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Old 03-14-2012, 01:08 PM   #1
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1991 generac NP-66G genset

The gen was running perfectly after I changed the oil, filters and plugs and now I have a starter issue, I hit the starter button and the starter motor spins and makes an ugly sound but does not engage the flywheel to start the motor.

I removed 4 bolts on the starter cover and broke it free but it only swings out a few inch and strikes the heaVY STEEL BRACKET SUPPORTING THE MUFFLER. thru the opening I can see part of the starter

Looking around with a flashlight thru the gen access door I can see only 3 bolts holding the engine top housing down and about 6 bolts holding the air inlet screen to the housing, (yes I have an exploded view of the sheet metal and all other parts of this thing) I just want to raise the housing about a 1/2 inch or so to get it off the starter cover so I can get at the starter.

Has anyone any experienced changing a starter on one of these that can give me some advice here?? I just hate to unscrew something that does not need unscrewing,.
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Old 03-14-2012, 04:59 PM   #2
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Originally Posted by Bilito View Post
The gen was running perfectly after I changed the oil, filters and plugs and now I have a starter issue, I hit the starter button and the starter motor spins and makes an ugly sound but does not engage the flywheel to start the motor.

I removed 4 bolts on the starter cover and broke it free but it only swings out a few inch and strikes the heaVY STEEL BRACKET SUPPORTING THE MUFFLER. thru the opening I can see part of the starter

Looking around with a flashlight thru the gen access door I can see only 3 bolts holding the engine top housing down and about 6 bolts holding the air inlet screen to the housing, (yes I have an exploded view of the sheet metal and all other parts of this thing) I just want to raise the housing about a 1/2 inch or so to get it off the starter cover so I can get at the starter.

Has anyone any experienced changing a starter on one of these that can give me some advice here?? I just hate to unscrew something that does not need unscrewing,.
I removed the air screen and sure enough, under it were two more bolts holding the top cover in place. well after some struggling in tight places I finally have access to the starter, but not so fast, one of the two starter attach bolts is just a tad behind the counter weight on the starter shaft, I have tried everything to get a socket on that bolt and all to no avail. The plastic gear is toast, there was a plastic retainer deal with a spring and some other parts that stopped the bendix gear from going too far up the shaft and it broke and the gear went way up jammed and got destroyed by the flywheel gear

I think there is something called a wobble extension for sockets that might let me get in there to remove that darn bolt, anyone ever heard of that???
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Old 03-14-2012, 05:37 PM   #3
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removing starter

you are correct there are socket extensions that alow a limited amount of flexability harbor freight sells them at a reasnoble price lee
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Old 03-14-2012, 06:02 PM   #4
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you are correct there are socket extensions that alow a limited amount of flexability harbor freight sells them at a reasnoble price lee
We got a harbor freight a few miles away I will check that out tomorrow, thanks
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Old 03-14-2012, 08:47 PM   #5
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You are going to want a spring extension not a wobbly.
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Old 03-14-2012, 09:06 PM   #6
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You are going to want a spring extension not a wobbly.
spring extension, I don't think you can get the torque I need to break the bolt loose with a spring
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Old 03-14-2012, 09:23 PM   #7
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Flex sockets are available many places (Lowes, Home depot, Auto Supply, Sears, Farm stores, etc.). Come in both american and metric sizes. Single sockets or sets. 3/8 or 1/2 drive. They also make flexable joints that go between the ratchet and a standard socket

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Old 03-15-2012, 06:56 PM   #8
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Flex sockets are available many places (Lowes, Home depot, Auto Supply, Sears, Farm stores, etc.). Come in both american and metric sizes. Single sockets or sets. 3/8 or 1/2 drive. They also make flexable joints that go between the ratchet and a standard socket

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I have some U joint sockets, they do not fit in the space allowed, I bought a 1/4 inch wobble extension, I will connect a 1/2 inch small socket and try to get it in there and get that bolt off
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Old 03-16-2012, 02:39 AM   #9
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I suspect that most often the entire gennie has to be dropped to work on them with any ease. Ours will drop down and forward to access the back.
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Old 03-16-2012, 05:46 PM   #10
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I suspect that most often the entire gennie has to be dropped to work on them with any ease. Ours will drop down and forward to access the back.
I made my own tool and it worked, I took a 1/4 inch drive by 1/2 inch socket and ground it down to almost half it's size, combined that with a 1/4 inch wobble extension from harbor frieght and I got that last bolt out. I took the starter to the Generac dealer and they fixed it for 31 bucks, now the issue is to get it back in. No one around here has a 1/4 drive by 1/2 inch flexible socket not even Sears, so I made it work.
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Old 03-20-2012, 03:39 PM   #11
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I made my own tool and it worked, I took a 1/4 inch drive by 1/2 inch socket and ground it down to almost half it's size, combined that with a 1/4 inch wobble extension from harbor frieght and I got that last bolt out. I took the starter to the Generac dealer and they fixed it for 31 bucks, now the issue is to get it back in. No one around here has a 1/4 drive by 1/2 inch flexible socket not even Sears, so I made it work.
Got the starter back in,m I installed the easy to reach bolt and my wife with her small hands and my home made special tool got the hard to get at bolt in. ONLY TOOK HER ABOUT A MINUTE
It's starting and running good again
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Old 03-20-2012, 04:11 PM   #12
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Got the starter back in,m I installed the easy to reach bolt and my wife with her small hands and my home made special tool got the hard to get at bolt in. ONLY TOOK HER ABOUT A MINUTE
It's starting and running good again
Good work! There's an immense satisfaction to diagnosing a problem, overcoming difficulty and, in the end, fixing it. Be sure to place your unique self-made tool someplace special so should you need it again it's right at hand.
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Old 03-20-2012, 08:42 PM   #13
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Good work! There's an immense satisfaction to diagnosing a problem, overcoming difficulty and, in the end, fixing it. Be sure to place your unique self-made tool someplace special so should you need it again it's right at hand.
That is not how it works. You place that special tool someplace special and 4 years later when you need it, it is right where you put it. But you don't remember where that is.

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Old 03-20-2012, 08:51 PM   #14
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Excellent, good work!
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