Starter Motor Troubles

OK, while my starter motor worked, the bike struggled to kick over. I found that the brushes were pretty much non-existant and there was a lot of carbon dust spread throughout the motor, so following Rick's Starter guide, I pulled it apart, cleaned it, replaced the brushes, greased what needed to be greased and put it back together.

However, when I test it by connecting it to the bike battery, all I get is sparks. The starter won't turn. I've pulled it apart and checked the set up around a dozen times but still no luck.

Testing manually, I can spin it until I put the central case on. Those magnets make it impossible to turn manually when using the external gear. Should I be able to move it in this fashion? My original thought in line with another thread was that it was not put together properly, but I have checked the schematic that many times....

Any suggestions for further tests would be appreciated.

Yours in Frustration,
oby

 

Magnets? I don't think there are any magnets. The starter is essentially electromagnets. No electricity, no magnetism.

What you refer to as the central case is a planetary gear set. They gear the starter motor down. Turning the output gear would be real tough even if the starter is together correctly.

Sounds to me like you are either binding something up when you put the planetary gearset on, or the brush holder isn't oriented properly.

Will the planetary gearset turn when not on the starter motor?

Also, which bike?

 

there R Magnets...permenant type

 

I've left my laptop in the office which has the XJCD's on it so sorry for the poor terminology.

The planetary gears are all fine and move smoothly.

The Magnets I refer to are attached to the inside of the tubular case - ie. not in the ends, but on the walls of the middle section which slides over the main section of the starter motor.

If the starter is now toast, is there anyway I can test this to be sure? I'm pretty sure that I have put it together correctly (even the brushes) as I've been pretty careful about it.

Sorry - XJ900

 

If your sure it's back together correctly ,then just attach the leads of ANY 12 volt battery to test, or reinstall it back on the bike and test.......IF it seems to work some of the time ,but sometimes you hear it ALMOST engage the flywheel teeth(providing the teeth are OK ) and you still have a problem with partial engagements then you may need a starter Solinoid located in a rubber saddle to the left of the battery compartment.
Good luck .......,,LionHeart

 

almost forgot.........make sure you have a good battery., sometimes there are weak cells that fool you into thinking it's a good battery

 

I'd also go over the reassembly ... that Brush Holder only works when it's fullu seated in the right position.

You can have the Starter out of the Bike and test it.
Hook-up 12V to the Electricity IN Post and Ground the Case.

I use my Battery Charger to test Starters.
I hook-up the Red Lead to the Power Post and touch the Case with the Black Lead. It should spin with ease.

If not ... something is binding or shorting and its usually the Brushes not properly seated right.

The exposed part of the Power Lead running from the Power Post to the Brushes gets shorted on the Platform or shorts-out to the case. Tape it or coat it with Liquid electrical Tape.

 

Thanks guys. I have tested it, and when I add the ground (from a brand new, fully charged battery), all I get is sparks. I thought I might be testing it incorrectly so I reinstalled it, but when I tried to start her I heard the same 'crackling'.

I will once again check the brushes, as it seems as though this might be a short and I am getting the assembly wrong rather than something stuck.

Back to the shed! Again...

 

OK, so now I have it so that it spins using the external gear and my hand. The new brushes came with insulation over the copper wires and the brushes seem to be seated properly.......

 

Here is to hoping...
That it spins that is. Let me understand this. You can turn the motor over by hand using the external toothed shaft. If you can, then a brush replacement and commutator clean up is a very sound first suspect for replacement/reconditioning.
Good call Oby.

 

Through some advice and some late night brainstorming I have decided there is some insulation issue. I'm off to the parts store today to try and sort it and will repost soon.

 

Insulation problem fixed.... Starter still not working.

Well, that is about it for me gang. I'm out of ideas. There was no insulation on the inside of the case where the brush bolt exits, so no idea how it worked previously. This has now been fixed, however I am still having no luck.

The brush attached to the positive lead now seems completely clear of all other elements within the housing and the other brush is grounded, so I'm at a loss.....

Any final suggestions?

 

Keep it as a Parts Starter and grab a used Starter off eBay.

Without being able to physically inspect the Starter ... I think we should suspect that it's burned-out from all the electrical testing that failed to get it to jerk or spin.