March 2024

When trying to fit the starter motor I encounter a new challenge with the transaxle.
The starter motor supplied from Ultima appears to be the correct one for G50/52 transaxle. The end of the shaft should insert into bearing in the bell housing part of the transaxle. My transaxle appears to have had this part removed from the housing so instead of a small bearing, there is a hole about 50mm in diameter.

Missing Bearing    Bearing    Bearing   


The starter motor being unsupported at the far end can move about and jumps out of engagement with the ring gear.
I run through ideas in my mind, such as build the hole up with aluminium weld and machine a hole, but it would be challenging to accurately locate the hole, and my milling machine would be too small to do the job. Other ideas were along the lines of machine a block of aluminium with the correct size bearing hole and then gradually reducing its size until it would fit in the hole, it could then be welded in placed and blended in with carbide burrs, files etc.

Looking around the internet I found a high torque starter motor from Heritage Parts Centre. This was not that cheap, coupled with the fact I also paid a fair bit for the one from the factory. I take some measurements and Heritage confirm that this should be fine for the G50/52. This starter has a much thicker shaft section and does not need or use the end bearing.

Measure Starter    Measure Starter   

 

When fitting it though it appears that shaft touches the outer edge of the clutch. I verify this by the use of a mirror and torch.
I decide that there should be enough material to allow me to machine part of the shaft housing down.
I make a bracket from a piece of cast iron salvaged from an old washing machine, this bracket was then secured to the mill table and the motor bolted to it. A machinist's jack was then used to support the shaft. I gradually mill a flat on the side until the housing undercuts the gear teeth.

 

Machine Starter   

 


Once reinstalled I can easily tighten the securing nuts and see a clear gap between starter motor and clutch. Connecting a battery to the starter confirms it can turn the engine over.