Starter Rennovation

Let me start by stating that I have searched and read 5+ posts on this issue, so I don't come unversed
Starter Repair?
Starter Motor????
Cleaned Starter Motor... Now Maybe Problem?
Starter Behaving Erratically
Starter rebuild

The Question:
Can someone give me a specific description of the grease I need to lube the motor after completely cleaning out the entire works? I know from reading that I need synthetic waterproof grease but in my shopping today, I found lots of lithium grease, and one claiming to be for Japanese made vehicles (including words like synthetic and -40 to 400 degrees). After reading the packaging of all the grease at three stores, I didn't find one I felt good about using knowing I needed synthetic and waterproof.

If it's not clear, I am a non-mechanic who is willing to ask these questions.

Secondly, in replacing the starter motor, I had some plastic disintegrate during dismantling. Looking at diagrams and visiting the dealer, I believe the part is/or is near #15 in the Starter Motor parts. The piece is two parts, it fits around the bolt attached to one of the brushes. Inside the case, the plastic part is square and holds the square bolt head from turning. Then the part has a shaft that sheathes the bolt as it exits the case. Finally, the second piece caps the plastic shaft outside of the case. I assume this is to prevent shorting out on the case. Well, I can't find a replacement. Where do I look? Is this parts #15 (nut special) the piece I need?

Thanks for any help.


-- Below I'll give some background... so you only need to read if it helps --

The Background
My '83 XJ750 Seca will start when cold in the morning, and then when I leave from work. But if I stop at the gas station, then attempt to start up, it will turn the engine once or twice, then sound like it is slipping/rattling.

My first action was to pull the starter motor from my parts bike, open up and clean out (re-lube with grease on hand, proper or not) and replace the current motor. After a test ride, and multiple restarts, I thought it was fixed. Later, I had the same symptoms and only when the bike was warm (cold it would start, and just stopped, it would re-fire right away).

While I have been renovating the other motor, the replacement from the parts bike has progressed into new noises and symptoms. When cold, it now turns the engine (more slowly than the previous motor), then when it sounds like the engine would fire, the whole works stops short and freezes. Following reattempts to start continue to freeze. The past week, I push started almost every day. On those days, when leaving work the starter completed its task like there was no problem.

signed, a baffled non-mechanic with grease under his nails.

 

Hi Tygor
try this lot
www.ramcospec.com/tg50.htm

 

From what I can see on the starter motor diagrams on BikeBandit and Powersportspro they are still available.

The stud insulator comes on Brush 2 (# 11) and the Special nut(#15)

 

Any good high pressure Lithium or Molybedum grease ought to do just fine for your needs Tygor.

 

Thank you all for your advice. It would happen that I will need to order two parts. As for the grease, I was concerned about gumming, but I was able to find today high pressure grease, so I will pick some up tomorrow and get this thing back together. Maybe my crushed pigtail insulator will still work though cracked.

 

A follow up:
Well, today, all the parts are back together and back in service. The parts starter motor is cleaned, lubed and in the working bike. It starts smoother and seems more trustworthy than the stand-in. But a week of riding it will tell the tale if the starting slip is still around.

I rested on Valvoline SynPower (this stuff) and it resembles the stuff I cleaned out. And it's texture doesn't seem as sticky. So I'm happy with this.

As for those unlisted plastic pieces... the cracked piece previously in service wasn't beyond use, so I reused it. I will probably put up the $20-some later.

What I learned:
A project that seems simple, like the starter motor cleaning, can be tricky if you're not careful. The full story is that I had already swapped starter motors from the parts bike, cleaning and lubing and the whole bit. I used grease on hand and must not have gotten the case back together where all of the notches lined up. Tonight, as I swapped for the second time, and cracked my previous handiwork open, it looked just as bad as before and the brushes were eaten up from misalignment. I am thankful that I have that parts bike.

 

Those plastic pieces that you refer to are not available from Yamaha.....never were available as service parts as far as I can tell. And yes, they are commonly cracked or ruined during service work.

I have a replacement set of plastic stud insulators available.....slightly different in configuration, but functions properly:

HCP6375 aftermarket starter motor brush STUD INSULATOR SET, used on the positive brush on all Nippondenso starter motors, where the positive brush stud comes throught he starter motor case hole. Has the plastic base plate, o-ring, and outer flat collar washer. Slightly different in design features than the original but fits and works correctly on both original and aftermarket brushes.
$ 9.00