xj550 Starter Motor

I just bought this xj550 last night for a good deal. The guy said the petcock leaked all over the starter and ruined it, so it just needed a new petcock and a new starter. I have the old starter and I took it apart to see what was wrong. First thing I noticed was that it was FULL of grease. My experience with a couple starters in the past has been that they're dry systems (which is why you don't want to be cranking on the starter for 10 minutes as it could overheat). Am I wrong on this one? Should it be loaded with grease?



I started wiping down the parts a bit to see if I could clean them up. They've still got a ways to go, but they're looking better:



So if this starter DOES need grease, what kind? And should it be only in the front end, not back by the brushes? or What?

Thanks!!

 

I just did my 550 Maxims starter a few months ago so I can help you with this.
Actually, it looks like somehow some water got into the starter (maybe from washing with a spray hose) through the end seals. I had to replace mine, although they looked fine, they had expanded and no longer sealed the casing closed. These 2 seals are pricey but a must. Check yours closely.
Measure your brushes, there is a post in the forum with brush specs that you can pull up or look in the Yamaha manual (I am on the road currently and dont have the info with me or I would give it to you.) Replace if needed.
Len at XJ4Ever.com has the grease you need for the starter and the chassis. The brush end cap bearing gets a dab, and the planetary gear system gets a liberal coating. On the other end cap... if you washed the snout in solvent with the gear end, then you need to pull the snap ring and grease the shaft as well or it will self disintegrate with time.
Spray electrical contact cleaner works great for cleaning brushes and plates.
Otherwise, all of your parts look serviceable, although I might polish the copper contacts a smidge with some fine sandpaper 800 grit.
Use loctite red on your bolts so they don't loosen up when reasssembling.
Make sure you put your brushes in exactly as they came out of the starter or it will run backwards.
Pay careful attention to the parts diagram when reassembling, spray your armature windings with WD-40 to clean and lubricate, as well as your brush holders, and your starter should be set to go for many years.
You can also do the armature resistance checks if you like, but your armature looks fine.
Grease, 2 seals, and brushes if needed, with some loctite red. That should get your starter going. (and if you have acess to a 12v car battery do a quick check with jumpers before you install it just to rule out other unknown issues with the bike) Len has everything you need. Any questions just ask.

 

Wow, that is some very thorough and amazing information! Thank you! Looks like I'll need to pick up a couple things before I can put it back together. Thank you, thank you! I'll update you after I've finished the restoration!