Super Jet ENGINE CRANK SLOWLY

[Ahmed AN9]

After I worked on my 2009 SJ engine replacing the crankshaft to HOT ROD after a crankshaft bearing failure, installing new 85mm pistons and new pins instead of 84mm. The engine turned easily by hand without the cylinder head and after I installed the head it became slightly harder to rotate but still it can be turned by hand. The starter motor disassembled and cleaned then put back to its location.

I assumed after I finished assembly the engine will start perfect but unfortunately when I hit the start button the starter relay gave a click sound then I jumped both terminals with a screwdriver and nothing happened so I replaced the relay with a new one after that I hit the start and the engine was cranking very slowly like (half rev, stop, half rev) with plugs then I remover the plugs and it cranked faster than before but still slow. When I thought to check the connections I found that the terminals of the battery and the relay are hot.


Plzzz any advice to solve this issue?

 

[Harbor]

Got a boat here now that cranks slow with plugs in, battery cables had high resistance and got warm cranking. Cables fixed it but it's a 96 not an 09.

If your battery is good and fully charged
above 12.6 volts, you could use jumper cables from battery ground to engine case, and battery positive to starter post and see if the issue goes away.

Any new paint between starter and case or cable and starter ?

Why did you take the starter apart ? Was the issue their before you inspected the starter internally ? Find any rust inside ?

Will the engine and pump rotate easily by hand from the coupler with the plugs out ?

 

[Ahmed AN9]

Harbor. I took the starter apart after I observed that the O ring is gone and a dust sound when rotate by hand and I didn't repaint it only cleaning and replacing the O ring.

I connected the starter directly to battery and I found the same that the engine crank slow.

I didn't check if the engine rotates easily with the pump I took the pump out.

Any ideas

 

[Quinc]

Did you check ring gap? @SVTPete83 installed some new Prox pistons this year and the rings that came with them where too big.

 

[Big Kahuna]

Sounds like a bad cable or battery.
Or starter

 

[Harbor]

If your sure your battery is solid 12.6 volts or higher, you can rotate the engine by hand easily with plugs out and you jumped battery directly to engine case and starter then it Sounds like the starter

 

[SVTPete83]

If u can rotate it by hand I don't think it's a ring fitment issue.

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[Harbor]

Have you had a closer look at That battery, is it the origional from 09? Normly wouldn't think it could make cables warm but if that start buttons held down for a while it might

 

[Ahmed AN9]

Am using Ballistic battery 12 cells I will use another battery if the same I'll take out the starter and check internals if nothing found I try another starter.

Question. Does the starter issue cause the terminals heat?

 

[Harbor]

Am using Ballistic battery 12 cells I will use another battery if the same I'll take out the starter and check internals if nothing found I try another starter.

Question. Does the starter issue cause the terminals heat?

Yes

 

[SVTPete83]

Yep. Any resistance will cause everything to heat up

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[Graham Buchan]

I'm lost, was the ground checked or not? Lol


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[freeride4me]

Got a boat here now that cranks slow with plugs in, battery cables had high resistance and got warm cranking. Cables fixed it but it's a 96 not an 09.

If your battery is good and fully charged
above 12.6 volts, you could use jumper cables from battery ground to engine case, and battery positive to starter post and see if the issue goes away.

Any new paint between starter and case or cable and starter ?

Why did you take the starter apart ? Was the issue their before you inspected the starter internally ? Find any rust inside ?

Will the engine and pump rotate easily by hand from the coupler with the plugs out ?

Sounds like cables. Did you try what Harbor said to troubleshoot it?
Cables get hot from bad connections- usually your connectors on the ends with broken and/or corroded wires hidden by the insulation which means the same amperage being pulled through half or less strands of wire. Pretty normal for salt water riding if that applies to you.

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[Ahmed AN9]

I replaced the starter and the connectors of the battery cables. Now the engine is cranking WELL .
Thnx guys for your cooperation.

 

[Ahmed AN9]

Thanks Harbor

 

[Harbor]

Welcome!!!