1980 XJ650 Maxim starter issues

I recently acquired a 1980 XJ 650. When I picked it up the motor was seized. When you would push the start button, the starter would try to turn. I pulled the cylinders and head off, found a stuck piston. I had the cylinders re-honed and put all new pistons and rings in. I put the engine back together, put it back in the bike, gave it a new battery, and filled it up with 10w-40 oil. The problem I’m having now is when I hit the start button, the selenoid clicks, but that’s it. When I jump the selenoid with a screw driver, the starter just spins but doesn’t turn the engine. I’ve pulled the starter out, taken it apart and tried it again. I’m hoping it’s not the starter clutch. Any ideas on troubleshooting would be greatly appreciated.

 

Sorry sounds like starter clutch
But there are a few things you can try.
Seafoam in the case with some kerosene and turn the engine with wrench on the end of crank to flush out the gunk. Then use a motorcycle oil JASO Ma2 rating and bump start the bike. And maybe that will clear it up.

 

Rebuild the starter. Spinning, and spinning fast enough, are different things. If the starter is even a bit too slow, the starter clutch will never catch.
Make sure that the battery is up to snuff as well.

 

Why am I only able to get the starter to spin by jumpering the selenoid?

 

Solenoids are cheap replace it , if it continues then you have another problem.

 

Because the solenoid also needs to be replaced, or the start button contacts need to be cleaned.

 

Gonna go with the 2 dumb questions, but it wouldn't be the first time this happened....

1. Did you accidentally forget to put the gear back on the end of the starter?

2. Did you accidentally put the plate back in the starter incorrectly, which will make the starter run in reverse? Found that at a carb clinic a few years back... reoriented the plate and the bike fired up for the first time in over 10 yrs.....

 

I know the gear is on the starter. I’m pretty sure the plate is in the right place. I’m going to by a rebuild kit for the starter just to make sure the starter isn’t or is the problem. I’ll toss a new selenoid in as well.

 

starter brush replacement.pdf

It's really easy to put the brush plate in so that it's not indexed correctly. The reason is that the starter's internal parts were used on several makes of motorcycle, and some needed to have the starter turn the other way.