fuel or spark, obviously the engine didn't start but I let it turn over for about 3 seconds. All was well. Starter engaged and disengaged fine. I put everything back together and put the engine back in the vehicle. As I went to install the drive pulley back onto the crankshaft I had to turn the crankshaft a bit to get everything lined up. I notice the crank would only turn about 60 degrees total. When it came to a stop it was quite abrupt, not like the engine was just building compression. After checking all the clearances of moving parts and removing the coils to make sure they weren't contacting the flywheel, I removed the engine once again to see if I could get a better look. This is the point I'm at now. I can't find a thing wrong. It almost sounds internal to the engine when it makes contact with whatever it is. I pulled the valve covers to double check the valves and also removed the spark plugs. It's crazy because just yesterday the engine turned over without issue. The vehicle gets driven mostly on gravel and there was a fair amount of gravels around the engine. I thought maybe one of those got lodged behind the flywheel but I can't see anything or hear it rolling around. I gave the engine a good shake while on the hoist hoping to dislodge something but no dice. The point at which it stops turning is just about where the flywheel magnet passes each coil. It will only move back and forth between those two points. I'm thinking of pulling the flywheel next, but I was hoping someone had another idea. Anyone had this happen?
Thanks,
Seth
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