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Garden Tractors Discussion Forum

Re: Honda GX390 starter?

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George Marsh

10-01-2013 09:51:04

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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.

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joe csuti

10-01-2013 13:10:45

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 Re: Honda GX390 starter? in reply to George Marsh, 10-01-2013 09:51:04  
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.

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George Marsh

10-02-2013 17:46:13

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 Re: Honda GX390 starter? in reply to joe csuti, 10-01-2013 13:10:45  
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.

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George Marsh

10-01-2013 15:59:05

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 Re: Honda GX390 starter? in reply to joe csuti, 10-01-2013 13:10:45  
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.


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