XJ550 starting solenoid just clicks

:?: I have a 82' Maxim XJ550 and I am having a starting issue with the bike. Whenever I press the starting button, you can hear the solenoid click and sometimes you can hear a whining noise where the motor is trying to start, but it won't turn over.
I have check the battery and even replaced it and that is not the problem.
I have check the starting solenoid according to the service manual that I have and it checks out okay.
I have took apart the motor starter and cleaned it and it spin pretty freely.
I was going to look at the starting relay but I am unable to locate it and I do not know what it looks like.
I believe that it may be either the starter relay or the igniter unit assebley but I am not for sure.
Any help would be greatly appreciated.
Thanks

 

Welcome to the fold Burhanwr, glad your here. I'm not a 550 expert but it sounds like you've covered the bases. I can only see one other facet you might want to look at. Check the resistance of the supply lines between the battery, the solenoid, and the starter motor. You shouldn't see more than 2 ohms on any line, more indicates corrosion resistance and should be replaced.

 

short the large 2 teminals on the relay with a screwdriver and that will let you know if the starter motor side is ok....

 

If shorting the two contacts on the starter relay doesn't work, check the negative (black) ground strap that goes from the negative battery terminal to the engine block. If this is lose or corroded, it will often times give you the exact same symptoms you are experiencing.

 

I took the motor starter off and jump started it with some jumper cables from the car battery and it seems to fire okay. I then put it back on the bike and I got the same result as before, just a click from the starting solenoid. I then tapped the motor starter and then it would try to turn over. I took the motor starter apart again and found that the brushes were gummed up again. I tried to built a working one from both starters and was able to finally to get the bike to start again but once it was warmed up, I could not get the starter to turn over again; just the clicking from the solenoid. Going to order a refurbished motor starter with a one year warrenty to see if that helps solve my problem.

 

You may wish to check for a rebuild kit and/or new brushes. There are a few threads on the forums of folks who have done it and their sources for these parts. I would search them out first before you part with a paycheck for a new one.

 

Fork out i you want to , but possibly a easy fix , one is supposed to emery [or sandpaper] the commutator where the brushes run and check the depth of mica spacers and then the brushes need to be a required lenght [in the book] , maybe all it needs....

 

I have taken my starter apart - a complete disassembly, and cleaned the commutator, measured the brushes, etc. It is very easy and would save you a lot of money. Again, did you check the ground strap to the engine?

 

I had the same issue with my 550 and it turned out to be two problems. One was worn out starter motor and the other was battery.

Battery charged nicely and held 12 volts but was dead under load. That and a starter that had worn brushes meant a no go.

Replaced the battery and went down the wreckers and found a good starter from a kwaka donor. It had good brushes and armature so I just swapped the end plates.

Starter solenoid rarely goes bad, usually problems in that area are just corroded terminals.

Check out this thread. http://xjbikes.com/Forums/viewtopic/t=6 ... tsuba.html

 

Thanks everyone for the help and the information, I really appreciate it. This is my first bike and I never worked on one before…learning mechanic.
I did check the wire connections on the bike and cleaned the area were the ground is terminated to the engine and to the battery case. May go back and put some dielectric compound on them.
I did not think it would be the starter since I just replaced it. It ran okay for a couple of weeks and then I started having the problem with the bike not turning over when it was warmed upped, just the clicking of the starting solenoid.
I had bought a starter from a salvage yard a couple of months ago because the original starter was dead. I bought a used starter from a salvage yard to replace it with the original and I figured that I would be good for awhile (got burnt instead, it did not even have the dust cover gasket on it).
Before I received the used motor starter from the salvage yard, my father-in-law and I took apart the original starter and inspected it. The brushes were covered with a lot of grease/oil. Not sure how the grease/oil got back there expect maybe from the gear housing and the grease getting to hot and working itself back there. We got the gunk off it as well as cleaned the brushes with carburetor cleaner and then I had no problems with the motor starter turning over. After a couple of weeks, that is when the starter would not turn over when the bike was warmed up. That is when I replaced the original starter with the used one. Before I installed the used starter, I took it apart and cleaned it before putting it on the bike (with cleaning solvent and made the mistake of cleaning the brushes with the solvent as well). All was good but short lived. When I took it apart the original the other day, noticed is was gummed up again with grease or oil. Tried to make one good one from both starters, was short lived. The lesson that I learned was not to use chemicals to clean the brushes, I believe that they are too saturated and ruined from the chemicals. They will be good for spare parts now.
I thought about getting new brushes and contacts for the starter and found some for around $38.00 on the internet, but I figured that I would need new dust cover gaskets for the outside of the original starter as well because they were over stretched and did not fit properly anymore (not sure if I really need them or not but I am anal about stuff like that). Anyhow the gaskets are about $16.00 apiece so I was almost at half the price for the refurbished starter and I get a one year warranty with it.
Again, I appreciate everyone for their input and time. I am finding this a good web-site for XJ Maxim oweners.

 

Yep, those gaskets are important. Mine was getting oil in it too.

Basically if the gaskets are worn backpressure from the engine alloew fumes to vent through the starter gumming them up. I think this is maybe a problem with the Mitsiba starter on the 550's as nobody with a nippon denso(650,750) seems to have the same problem.

I replaced my seals with tight fitting o-rings found in a truck mechanics huge box of spare o-rings.

Also check your engine crankcase breather for blockages.

New brushes would be a good investment along with the seals.

Depending on the chemicals you use, you can still give them a good clean.

I used WD40 and degreaser followed with a good dry with compressed air and never had any problems.

If you put new brushes in then pick the best armature/comutator from your spares and make sure the grooves in the contact surface are clean.

Hope this helps.

Cheers
HG

 

I had the same problem with my 700. It turned out to be a bad cable from the battery. Replaced both cables and have not had a problem since.

 

oil soaked brushes , leave in a tin of acetone [spelt right?] or carb cleaner , or even petrol for awhile and they will be ok...

 

Sorry it has taken me a while to reply back, work requires traveling and that is what I have been doing for awhile. Finally got the re-built starter, thought it was wrong but just the gear on the end was missing. I put the new starter in and it sounded strong and the XJ550 started once she was primed up. The bike starts quick now and usally on the first time. I no longer have problems with it not starting when it is warmed up either. Definitely the starter. Had a chance to ride it a couple of times when I am not traveling on the road for work.
I want to thank everyone for their input and help. I really like the XJ550, it is a nice looking bike.
I bought a sissy bar on Ebay for it and at some point I would like to get a luggage rack for it. I seen them on Ebay every now and then but that is about the only place I can find them.

 

had this problem solenoid just clicking. at first thought the battery was not holding enough charge. then I read this post. I took my starter apart and it was full of carbon build up, completley filthy. Gave it a good cleaning. one brush looks a little worn but put back together and it started right up. Once again this site saved me.