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Starter or Battery Problem

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TxSkyBolt

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At the conclusion of the recent condition inspection on my Skybolt (IO-360, odyssey PC680P behind the rear seat, B&C starter) I started the plane successfully. Had to shut down for an issue with one of the mags and restarted no problem. Shut down again and when I tried to restart, it sort of "kicked-back" and I immediately stopped cranking. A few seconds later I tried again and the starter ran, but the starter pinion wouldn't extend.

Removed the starter and took to an auto electric place and it bench checked just fine with starter pinion extending correctly.

According to the B&C starter trouble-shooting guide, the contacts can stay shut due to low voltage, causing the pinion to stay retracted.

My mechanic checked the voltage at the end of the wire (at the starter) and was seeing 9.5 volts. The battery was installed new just 25 months ago and the specs on their website call for an 8-10 service life. The TS guide says a minimum of 8.5-9 volts at the starter is required to operate.

I went ahead and ordered a new battery. I plan to measure the voltage at various points along the starter wiring to see if I'm losing a higher than expected amount of voltage. Might also check the total resistance from battery to starter.

The starter was installed in 1989. I've always experienced a little bit of difficulty in starting the engine. Seems it often gets hung up on the compression stroke and the starter cannot turn the engine. I sorta have to bumb the ignition switch to get it to go past that point, at which time it normally spins rather well.

Other than all that, is there anything else I might want to check?
 

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