Weird starting problem

[KevW]

The Excel has a problem with the first start up of the day..

I turn the key and the starter begins to turn the engine over normally but with 2 seconds there is a loud thump as if someone has stuck a spanner in the works and everything stops dead. If I turn the key again the starter begins to spin very, very slowly and usually after about five seconds it suddenly bursts back into life, turns the engine normally and the engine starts. For the rest of that day the car will start on the button.

Occasionally if I go out in the morning to start the car the starter immediately turns very slowly and then groans to a halt. You would think the battery was dead but if I try again a short time later -sometimes as little as five seconds- it will fire up normally and the car will be fine for the rest of the day.

The battery is new and healthy - it would have to be to withstand this sort of abuse. I've taken the starter motor off the car and bench tested it and it seems fine. I had the bendix fixed last year. The teeth on the flywheel look OK and the engine earth lead looks fine too. Ambient temperature has no effect as it behaved the same at -8c as it does today at +11c.

Has anyone got an idea as to what is going on ?

[kent_racer]

Got the same trouble.
Starter was faulty. I buy new light powerfull unit which is delight.
Never got trouble. Start even with a nearly flat battery

[amarshall]

It might be a faulty solenoid with a problem that only shows up under load.

[don.hasi]

Enough oil is in the engine ?

[lasjw]

Hi Kent racer where can i purchase this light powerfull starter unit as my has the same problems?
thanks

[KevW]

Yes, plenty of oil in the engine. I suppose I could take the starter off again and take to over to the auto electrical place for them to test. Thanks for the suggestions

[kent_racer]

Hi Kent racer where can i purchase this light powerfull starter unit as my has the same problems?
thanks

@ kelvedon

http://www.kelsport.net/parts/product_d ... ectionID=5

worth the price...far better than M100

[KevW]

Well to cut a long story short my starter motor is fine. I had taken the car off the road until the problem was dealt with. It appears the starting problem is being caused by petrol pooling on top of the pistons and hydraulicking the engine on start up. Petrol is also finding it's way into the sump which has increased the oil level. No sign of mayo anywhere. I initially thought I was looking at HGF but after chatting to a well known Lotus parts specialist of some repute it appears the problem is being caused by faulty or worn carb needle/s. I've got a bit more examining to do but it looks like a carb re-build is next.

[Lotus-e-Clan]

Eurocarb (google them) sell rebuild kits for DHLAs with the correct sized viton-tipped needle valve for Lotus.

Luckily the petrol never leaked from the venturies to the outside world otherwise you may have had to use the fire extinguisher you always carry stored under the passenger seat....

[kent_racer]

Luckily the petrol never leaked from the venturies to the outside world otherwise you may have had to use the fire extinguisher you always carry stored under the passenger seat....

not never but often...It happens to me. The rear carbs was leaking on my starter motor ... who did not like it ... hence a new one

[steven popay]

isn't the fuel cut off valve supposed to stop that, and doesn't fuel in the oil damage the engine when run?

[KevW]

Fuel in the oil will certainly lower the viscosity Steven. I'm hoping I have caught the problem before it's had any chance to cause damage. The snowy weather followed by me noticing the problem and taking the car off the road means I have done next to no miles of late.

[steven popay]

It might be worth checking the fuel cut of switch in the boot, im sure it is supposed to stop fuel syphoning into the carbs

[KevW]

With the help of my mate I fitted two new float needle valves and seats. The carbs themselves looked in great condition and as clean as a whistle inside. I then changed the petrol contaminated oil.

It appears the problem is being caused by the fact that my drive is on a slight incline and I always park the Excel nose-down. The reason petrol is able to flow under gravity through the carbs is that the car does not have a flowlock fitted to prevent it. I've found if I park nose up everything is fine. Some P.O. or the dealer I bought the car from must have replaced the flowlock with a 5 inch piece of fuel hose. I thought I was being a bit thick and just couldn't locate it. Quite how the car has managed to run perfectly well for almost 4 years before this issue has manifested itself I'm not sure.

I've ordered a flowlock and the car is staying off road until it's fitted. Now I'm hoping no long term damage has been caused by the oil being contaminated and the car hydraulicking slightly on start-up. I took it for a test drive after the oil change and ironically it's never run better. The engine itself sounds as much like a sewing machine as its possible for a 912 to.

I would strongly advise anyone who knows they don't have a flowlock fitted to think about fitting one asap.


I'll post an update when I fit the flowlock - fingers crossed ...

[KevW]

Problem is fixed. Sure enough it was caused by the lack of a flowlock.

I ordered a used one from Lotusbits and it arrived 15 hours after placing my order.