Coleman Mini Starter Problem - Won't Stop!

John LaBarbera · Joined: 23 Dec 2012 Posts: 14

I have a brand new Coleman Mini Gear Reduction Starter. The switch box which is the ON button for this starter provides a circuit break, so the starter will not run unless you press the button close the circuit to the ground to the steel frame.

PROBLEM - It seems when the battery starts to lose some charge, this ON button switch stops working, and as soon as you connect the switch up the starter runs without pushing the ON button. I charged up the battery and it stopped but not long after just a few uses it had same issue. I replaced the switch just a few days ago with a new one provided by Coleman via BMI Karting, same issue. I guess I need to make sure the battery is good but it's also brand new...bought the whole thing in January this year...

Anyone had this issue....???

Jeff DeMello · Posted: Mon Feb 18, 2013 7:26 pm Post subject:

Sounds like you have a short to ground
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Jeff DeMello
Emmick F125 Pavesi

Brian Degulis · Posted: Mon Feb 18, 2013 9:21 pm Post subject:

Yes What's happening is the contacts in the switch are arcing and getting stuck together. You may have a bad motor that's drawing to much current or a bad battery. Or whatever your using it on is to much for it. That switch is not so good I use one to start a CRF 250 on the axle so the load on the starter is very high. I had to replace that switch with a regular heavy duty solonoid.

Brian

John LaBarbera · Joined: 23 Dec 2012 Posts: 14

I just replaced solenoid with brand new one, seems like it would have lasted longer...I'm starting a Leopard...just spun it a few times...I think I'll try the battery next....and test a different solenoid....I hope it's not the motor, brand new,,,hard used....thanks guys

John Matthews · Posted: Tue Feb 19, 2013 7:08 am Post subject:

If it's brand new contact the manufacturer or retailer you bought it from. Lots of things have a warranty UNTIL you start fixing them yourself Wink

Cheers,
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John Matthews
Heartbeat Power, LLC.

Tim Koyen · Advertiser Joined: 26 Nov 2002 Posts: 1556

I had the same problem. Apparently the solenoids they are using now can be too easily overtightened and it causes arcing. On the ones I had, just backing the nut down a bit cured it.
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John LaBarbera · Joined: 23 Dec 2012 Posts: 14

Spoke with Coleman rep in Colorado, he says some of the solenoids appear to have manufacturing error causing the height between the switch contact point to be too close, causing arcing. Even in the brand new solenoids. They need better quality control on this! He is sending me a thoroughly inspected new solenoid, we will see!

John Matthews · Posted: Wed Feb 20, 2013 10:32 am Post subject:

Coleman has been in the biz for a long time and I'm sure they're working hard to fix their supplier problem.

I always like to give the manufacturer or distributor the chance to take care of any problems before I look to the Internet, none of us are perfect 100% of the time but given the chance most companies will do what it takes to keep their customers happy Very Happy

Cheers,
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John Matthews
Heartbeat Power, LLC.

Brian Degulis · Posted: Wed Feb 20, 2013 7:34 pm Post subject:

The design could be improved. It looks like they're using an ordinary solonoid and just putting a push button on top. If that's what they're doing it's a week spot. Those contacts are meant to be closed by an electro magnet which is much faster and more positive than a manual button. The slower weaker closing of the contacts leads to arcing and welding of the contacts.

Brian

John Matthews · Posted: Wed Feb 20, 2013 7:45 pm Post subject:

Brian Degulis · Posted: Thu Feb 21, 2013 5:45 am Post subject:

If you strain or overload one like I do starting a CRF 250/450 from the axle you find the week spot that's all I'm saying.

Brian

John Matthews · Posted: Thu Feb 21, 2013 7:47 am Post subject:

Brian Degulis · Posted: Thu Feb 21, 2013 8:18 am Post subject:

You bet I remember starting the mac's we used a starter mounted to a hand truck and a belt. Lean it back hit the button and off it goes.

The CRF's are 4 stroke shifters so there is no acces to the crank shaft plus there are a bear to start. It can be done with a belt but it really takes a lot. Push starting is also very difficult. This actually works pretty well but I had to replace the original switch with a magnetic actuated solonoied.

There is a modification that can be done to get acess to the crank shaft but it involves modifing the case. I will do that one day and that will make it much easier to start plus I'll be able to try a slipper clutch.

Brian

John LaBarbera · Joined: 23 Dec 2012 Posts: 14

Go the new solenoid in....works great now....again for everyone's benefit a recap....

Bought the mini gear reduction from Coleman

Worked great for a few weeks, but starting running without the start button being pushed

Contacted supplier (BMI Karting), they sent me a new solenoid....same thing happened after one or two uses....

Contacted Coleman direct in CO, they admitted they were having quality issues, contacts in solenoid were not far enough apart, causing arcing, they double checked the spacing between the contacts, and sent me a new one...(my third)....working fine now....fingers crossed

John Matthews · Posted: Sat Feb 23, 2013 4:38 pm Post subject:

Happy to hear you got it fixed, I'm sure it will give you many years of good service Very Happy

Cheers,
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John Matthews
Heartbeat Power, LLC.