Oh the battery was dead.....nope

[JoeM 8,175]

Working on a winter project, using a K181, and trying to test start the engine I ran into a problem. At times the starter would not engage or engage and crank slow

Oh the battery was dead...nope.

Looked at the solenoid, actually jumper-ed the solenoid.....nope.

Rechecked the grounds to the engine and battery connections...all okay.

Now I am focused on the starter, took a hammer and gave it a few light taps...still no change.

I left the hammer laying on the starter and decided to try it again and the head of the hammer was between the frame and starter frame...spark city.

As it turned out, I had painted the engine and starter separate, then assembled when dry, there was enough paint to cause a bad connection. 

Buffed off the paint on block and starter mounting area and she started like a new one. 

One would have thought the bolts would have made enough contact....nope!

I know a lot of people here refurbish engines and just wanted to pass along as an area not to over look.

 

[ZXT 2,401]

I had a similar experience on the HH120 on my C120! Brought it home and it never cranked right. Always cranked hard like the battery wasn't up to the task. Finally pulled the starter off one day and tried to jump it to it to test with jumper cables. No dice. It was a replacement starter that was fairly fresh. Cleaned the paint off of the side that mated to the block as well as where the bolts seated, and it made a big difference. Starter had already been damaged though from it cranking hard and getting hot, so it didn't last very long. I used the bad starter as an excuse to put a Kohler on it.

[ebinmaine 71,878]

Yepp.

The mount plate of the starter IS the ground.

 

I don't know where I learnt it but I don't rely on a bolt to be a ground.

 

A bolt is a fastening device.

 

[953 nut 59,286]

That is why these are a must.                     

[ZXT 2,401]

10 minutes ago, 953 nut said:

That is why these are a must.                     

I always figured they were just another way to keep a bolt from backing out, I'm assuming they scratch the paint to make a better connection?

[ebinmaine 71,878]

1 minute ago, ZXT said:

I always figured they were just another way to keep a bolt from backing out, I'm assuming they scratch the paint to make a better connection?

Correct.

Scratch through mild rust as well.

 

[The Tuul Crib 7,339]

11 hours ago, 953 nut said:

That is why these are a must.