Another possibility for those with starter clutch issues...

I have been contemplating a starter clutch replacement for a while now. Standard symptoms, started fine cold but sounded like a jar of marbles when cranking hot. Usually meant I'd be bump starting if it wasn't the first start of the day. I had read and followed every single post on here about what to do BEFORE attempting that but nothing seemed to help me. I tried:

- Short oil changes with correct oil
- Brand new battery, fully charged
- New solenoid
- Starter button cleaned
- can of Seafoam in crankcase, run for 10min, then oil and filter change.
- Overhaul of starter (new brushes, cleaned and re-greased everything) (did this BEFORE bike was ride-able)

Today it hit me, I used an ebay starter motor rebuild kit that came with slightly different 'fittings' on the bolt that goes through the casing that provides positive voltage when engaged. I was probably rushing through the job and didn't think things through. You can see where this is going. I pulled it off the bike and sure enough the insulating washer on the outside of the casing was not providing enough insulation. That nut was within 0.1mm or less of touching the casing of the motor. I guess this somehow pulled enough juice from the starter to cause my issues, but not enough to cause the motor to not work at all. Went back into my bag of old parts and changed back to the original plastic pieces and washers. Problem fixed.

Now, maybe I am the only one here that is dumb enough to not realize that the positive input should probably be well insulated from the negative casing, but in case there are others that share my affliction, I hope this helps!

Lessons learned:
Order only from a reputable and knowledgeable parts dealer and think things through! Don't just disassemble and reassemble, take the time to learn HOW a part does what it does.

Thanks to everybody here for doing what you guys do. I have had an absolute blast riding and working on this bike.

 

Why go any where else?

http://www.xjbikes.com/Forums/viewforum/f=23.html