Trouble Shooting
Operation of your IPU Starter should be trouble free, as long as the starter has been fitted
correctly (see installation – page 8), and the correct engine and starter operation is adhered to
(see operation – page 11). If a problem does occur it is often possible for the operator to identify
and correct the situation.
Faulty Winding Mechanism
On turning the winding handle two turns in a clockwise direction the winding adapter should
rotate smoothly, thus causing the drive pinion to move forward and engage with the flywheel ring
gear. Further rotation should cause the spring pack to gradually compress as viewed through the
body inspection window.
Winding adaptor is jammed so
that cranking handle will not
turn
The bevel pinion is broken
and is locking the drive gear
rotation
The bevel pinion must be
replaced and the drive gear
checked for damage
Winding adaptor’s rotation is
‘stiff’ or not-smooth
The meshing between the
bevel pinion and drive gear
is too tight
Shims (part no. 20026) must
be added or removed from
between the rear housing
bearing and the drive gear
Winding adaptor rotates but
the spring core does not
compress and the pinion and
core pack does not rotate.
The bevel pinion or the input
shaft is broken
The bevel pinion or input
shaft must be replaced
Winding the adaptor does not
cause the spring pack to
compress or the drive pinion
to move forward to
engagement (the drive pinion
does however rotate)
The drive ratchet is broken or
the circlip has come loose
Fit new ratchet or circlip as
appropriate
The pinion is jammed on the
drive shaft due to burring on
five start thread or due to
excessive rust
Burring can be removed with a
grinding stone or a new drive
shaft fitted
Operation is normal up to
compression of spring pack,
but starter then discharges
prematurely before pack is
fully compressed
The lock height is incorrect
Adjust lock to correct height,
using lock height gauge.
The lock and/or ratchet are
worn
Replace worn component(s)
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