Powerlite starter motors

[Stevedavies]

Decided to upgrade to a Powerlite starter RAC303 for my e type. Starting was accompanied by occasional grinding of metal and general horrible noises. Got worst until eventually starter just spun with no engagement.

Removing starter found damage to face of ring teeth. It seemed the Powerlite motor was only just engaging with flywheel (guess 1mm). Starter wore this down until no engagement.

Powerlite pinion throw is 30mm, they also recommend using the spacer fitted to original starter. This only gives approx 26mm of throw to flywheel ring.
Lucas starter is approx 40mm throw, minus 4mm fir spacer giving 36mm throw. Ie 10mm difference than Powerlite.

If you are fitting an RAC303 (as recommended by Powerlite) unit to your car, do not use the original spacer (despite being told by Powerlite it is neccessary). Even without spacer, engagement will be minimal and in my experience damaging to flywheel ring.

You need more throw than the RAC303 can give (certainly from the measurements I took )

[mgcjag]

Hi Steve....what model car do you have...please try to put it in the signature area........what Bellhouseing and flywheel do you have fitted........the 303 has a 29mm pinion.....and is deffinatly not to be fitted with the original spigot plate (Spacer).....i discussed this in depth with Powerlight tech......Steve

[Stevedavies]

Steve, I also had extensive discussions with Powerlite over last 2 weeks and they were adamant that the spacer WAS required, they said if it was on the car originally then it was needed for their unit. It didn’t make sense after taking measurements.

I read your comments on forums etc re the spacer and it agreed with my findings and experience. Unfortunately Piwerlite we’re saying the opposite!! I ended up sending them both their unit and my original Lucas starter.

Only then did they change their stance. They told me to fit an RAC300 starter which had a longer pinion. I then pointed out that the electrical connection were wrong for the RAC300 as they were to close to block.

They then suggested removing the spacer plate!!! Even with spacer plate removed I don’t thing the engagement with Powerlite unit is good enough. It has already damaged my starter ring. I won’t risk using ut again. It’s going to be a paperweight from now on.

I have an all 4.2 set up, bellhousing, flywheel and starter

[mgcjag]

Hi Steve......im contacting Powerlite to discuss as there is conflicting info re fittment......as with all aftermarket products its really down to us to ensure that they fit correctly and work as we expect without just relying on what were told to fit.......i have know parts to be supplied with incorrect part numbers. ......Steve

[Red Kite]

Thanks Steve.

I'm following this. as i fitted an RAC303 with the spacer, as advised by email directly from Powerlite.

[mgcjag]

Have discussed this RAC 303 issue with the tech guys at Powerlight.....a couple of years ago they said no spacer.(i have it documented)..today they said fit a spacer.......i wasnt happy.....its now refered to their design team so awaiting an update......personally i wouldnt fit one anyway without measureing the starter pinion throw and my bell houseing to flywheel space.....and ensureing i know exactly what flywheel and bellhouseing i have and not just assumeing it was a 4.2 setup just becaus i have a 4.2......bellhouseings, gearboxes, flywheels get changed over the years so knowing what you have to start with is a must.......Steve

[Stevedavies]

Gerry, in my case the RAC303 was only just engaging and after a short period of time shaved the face of the flywheel ring and as a result no engagement was possible, all with spacer fitted.

If you hear grinding/ unusual noises at start up then I would refit with spacer removed.

I took the decision to refit an original Lucas starter. In my case even with spacer removed then there would be best case 4mm of engagement. Typical starter engagements for a 13mm wide ring is 6 to 8mm. So I didn’t think the Powerlite engagement was enough.

It’s a paperweight now

[Gfhug]

Have discussed this RAC 303 issue with the tech guys at Powerlight

Steve, thanks for taking up the task of trying to sort out this issue. I may need the answer to this in a year or two, so I very much appreciate the time and effort you put into getting the definitive answer on our behalf.

Geoff

[mgcjag]

Steve...have i read your post above correct. .....you have fitted an original starter with no spacer?.....not sure this is the best option.....what bolts have you used to secure it?.....the original bolts should go tnrough the spigot dowls and thread straight into the starter......with no spigot dowls there is possible room for tbe starter to move.....Steve

[Stevedavies]

Steve, no original starter fitted with spacer as per original set up

Steve

[mgcjag]

Hi All......just for info.....Powerlite have read this thread and are still looking at the issues......so will post an update as soon as i have one.....Steve

[Stevedavies]

They should already have all the relevant information. At my request I sent them both their RAC303 and my original Lucas starter. Thus gave them the opportunity to measure both units on the bench. I assumed they did this and came back to me and told me to remove the spacer plate. For me the (best case) 4mm engagement was not enough ( the Powerlite unit was no longer engaging at all due to the ‘shaving of the front of the ring teeth).

Steve

[mgcjag]

Hi Steve....Just to be clear iv contacted Powerlite to get some definative information on installing their starter into E types.......Im not getting involved in your discussions with them or the fit of what was supplied to you and how it was fitted.......Steve

[Petet]

Hi all, I too fitted this starter and quickly realised it wasn’t going to work without some fettling. These are the problems,

1. Original spacer must be removed for the reasons already stated
2. The alignment dowels must be ground back not removed. If you remove them the hole is to big for the bolts.
3. The 3/8 bolts supplied are way to long.
4. The trigger wire connector needed to be changed to a smaller size.

Apart from that it works fine. I contacted powerlite and informed them of these issues. They agreed to make changes to the product to make it an easier installation. Nice people to deal with which always helps. Hope this helps.

Regards, men in sheds

[chrisfell]

This problem comes up often on these forums. One thing we all must keep in mind is that our cars to 61 years old, and have had many owners, including some, more or fewer, who have not maintained the car well or to its original specs. In my case my 1967 S1 4.2 has an engine from a DS420 saloon and a flywheel and clutch not fitted to E-Types in 1967. Knowing this I was careful to check and measure the throw out of the new starter when I fitted it.

I do this for all replacement parts as I cannot be sure that what I take off originally came from the factory on this car.