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post #1 of 28 (permalink) Old 03-04-2010, 02:41 PM Thread Starter
 
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Anyone replace starter gear/intermeadiate gear?

It sadly appears the starter gear/intermeadiate gear is toasted on my Revolt. I pulled the starter and can clearly see at least half the teeth are gone from the gear. Has anyone had the side cover off to perform this repair yet?
Oh yeah, the motor only has 15.5 hrs on it!

2007 Revolt
2 Honda Pilots
KX500
YZ250
2002 CR250
Polaris 500 4x4
DRR 90cc mini,xr50
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post #2 of 28 (permalink) Old 03-04-2010, 03:34 PM
 
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Re: Anyone replace starter gear/intermeadiate gear?

any pictures?
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post #3 of 28 (permalink) Old 03-04-2010, 07:36 PM
 
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Re: Anyone replace starter gear/intermeadiate gear?

Yes Many times!! It is a common problem that is associated with the cold start map of the stock ECU. it is much too lean and it causes the motor to kick back on the first fire of the motor. I would extremely advise that you fully dissessamble the entire motor. This is a dry sump motor that has many oil squirters that percisely oil important engine parts. If one of those oil passages gets any fragment in it is will certantly cause a seizure. I have seen this quite a few times. The gear is overhardend and has become brittle. This a is manufacture default, as is the cold start map of the Ecu. Hope this Helps. Thanks, Mark Queen
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post #4 of 28 (permalink) Old 03-04-2010, 08:03 PM
 
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Re: Anyone replace starter gear/intermeadiate gear?

So was this a recall? How can they be sold with a common problem that leads to motor failure?
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post #5 of 28 (permalink) Old 03-04-2010, 08:18 PM Thread Starter
 
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Re: Anyone replace starter gear/intermeadiate gear?

Quote:
Originally Posted by Queen Racing View Post
Yes Many times!! It is a common problem that is associated with the cold start map of the stock ECU. it is much too lean and it causes the motor to kick back on the first fire of the motor. I would extremely advise that you fully dissessamble the entire motor. This is a dry sump motor that has many oil squirters that percisely oil important engine parts. If one of those oil passages gets any fragment in it is will certantly cause a seizure. I have seen this quite a few times. The gear is overhardend and has become brittle. This a is manufacture default, as is the cold start map of the Ecu. Hope this Helps. Thanks, Mark Queen
Queen Racing
So, the area under the side cover and the bottom pan on the motor are not 2 separate areas? The guy at Redline went over what needed to be done and he never mentioned pulling the entire motor? I was also told after 6 months Im on my own. My Revolt was bought 7 months ago haha.

2007 Revolt
2 Honda Pilots
KX500
YZ250
2002 CR250
Polaris 500 4x4
DRR 90cc mini,xr50
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post #6 of 28 (permalink) Old 03-04-2010, 08:44 PM
 
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Re: Anyone replace starter gear/intermeadiate gear?

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Originally Posted by lutrev View Post
So was this a recall? How can they be sold with a common problem that leads to motor failure?
I guess Toyota might have the answer for that one. No it is not a recall.
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post #7 of 28 (permalink) Old 03-04-2010, 08:49 PM
 
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Re: Anyone replace starter gear/intermeadiate gear?

Quote:
Originally Posted by zaniac View Post
Quote:
Originally Posted by Queen Racing View Post
Yes Many times!! It is a common problem that is associated with the cold start map of the stock ECU. it is much too lean and it causes the motor to kick back on the first fire of the motor. I would extremely advise that you fully dissessamble the entire motor. This is a dry sump motor that has many oil squirters that percisely oil important engine parts. If one of those oil passages gets any fragment in it is will certantly cause a seizure. I have seen this quite a few times. The gear is overhardend and has become brittle. This a is manufacture default, as is the cold start map of the Ecu. Hope this Helps. Thanks, Mark Queen
Queen Racing
So, the area under the side cover and the bottom pan on the motor are not 2 separate areas? The guy at Redline went over what needed to be done and he never mentioned pulling the entire motor? I was also told after 6 months Im on my own. My Revolt was bought 7 months ago haha.
No it is all open to eachother, it flows directly into the low pressure oil pump. one piece in the low press pump and the motor will not suck oil out of the sump tank and you will seize everything up. I am not trying to scare you, I just dont want you to be underinformed. Please dont hesitate to ask questions, I may be slow to answer, I am very busy now. But I will help you out.
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post #8 of 28 (permalink) Old 03-04-2010, 09:14 PM
 
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Re: Anyone replace starter gear/intermeadiate gear?

So are all revolts ecu mapped lean for starting,or was this corrected, and how can you tell? They are easy to remap if you have the proper programs, so I just find it suprising when your reply was "Yes many times" on replacing the starter.
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post #9 of 28 (permalink) Old 03-04-2010, 10:30 PM
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Re: Anyone replace starter gear/intermeadiate gear?

Quote:
Originally Posted by lutrev View Post
So are all revolts ecu mapped lean for starting,or was this corrected, and how can you tell? They are easy to remap if you have the proper programs, so I just find it suprising when your reply was "Yes many times" on replacing the starter.
Redline sent out a bulletin I believe in July of 2008 ( I don't have my bulletin in front of me to be exact) to address the ecu map issue along with check engine light problem that would come on when there was nothing wrong. It is isolated to the 2007 models. The factory told me the the 2008 models and on have the corrected mapping. One of the indicators that you car has been done is that the wires behind the dash for the check engine light are hooked up. They weren't hooked up originally because of the check engine light issue. If you find them un-hooked, hook them up; Light Blue to Black and Pink to Red. Turn you car on and if the light blinks your ECM needs to be flashed.

Now, not to confuse anyone, but there was actually two ECM updates for the '07. The first one fixed the cold start but not the light. Around the fall of '08 they got the programming fixed to make the light work correctly. So, it is possible to have a an updated ECM for the cold start but not the light. Check out the wires!

Mike

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post #10 of 28 (permalink) Old 03-05-2010, 02:43 AM
 
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Re: Anyone replace starter gear/intermeadiate gear?

Man, I hate to hear a new revolt owner is having all of these issues. You did just buy this used right? It really hurts the perception of these machines. I have an 09 and the yellow light is coming on when I start mine. When I sent it up to wastelend during loading I noticed it came on and did not go off. Now I am scared!!. Hopefully when it comes back the problem has vanished.



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