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D8 2u electric starter for pony question

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4 years 2 months ago #219986 by Jknarfal
Hi I'm having issues getting this old pony motor to start. It is a pain to hand crank. It has a electric starter for the pony motor. But unfortunately when I can actually get it to engage properly it doesn't seem to have any torque. I'd like to see if it can be rebuilt. It's a old delco Remy. Not sure if it's a common style of starter. Anyone know anything about these? I'm sure the pony could use a rebuild as well. Not sure what parts are available for that. It will run but is extremely hard to start by hand. Any information would be greatly appreciated thank you

Ten, fifteen, D2-3j, D2-3j wide, D2-5j, RD-4 4g, D-7 7m, D8-2u.

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4 years 2 months ago #219998 by neil
For your electric starter, before rebuilding it, check your battery cables. If your starter is 6v, you need 00 minimum cables to ensure sufficient current reaches the starter. The battery, cables, solenoid, and clamps should be in good condition, with all connections bright, clean and tight. For 12v, I'd go with 0 cables personally - same other conditions apply. Some folks will use 12v on a 6v starter - your risk there is that it can be harder on the Bendix assembly but many folks report no issues. I"m personally a fan of keeping it stock but do what you need to do to get it running how you like.
You need all of that regardless of whether the starter needs rebuilding. You can make the cables yourself to get the length right - shortest run with adequate routing so the cable is not a danger to itself or peoples' feet. If that doesn't perk up the starter, then go ahead and send it out for rebuilding. If you would like to check things in the starter motor yourself first, check that the brushes are not worn out and move adequately in the brush holder. Also confirm that the bearings are in good shape. If the bearings are dry/on the way out, that can affect its ability to start the pony. If all that looks ok, then send it to the shop.

For the pony itself, check the compression real quick. If you haven't recently changed the oil, do so. Can sometimes "cure" a poorly starting pony with a change of oil. Assuming it's in good shape, then two things will get it easy to start - carb in good shape, and magneto/ignition in good shape. Given that 90% of carb problems are ignition-related : ), start with the mag, plug wires, and plugs. Replace the mag condensor (usually starts showing its weakness when the pony is already hot), and confirm that your plug wires are solid copper core. If not, go ahead and replace them immediately. You can buy new plug wires on the web, or make them yourself with some solid core from the auto shop. Might as well put new plugs in since you're there. You can get an OTC plug checker that you can use to confirm that the spark is bright and hot. The checker is purposely set to make it harder for the spark to jump, exposing any weakness in your ignition. Also verify that the grounding switch does actually open reliably. You can easily isolate it by removing the grounding wire from the mag to rule it out. Check and clean the distributor rotor from the mage and the inside of the cap. Clean with a dry clean cloth.
If none of that helps and you've verified the timing, then go to the carb. If the pony starts easily but dies, verify that you have sustained full flow from the tank. Disconnect the fuel supply tube from the carb and let it run full flow from the tank for at least 30 seconds. If the flow drops off, you need to identify where the blockage is. Note that foreign objects in the tank can obstruct the flow sporadically, but they may be very difficult to see in the tank. Thorough method is to remove the tank, drain it, and give it a good shake and inspection to confirm it's clean. If you do have good sustained flow, check the fuel bowl float level. Too low and it can be hard to start. Too high and it risks flooding (but you would have seen that by now). If you get a carb kit, you can disassemble the carb and carefully clean all the passages and jets/tubes. I'm not familiar with the carb on the 2U but the 5U carb has a couple of passages that are vulnerable to blockage, but once cleaned, works very well. The two tests I like are how many pulls it takes to start the pony, and how well it runs at low idle and under full power. If any of those arent' satisfactory, it's time for a tune-up.

Please send us an update as you work through it and get it back to easy-starting condition. We love pictures and videos too!

(Edit - apologies, forgot one of your questions. Yes many parts are still available new, and there are plenty second-hand. machinerytrader.com has a parts search link that you can put your part number into, and most parts can still be found. I try to buy parts from Cat themselves when the price is not horrendous because so long as the parts are still sold, they will still make them)

Cheers,
Neil

Pittsford, NY

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4 years 2 months ago #220012 by Jknarfal
Ok thank you for the information. I had just quickly tried the starter with a good 12v battery and jumper cables. I believe the starter is probably 6v. It has trouble engaging. Engages only once in roughly every 50 tries. As for the pony I have had it running many times last year. I have recently removed the fuel tank and ran a chain through it. Cleaned it out. The carb had some crud in it the other day. Main jet was seized in and the head was stripped off. I drilled it out and machined a new threaded end. This seems to have worked. I got it to run on it's own fuel system after that. But it died when I went to engage it to the main. It seems to have good spark. I get it to pop almost every pull but it just really does not want to start. Very sluggish.

Ten, fifteen, D2-3j, D2-3j wide, D2-5j, RD-4 4g, D-7 7m, D8-2u.

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4 years 2 months ago #220013 by ag-mike
u'll have to remove the starter, investigate the gear and its engagement to the engine flywheel teeth. Makesure everything is adjusted correctly. Maybe trashed by now. There is factory printed info about this procedure. Get this done, then on to the starter itself and its adjustments needed to get eveything spinning.

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4 years 2 months ago #220015 by gemdozer
Replied by gemdozer on topic poney

Ok thank you for the information. I had just quickly tried the starter with a good 12v battery and jumper cables. I believe the starter is probably 6v. It has trouble engaging. Engages only once in roughly every 50 tries. As for the pony I have had it running many times last year. I have recently removed the fuel tank and ran a chain through it. Cleaned it out. The carb had some crud in it the other day. Main jet was seized in and the head was stripped off. I drilled it out and machined a new threaded end. This seems to have worked. I got it to run on it's own fuel system after that. But it died when I went to engage it to the main. It seems to have good spark. I get it to pop almost every pull but it just really does not want to start. Very sluggish.


You should removed the small switch on the startor and check inside she must be full corrosion on the small brace plate

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