2015 8000 Electrical and Starter Issues - HCS Snowmobile Forums

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Old 10-30-2017, 10:32 AM   #1 (permalink)
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Join Date: Feb 2014
Posts: 1,107
Current Sled(s): 12 XF 1100 Turbo
Previous Sled(s): 04 ZR900, 98 ZRT w/1000D&D, 93 T-Cat, 86 600 Indy w/707 SLP,
Location: Ohio
Favorite Riding Area: U.P.
19-20 Mileage:
18-19 Mileage: 1500
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Age: 62
Riding Since: 1964
Default 2015 8000 Electrical and Starter Issues

Friend of mine has a 15 8000 as a backup to his Thundercat and has had issues with his electric starter and voltage regulator.

Soon after he installed LED headlight bulbs he started having voltage issues. To make a long story short turned out the LEDs were drawing so little current the regulator could not absorb the excessive current and failed.

He's also had starter issues before he changed to the LEDs. Bendix gear was chewing into ring gear on clutch.
Dealer repaired problem, but after a short period of time starter would just spin without spinning the motor over.

He bought the Cat kit to convert the sled over to full DC to solve the charging/regulator issue.

So yesterday I was helping him install the DC kit.
While installing the kit I noticed the throttle lever would not move passed 1/16 throttle......Now WTF.

Turned out the gear on the starter jackshaft had slid way over towards the clutch side of the sled because the snap ring holding the gear in place had popped out of it's groove. See pic.

The oil pump arm was hitting the mis-positioned gear preventing the throttle from being opened.
This is why the starter motor just spun without turning the engine over.

The gear easily slid back in position and then we pushed the snap ring back in it's retaining groove.
Just hope the snap ring stays in place now.
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