Starter rebuild

I'm in the need of a starter rebuild kit. Any direction on where to purchase one from? The local yamaha stealership wants about $60.00 for the parts I need. (1981 Seca XJ750)

Last night after purchasing new battery & charging it for the recommended 10hrs, I slapped it into the bike and tried to start it..... would turn over 3-4 times starting normally and slowing to nothing... try again and solenoid click, or I'd get some hard to describe noise from starter area. I pulled the starter, disassembled and cleaned out carbon and oil/grease from places it shouldn't have been. Brushes seemed a worn, but I figured I'd attempt not changing them at current time (11pm-pars store isn't open anyhow). Get it all cleaned up and reassembled, reinstall on bike.... hit the starter button.... click and onw the smell of crispy starter parts. Pull it off the bike and disassemble once agian.... one brush and spring partially melted??!! What's my real problem here?? Please help me trouble shoot this POS!!

I should also state that sometimes if I'd tap the starter with a hammer it would than spin/crank again.

Thanks for any help in advance!!

 

Bikebandit.com has the started parts. Also a good exploded view so you can pick and choose just what you need. As far as the melted parts is the new battery the correct size? Too many amps can do some damage.

 

If you have old "Caked" grease inside the Planet Gear end ... that will really slow-down a starter.

That, plus worn-out brushes.

 

Here's my Starter write-up.

Pull the starter. Clean the heck out of it.

After you get it on the bench ...

Two long screws hold BOTH indexed ends to the main body.

Remove the gear end and COMPLETELY clean and re-lube that end.
You'll need to spread one Circlip to get the Planet Main Shaft out.
Keep track of washers and spacers.
Look on the ends of the shaft and inside the housing for thin Thrust Washers that like to stay stuck where they are.

Keep everything in order as you disassemble the Planet end.
Two small Planet Gears on opposed shafts.
The Ring Gear and Main Shaft.
Every Spacer and Thrust Washer.

Clean the "Whole-works" of the "Business-end." All of it so nice and clean a Marine Drill Instructor would have the Company check-out yours as good example.

Check for washers and thrust washers hiding on shafts and bearing ports.

Clean the Electric end; too.

Pull the Case away from the Motor -- slowly.
There's NO slack in the wire connecting the Brushes to the External Power Post.
Slip the Brushes off the Commutator.
Look for a Thrust washer - inside the Case - surrounding the port for the case bearing bushing.

With the starter exploded. Clean.
Use straight Isopropyl Alcohol loaded into a sprayer that has the Stream or Spray option.
("Honey, did you see the Windex. I can't seem to find it.")

Withdraw the Armature.
Spray everything until its completely clean and what you are spraying ON is as clean as what is dripping OFF!

Shoot the Commutator, Brushes, Brush Housing, Electrical Lead and the inside of the Electric end Case. Clean.

Shoot WD-40 on the CLEAN windings and magnets.

Lube the whole-works as you reassemble the Starter.

Using Top Quality Synthetic Waterproof Grease:
Everything and every surface on the Planet - Business End - gets lubed as it's reassembled.
Shafts, shaft bushing ID's, washers, spacers, gears, pivots, bushings, etc.
Grease everything. Either liberally -- for function, or smeared-on for both rotational forces on it ... or, to hold it from slipping as you reinsert bearing shafts into bushed port on the case.

Spin the Planet Shaft after its re-clipped in and grease the rotating Planet Gears -- "On the Fly" ... as they rotate around the inside of the Ring Gear.

Lightly smear washers and spacers on the Electric End ... but, don't allow the grease to contaminate electric connections and Commutator.

Get a dab of grease into the port on the Electric end; and smear the end of the shaft which fits there.

Now, the fun and games of getting the Brushes lifted onto the Commutator and everything lined-up and back together begin.

It's like a Chinese Puzzle.

Only ... "Made in Japan" !

 

Thanks Rick! I'm going to head down to the local electric shop (rebuilds starters, alts, motor, ect) and pick up the parts I need. Just had a coworker remind me of them... I remember now from my last starter rebuild project on an old Honda 4 wheeler that they were alot cheaper for parts needed!!

Thanks for the write up once again!!

Hopefully I can get to it next week, we've got out big Fire Hall spring cleaning this Saturday and annual Pancake feed Sunday.... and some rest I hope, busy/long couple of days!!