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Old 07-11-2015, 01:22 PM   #1
kgsc
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Join Date: Dec 2009
Location: Aiken, SC
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Default Starting issue with 09 RXV with Kawasaki

Guys/Gals,

Was having issues with my RXV starting in gear. New good battery but just weak. Checked the brushes and they were good. Checked solenoid and it was good. Started searching and heard rumors about people having this issue and the fix was putting a smaller pulley on the starter. The new AMD starters already have it but this is a Hitachi starter which I was told by EZGo those were only on the 08 and early 09s. Was searching EZGo site and found a package that was a pulley and belt. Part number 612031pkg. No real description but made me curious so I called EZGo. I told him the problem I was having and he said I needed a new starter. Asked him about the pulley package and had not heard about it. He looked it up and response was, hmmm, didn't know about that but that is what it for and should fix my problem. Original pulley was 3 inches in diameter and the new one is 2.5. Kit came with a new shorter belt but couldn't get it on with adjuster all the way closed so compared it to the old one and only difference I could see was it was shorter. Installed pulley and put it all back together. Wouldn't start at all.. Hmmm maybe if I hook up the ground to the battery that I had disconnected hooked it back up and hit the pedal. Fired right up in neutral. Now the real test. Put it in gear and again it fired right up. Took it out for about a hour spin with a bunch of starts and stops. Started every time.

So short version
New pulley part number 617172
New belt I didn't need 630857
Package part number 612031pkg $30

Starting problem solved
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