82 XJ550 Seca Won't Start

I've been trying on and off for a few months to get a 82 XJ550 to start that I've acquired. No luck as of yet.

-I've fully cleaned all the carbs. They where a mess.
-Pulled the starter and cleaned it. Brushes looks real good.
-Airbox is removed, so it's open carb right now.
-New spark plugs

I tried starting it with this and the starter would try to turn over the motor and then they starter relay(?) would just click, and then nothing would happen. It has a crappy $30 battery so went and bought a really nice gell cell battery.

After install it was really close to starting... but nothing. I charged the battery back up and let the bike sit for a few days. At this point the starter sounded like it was trying to do something for about 3-5 seconds and then the relay just clicks.

Do I need a new starter? What am I doing wrong? I don't have tons of experience with bikes.

 

you can rebuild the starter. could be solinoid did you try jumping across the solinoid?

http://www.xjbikes.com/forums/threads/replacing-your-starter-motor-brushes-w-pics.45727/#post-406938


wiring diagram for you
http://frankjohansson.com/stuff/xj550/XJ550ElectricalDiagram.html

need a manual
https://www.tradebit.com/filedetail.php/237530250-yamaha-xj550-rh-service-repair-manual

more manuals
http://www.tradebit.com/filesharing.php/search/0/xj550

 

This might be a stupid question... but how does that compare to a new/used one. Does it sound like a starter problem? I should mention that when trying to crank it over the starter gets very warm/hot.

 

Try this ⬆. If your bike starts it may be the solenoid. Are the valves in spec? Are you certain fuel is getting to all the bowls? Did you wet set the fuel levels? The carbs must be zestfully clean in order for your bike to start and run properly.

Gary H.

 

First start after rebuilding the carbs: Have you confirmed that the float bowls are full of fuel? Did you set the petcock to prime and let the bowls fill for a few seconds before trying to start the engine?

 

I guess we are just going to throw everything at you.

1.- Do you have spark? check if your new plugs are firing
2.- Do you have gas? like K-moe said check your fuel bowl levels, if they are too low it may not start, if they are too high they will flood the engine (if the oil smells like gas it happened).
3.- It won't hurt to connect a volt-meter to the battery and see what it does when you crank the starter.

 

Have you pulled the starter and inspected it?

 

rebuild kits 20 ~30 dollars used starters 50 ~150 dollars.
starter solinoid 10 ~20$
your bike has a solenoid ,a solenoid is just a big relay it is the thing next to the battery that the positive wire connects to. there is also a relay under the tank.
we do not want you to needlessly spend money.,

so if you have confirmed gas in the bowls by opening a drain screw.
try jumping across the solenoid . the 2 big nuts with a screw driver. its going to spark big.
if your starter spins and cranks the motor showing improvement over using the starter button
you will probaly need a new solenoid. if it sounds like your stater is still dragging (turning motor slow) i would look into a starter.
as suggested hook a meter to the battery and see how low the voltage drops when trying to start it it has to stay above 10 volts goes really low another indication it is your starter.
do you have an auto parts store you trust that tests starters?
tomorrow when I start my bike i will see how hot the starter gets.

 

Yes gas is getting to the bowls.. How do you wet set the fuel level? I tried searching but just got an error.

 

I pulled it originally and it was a dirty mess. the brushes looked good, however the armature looked rough. In did clean it.

 

Yes, I have spark so they are firing.

I am not sure the fuel level in the carbs.. I do know they are getting gas.. just not how much.

I'll check on the voltage when trying to start.

 

can you try bump ( clutch) starting it.

 

so you have not done a wet fuel height test?

I gave you a link to a factory service manual you can down load a pdf file for 10$ if you do not have one you will need one

 

You can start here
http://www.xj4ever.com/setting fuel levels.pdf

 

if the carbs are on the bike you will want to test them first before doing above


bike wants to be on centerstand and level from side to side. to check if bike is level measure the fuel height on both sides of the carb bank for carb one,

 

I'll try to bump start it this weekend. I have a manual already.

I purchased a starter rebuild kit and new starter relay. Should be here this weekend. I'll work on wet setting them.

Will trying to start it will open carbs make a huge difference rather then with an air box installed?

Oh.. I really appreciate everyone's help, Thanks!

 

It does make a difference, as the air box and carb boots control the air volume and velocity into the carbs. This is a biiig part of why pods are a problem on these carbs, Obviously, tuning it in this state would be pointless, as when you put the air box back on, the condition you tuned it for will no longer exist. However (somebody correct me if I'm wrong), if you just wanna know if it'll start, it shouldn't hurt too bad to run it for a short time without.

 

Yes you can start and run your bike with out the airbox or carb boots connected it will run fine throttle up , you can adjust the idle . it will not run that well if you try to run down the road. any adjustments you do will have to be redone after airbox is connected.
the air box set up is what makes the slides in the carb operate the way they are ment to ,as it is the vacuum that makes them rise and fall
try some starter fluid when you bump start it.

and just to check your pilot/air mixture screws are set to 2-1/2 turns open from a light bottoming out?

could you explain brefly how you cleaned your carbs?

 

So with the battery fully charged I tried to start it again by jumping across the starter solenoid. I got no response. Not a click at all.

 

across the large nuts correct, where the battery and starter main wires connect? did you get sparks when you did it? solenoid will not click. the starter should turn unless it is shot.
just for s$g clean your battery ground wire at the frame.

 

this is starter circuit starter button not shown l/w and r/w is the wire to starter bottuo

 

When I touched these two with a screwdriver, there was no spark or noise. There has been previous to this though.

 

your battery connects directly to one of those nuts so with a multimeter check voltage from that nut to ground should be 12 volts then check for continuity between the other nut and the connection on the starter should read 0 ohms. while you are at it check continuity from starter case to negitive terminal of your battery this should read 0 ohms too.
if you have voltage to first nut and continuity to the starter and to negitive terminal of your battery you most likely have a open/ broken wire inside the starter. when you rebuild it you will want to look for that wire, your rebuild kit should fix this problem

if you have no reading to ground negitive terminal from the case it is your ground from frame to battery

 

That ⬆ and you can remove the starter. With a fully charged battery and two jumper wires...jump battery + to bolt through starter. jump battery - to anywhere on the starter case. The starter should spin. Do not let the starter spin for a extended period of time.

Gary H.

 

Got the rebuild kit, pulled it apart and took some pics.
1. It smells really bad like it's "burnt"
2. on the inside of the sleeve there is like a glossed over sticky substance.
3. The armature looks pretty worn.

 

You have a shot winding. Look for a replacement starter, or you can have an alternator shop rewind it. The loose magnet is the culprit.

 

Yup that's what my starter looked like too. Got one from chacal.

 

Did it start right up after?