Starting problem

Alright I have a 82 XJ650. The problem is the starter won't turn the engine over. About 3 weeks ago it was though. It has a brand new battery in it. When I got to start it the solenoid keeps clicking (Chatters) as long as I hold the button down. I was thinking it wasn't getting enough juice so I hooked the jump pack up with it but didn't help. I hooked the jump pack up directly to the starter, and the starter still does nothing. Took the starter off and hooked it up, and it turned but not very fast. Should the starter spin pretty fast and be pretty torque like a car starter?? I am assuming the starter is bad, what do you guys think?? Thanks

 

Sounds to me like the bearings are dryed up. As long as the windings brushes etc. are still good, you should be able to disassemble the starter and clean out the armature and bearings with some brake parts cleaner, emry cloth the surface smooth again and relube them, the starter should spin with your fingers without too much effort.

 

Alright I will go try that right now and see what happens thanks

 

Here's my Starter write-up.

Pull the starter. Clean the heck out of it.

After you get it on the bench ...

Two long screws hold BOTH indexed ends to the main body.

Remove the gear end and COMPLETELY clean and re-lube that end.
You'll need to spread one Circlip to get the Planet Main Shaft out.
Keep track of washers and spacers.
Look on the ends of the shaft and inside the housing for thin Thrust Washers that like to stay stuck where they are.

Keep everything in order as you disassemble the Planet end.
Two small Planet Gears on opposed shafts.
The Ring Gear and Main Shaft.
Every Spacer and Thrust Washer.

Clean the "Whole-works" of the "Business-end." All of it so nice and clean a Marine Drill Instructor would have the Company check-out yours as good example.

Check for washers and thrust washers hiding on shafts and bearing ports.

Clean the Electric end; too.

Pull the Case away from the Motor -- slowly.
There's NO slack in the wire connecting the Brushes to the External Power Post.
Slip the Brushes off the Commutator.
Look for a Thrust washer - inside the Case - surrounding the port for the case bearing bushing.

With the starter exploded. Clean.
Use straight Isopropyl Alcohol loaded into a sprayer that has the Stream or Spray option.
("Honey, did you see the Windex. I can't seem to find it.")

Withdraw the Armature.
Spray everything until its completely clean and what you are spraying ON is as clean as what is dripping OFF!

Shoot the Commutator, Brushes, Brush Housing, Electrical Lead and the inside of the Electric end Case. Clean.

Shoot WD-40 on the CLEAN windings and magnets.

Lube the whole-works as you reassemble the Starter.

Using Top Quality Synthetic Waterproof Grease:
Everything and every surface on the Planet - Business End - gets lubed as it's reassembled.
Shafts, shaft bushing ID's, washers, spacers, gears, pivots, bushings, etc.
Grease everything. Either liberally -- for function, or smeared-on for both rotational forces on it ... or, to hold it from slipping as you reinsert bearing shafts into bushed port on the case.

Spin the Planet Shaft after its re-clipped in and grease the rotating Planet Gears -- "On the Fly" ... as they rotate around the inside of the Ring Gear.

Lightly smear washers and spacers on the Electric End ... but, don't allow the grease to contaminate electric connections and Commutator.

Get a dab of grease into the port on the Electric end; and smear the end of the shaft which fits there.

Now, the fun and games of getting the Brushes lifted onto the Commutator and everything lined-up and back together begin.

It's like a Chinese Puzzle.

Only ... "Made in Japan" !

 

I'd also add that you might pull all 4 sparkplugs and put the bike on the center stand put the tranny in 3rd gear and see if you can turn the back wheel by hand (to verify that the engine is free)
Not sure if you said you just got this bike, no did you say it ran well before.

I hope I didn't miss a string some where as I've been away for a while

 

Re: Starting problem (back from the dead)

If it looks this bad inside fear not. Set of brushes, turn the comintator, clean lube & put it all back togeather. This one is woringk on my 650 now and starts her every time.

 

Thanks for the input guys I pulled the starter and cleaned and lubed it. It wasn't as bad as it seems. Put it back on, and she fired up. Thanks guys for the help

 

Wow!

Here's another photograph for the Hall of Shame!
DON'T let this happen to YOU!
Check your Starter Brushes.

(Glad you didn't totally burn it up.)

 

Yep this one was pretty bad. Just on the ragged edge of being able to be saved. It was on the 81 650XJ that I'm reworking for a friend. Prime cause, carbs that had been sitting with fuel in them for a year. Like all starters these things have a duty cycle. This is what happens if its exceeded.