Honda GX390 starter?

Geo-TH,In

Well-known Member
I'm trying to convert my Gx390 to an electric start. Got a kit on ebay. What a battle getting the flywheel off. The flywheel nut was put on with lock tight. Won't be put back on with lock tight. Had to make bolts to pull flywheel off. Then I find out the hole where the starter goes measures 6.2 mm and the starter's diameter is 6.5 mm in diameter. What should it be, 6.2 or 6.5?

Thanks
George
 
First thing to do is determine yr eng made,if you bought kit from deezee auto or the parts barn both listings specify 2011/older eng,if eng 2012-2013 you may need a different kit or same not avail in an aftermaket kit,call/email seller & explain problem,both have a return/refund policy.
 
I did get from deezee. Going to call them tomorrow when they are open. My engine is about 10 years old. I made a mistake. The diameter of their starter is 65 mm and my hole is 62 mm, 3 mm smaller, close to 1/8 inch smaller.
 
Joe,
Called deezee and they said I must enlarge hole 3 mm. I think everyone needs to know this ahead of time.

I think I can do it with a 2.5 inch bi-metal hole saw. Been to two places this morning and both are out of the 2.5 incher.
George
 
George-I don't think hole saw will work as you have no center for pilot bit to ride in as a guide for hole saw,what you'll probably have to do is use a adjustable straight reamer to open hole or take eng/starter to a machine shop & have them ream hole as center of hole is critical not only for starter mounting bolt centers you also have to consider mounting holes on starter may be slightly oversize & id of hole for starter may affect side/side & up/down position of starter motor,this also affects gear lash for starter drive/flywheel ring gear,if lash not correct you may get short starter gear/ring gear life or break nose off starter if lash too tight,I've seen this happen on small eng & auto eng.
 
Joe, I had a 2 1/2 hole saw. Put it in a drill, spun it in front of the grinder and ground everyone other tooth out that was sticking out. That fit perfectly in the factory opening that I drilled out without the 1/4 inch drill installed. That worked to remove the back plate.

Then I took another 2 1/2 inch hole saw and enlarged the opening a little. Not enough. So I used a half round file and went to work. 4 hours later the starter fits perfectly.

There isn't enough money for me to do this to another GX390, NEVER AGAIN.

I also had to drill the flywheel to tap the 3 places for a flywheel puller and had to tap the place to mound the charging coil. Once is enough for me. Wish I had removed the metal filings from drill press. They stuck to all 3 magnets on flywheel, gray moment.

There were no instructions included, so I called deezee and they emailed me the wiring diagram.

George
 
If you ever need to get locktight loose, just heat to about 3-400 degrees, with a propane torch. loosens right up.
 
Diyguy,
If I had put lock tight on the nut, I would have known to heat it. Who puts lock tight on a flywheel nut? Never seen it before. Won't be there when I'm done. Do you see a need for it?
George
 
Joe, deezee said I have to enlarge hole with a dremmel. OEM was close to 2.5 inches, 62 mm. Starter is close to 66 mm. I enlarged with hole saw and then a round file on a drill. Got it close. Then switched to a half round file. Put a light behind the starter to find places that needed filed. Worked all day on the hole. Got it perfect. Starter bolts were both centered in the holes. Starter works as it should. Engine started on first crank after setting for almost a year.

3 days is too long to make this work. I even drilled and tapped the 3 holes in flywheel to use a gear puller to remove flywheel, because starter bolts are hidden behind the flywheel and my worst fear is removing the flywheel without using a puller.

Never do this again. If starter doesn't fit, I won't do it.
George
 
Hard to tell whose been there before you! I had a neighbor bring me one of his aerators up, day before yesterday, the flywheel nut had come loose and stripped out the nut, and boogered up the threads on the crank, pretty bad. I used a thread file, to clean it up, then cut a slot down a lock nut I happened to have, and used it, and a pair of vice-grips to chase the threads a little smoother, then put a new lock nut on, and yes, used red medium locktight on it. Sometimes its a necessary evil!
 

We sell tractor parts! We have the parts you need to repair your tractor - the right parts. Our low prices and years of research make us your best choice when you need parts. Shop Online Today.

Back
Top