Bandit 90XP Issues

P

Patrizio

Location
Maine
Hello,

I have a 2012 Bandit 90XP that is having some starting issues...

About 2-3 weeks ago it started to have this issue where it would not crank on the 1st turn of the key... You get a "click" when turning the key but but by the 5th or 6th time trying, it would finally crank and start. I figured maybe just cause its so cold out the cold is messing with something and I was OK with that... As long as it starts. Once it is running, it runs totally fine with no issues.

Fast forward to yesterday morning.. I had to do some maintenance so went outside to start the chipper up and again, on the 4th or 5th try it started up. I let it warm up so I can just get things moving and warm up engine oil / hydro oil.

I shut it down and went to do my maintenance and then after I was done I tried to start it up but it will not start now. I can heat the glow plugs and everything looks fine on the panel until you go to turn the key to actually start the engine.. It just gives one click like it would previously but now doesn't crank at all no matter how many times I try to turn the key.

After that, I got out the voltmeter just to make sure I was getting power to the starter and I am. After this, I arced the starter posts to get it to run and it did... the motor ran in the starter but it seems liked it wasn't engaging the flywheel.

So I went out and bought a new starter, put it in and I am still having the same issue.

I am stumped. Am I missing something? Thanks
 
Patrizio said:
Hello,

I have a 2012 Bandit 90XP that is having some starting issues...

About 2-3 weeks ago it started to have this issue where it would not crank on the 1st turn of the key... You get a "click" when turning the key but but by the 5th or 6th time trying, it would finally crank and start. I figured maybe just cause its so cold out the cold is messing with something and I was OK with that... As long as it starts. Once it is running, it runs totally fine with no issues.

Fast forward to yesterday morning.. I had to do some maintenance so went outside to start the chipper up and again, on the 4th or 5th try it started up. I let it warm up so I can just get things moving and warm up engine oil / hydro oil.

I shut it down and went to do my maintenance and then after I was done I tried to start it up but it will not start now. I can heat the glow plugs and everything looks fine on the panel until you go to turn the key to actually start the engine.. It just gives one click like it would previously but now doesn't crank at all no matter how many times I try to turn the key.

After that, I got out the voltmeter just to make sure I was getting power to the starter and I am. After this, I arced the starter posts to get it to run and it did... the motor ran in the starter but it seems liked it wasn't engaging the flywheel.

So I went out and bought a new starter, put it in and I am still having the same issue.

I am stumped. Am I missing something? Thanks
Click to expand...
On my old chipper I use to have starting problems also sometimes it would sometimes not
After 3 years of batteries, alternator , and starter come to find that the hot cable from starter to battery was a welding lead which is fine (more strands)wire vs thick strands
Changed it over and never had another issue
 
My guess right off would be that you’re having a current flow problem. Remove the battery cables and clean both ends very well. While they’re off, flex the cables in your hands, if you feel any hard places in the cables, there is corrosion inside and that cable needs replaced.

Also, the starter relay could be failing and need replacement, that is probably attached to the back of the control panel or the inside of the engine case somewhere. It should have some rather large cables attached to it.

Check on those and post what you discover, if that does not fix it I’ll do some more thinking. Also, what engine is on that machine? There are a few options on that one, if my memory is correct.
 
EDIT: Reach beat me to the punch!

Sounds like a loose heavy duty cable connection or maybe the solenoid is going bad and not making a good internal contact. They do wear out over time. It could even be starter brushes going bad but start with the easy to check stuff first. Are you familiar with how to use a volt meter?
 
All connections to the starter are solid and the machine is in really good shape - there’s 500 hrs on it.

It has a caterpillar C2.2 Diesel on it.

I replaced the starter yesterday with one straight from CAT… but having the same issues. I even jumped the starter solenoid with a screwdriver but it’s still not starting - the starter motor will run this way but it is almost like it is not engaging the flywheel because the engine will not turn.

But it seems like there’s a problem even before that - the click. If the starter motor runs when I arc the starter solenoid, shouldn’t it do the same when I turn the key? So there’s something in between missing. I get nothing at the starter when I turn the key, but jumping with the screwdriver turns the starter. But then there’s this second issue where even though the starter motor runs, the engine flywheel is not turning almost like the bendix is not engaging- so I am wondering if there is something in between preventing the bendix from coming out and also affecting the power from the ignition switch to the starter - or is that just not how it works? Thanks
 
Jonny said:
I was thinking solenoid, should be easy to troubleshoot, or cheap enough to just change it.
Click to expand...
You mean the solenoid mounted to the rear of the engine box hood or the starter solenoid? The starter solenoid is new as it came with the new starter from CAT.
 
TreeCo said:
EDIT: Reach beat me to the punch!

Sounds like a loose heavy duty cable connection or maybe the solenoid is going bad and not making a good internal contact. They do wear out over time. It could even be starter brushes going bad but start with the easy to check stuff first. Are you familiar with how to use a volt meter?
Click to expand...
I used a voltmeter and everything checks out.

Starter got replaced yesterday with one straight from CAT
 
Reach said:
My guess right off would be that you’re having a current flow problem. Remove the battery cables and clean both ends very well. While they’re off, flex the cables in your hands, if you feel any hard places in the cables, there is corrosion inside and that cable needs replaced.

Also, the starter relay could be failing and need replacement, that is probably attached to the back of the control panel or the inside of the engine case somewhere. It should have some rather large cables attached to it.

Check on those and post what you discover, if that does not fix it I’ll do some more thinking. Also, what engine is on that machine? There are a few options on that one, if my memory is correct.
Click to expand...
There is a relay and another stand alone solenoid attached to the back of the engine case - I’ll see if I can change them out, doesn’t hurt
 
Hi guys,

So after much prayer and deliberation the issue was the stand alone solenoid mounted to the engine case.

After replacing the starter I tested it and found out it was doing the same thing as the old one when that was tested as well.

There are three poles on the starter solenoid. I jumped the + positive pole to the other large pole (Neutral I think) and found that only the starter motor spun but the bendix did not protrude out of the housing. I then took my + battery cable and instead of going to the + pole on the starter solenoid I put it on the smaller pole and realized the bendix protruded but had no motor spin. So I realized both poles need power on that starter solenoid for it to work correctly.

noticed the wires were tied in to another solenoid that was mounted on the rear of the engine case so I replaced that solenoid and all is working now.

So looking back it actually wasn’t the starter but that other solenoid. Thanks for all the help! Maybe this helps someone down the road.
 
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