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Starter starting to get to me.... have a couple questions

Discussion in 'XJ Technical Chat' started by Gitarded, Jul 6, 2011.

  1. Gitarded

    Gitarded Member

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    Hi folks

    I tore my XJ650 starter apart. I put new brushes in and cleaned it all up. It ran fine on the bench when I used the battery from my mower. I reinstalled it into the bike and when I tried to turn it, it ran for a couple seconds real slow then nothing. I took it back apart and found that the negative brush spring was melted and the new brush was cracked. I am going to try another rebuild. This time I am getting the plate with the brushes installed and the negative brush pre soldered to the plate.

    I have a couple questions if anyone knows.

    First. I checked the armature segments and they appear to be a very low resistance reading between all segments. I think they are ok. The manual states something like .014 ohms which is essentally a short circuit. I don't think my DVM can read as low as the spec states. Does this seem right?


    The new rebuild kit has a rear case bearing. I would like to swap it out. Any tips on how to get the old one out? I was thinking about grinding down a hack saw blade and sawing it to split it. Anyone have a tip here?

    There are 2 washers in mine, one goes below the plate under the gears
    that that sits on the tip of the armature. The other is below the commutator between the shaft and bearing. It does not appear to be a thrust washer, looks like a thin flat washer. Maybe it's just old and warn out like me. Are there other washers that are missing?

    Also when I rebuilt the starter the first time. I could not turn the armature befoer I installed the gears and assembled it. Once it was back together it turned freely? Does this sound right?

    Thanks
    Pat
     
    Gitarded, Jul 6, 2011
    #1
  2. JFStewart

    JFStewart Member

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    The motor is basically a smart short circuit. The resistance numbers are typical. Usually a growler is used to check the armature windings.

    The bushing can be removed by gently tapping a fine chisel or punch between the bushing and the end plate. That should bend a portion of the bushing away from the bore and reduce the diameter letting it fall out.

    Here's a link to Yamaha Parts so you can check the assembly order..

    http://www.yamaha-motor.com/partviewer/ ... MOTORCYCLE)/STARTING_MOTOR_(XJ650H_-_1981)
     
    JFStewart, Jul 6, 2011
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  3. adrian1

    adrian1 Active Member

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    adrian1, Jul 6, 2011
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