In some cases, engine kickback will fracture starter drive gears. Kickback is related to engine set up and can be anything from incorrect timing to problems with the fuel system. If kickback is noticed as a common occurrence on the airplane, diagnose and repair the problem or the replaced starter drive may fracture again. Many of Sky-tec's current starters offer kickback protection.

This condition is related to the starter drive extension and retraction and affects all styles of starters. If, during normal extension, the gear does not extend completely, stress will be placed on the drive gear. If the starter drive does not disengage after start, the engine will tend to drive the gear placing stress on the gear and destroying the motor. In either case, the gear will rapidly wear or fracture.

Sticking mechanical starter drives, e.g., Bendix drives, should be cleaned with mineral spirits and only lubricated with silicone spray. Oil or common greases should not be used as they will attract and retain dust and grit causing the starter drive to stick or wear rapidly.

Solenoid-actuated starters do not require any type of cleaning or lubrication. If the starter is not going to be used for some period of time the shaft can be oiled to prevent corrosion.

There are two potential causes of this condition. If it is a mechanical starter drive (Bendix) and sticks intermittently, it most likely needs to be lubricated. This type of starter drive is initially lubricated to allow smooth operation. The drive gear must move in and out and also rotate. In use it can become dry and may begin to stick and fail to engage or disengage. We recommend lubricating this type of starter drive every fifty (50) hours of operation.

The other likely factor for intermittent engagement would be a faulty starter contactor. If you want to check a contactor, it is best to do so with a load applied. Resistance in the contactor, even a fraction of an ohm, is enough to produce poor or no operation due to the high current field. In a 12-volt starting circuit drawing 60 amps, for example, the addition of 0.2 ohms of resistance due to an oxidized connector or carbonized contact may drop the current to the load to 36 amps. This is a 40-percent loss in starter operating power caused only by a 0.2-ohm resistance.

Checking the circuit without a load would require that a lot of resistance be placed in line. The best method of checking the contactor is to disconnect the lead from the starter and connect it to a battery load-meter tester. Activate the contactor and check the voltage on each side of the contactor. A 0.1-volt drop is normal for a new or nearly new contactor. If you find any more than 0.3-volt drop, replace it.

This is normal for a permanent-magnet starter. Although power is removed by releasing the key/start button, a permanent-magnet motor will actually provide power to itself as it winds down and will keep the starter drive engaged for about a half-second until it loses sufficient RPM to fully disengage.

THIS CAN BE A DANGEROUS SITUATION. The starter contactors in many older aircraft may become welded shut after years of use. BE EXTREMELY CAREFUL. A starter contactor that is welded shut could cause the propeller to rotate when the master switch is energized, regardless of the position of the start button or switch. Replace the starter contactor. Your starter may have been damaged by this as well and may also need to be overhauled or replaced.

Lightweight starters do not have as much housing bulk surrounding them, so they aren’t as effective at insulating the gear train noise from the operator. To compound the issue, switching from a legacy heavyweight starter to a lightweight starter may also change the design style from a direct drive to a gear reduction drive in order to obtain the same drive torque. Gear-reduced starters have a much different noise signature than direct drive starters.