XJ550 Not Starting - But Bump Starts Easily

I have a 1982 XJ550 with starting problems, but it bump starts just fine.

I've rebuilt and tested the starter motor, replaced and tested a new starter solenoid, charged the battery up to 12.4V, and cleaned the starter switch on the bike.

When I put everything back together for the first time and went to press the starter switch, the starter was turning the engine, but the engine never turned over - come to find out, the last guy never plugged in the fuel lines. The bike bump starts just fine, BUT NOW when I try and press the starter switch, it doesn't start or even make the click noise when I press the switch.

It's kind of frustrating because the starter was working just before I realized the fuel lines weren't plugged in, but now the starter doesn't work.

On another note, when I press the starter switch, the oil level light comes on - not sure if that's supposed to happen or not. Anybody have any ideas?

 

Okay one thought if your brush plate is clicked wrong starter will spin in opposite direction ( ask me how I know this) the other thing you state it was spinning did it sound like a bunch of bolts in a coffee can? That is start clutch slipping ,that is a little involved to fix splitting the case so engine has to come out of frame. So my vote look at brush plate a little closer if I recall looking at starter gear it spins counter clockwise , pull it and jump it to see which direction it turns.

 

I heard that was a common mistake so I made sure to put the brush plate in the correct way, but this is my first time rebuilding a starter so I might've put it together the wrong way.

It didn't sound like there was anything wrong with it when it was starting, it just wouldn't fire the engine over because there was no fuel getting to the engine.

 

The starter clutch on the 550 is much easier to get to, but let's not go there just yet.

Making sure that the starter brushes were clocked the right way is worth looking into, and probably the cause for the engine not spinning.
Replacing your starter motor brushes w/ pics


If you remove the round cover on the left side of the engine, toward the front (has YICS on it) you will expose the ignition plate and can see if the crankshaft is spinning when you thumb the starter.

If the engine is spinning, then I'll suggest that the float bowls are not filling. The petcock has three positions; PRI, ON, and RES. PRI stands for prime, and allows gasoline to flow freely so the float bowls can fill after the bike has been stored. Set the petcock to prime, count to 30, and then switch it back to ON before starting the bike.

 

Just to know what I'm looking for, how do I know if my brushes are installed backwards?

 

It is not the brushes it is the plate that hold the brushes ,as I suggested if starter is pulled out and look , jumping it spin it up see if it spins clockwise or counterclockwise , or as kmoe stated remove crank cover on right side push starter if rotor spins then starter is working correctly it not then that is indication plate is wrong.

 

Btw it’s normal for the oil light to come in when pressing start. It’s a test for the bulb.

 

recap
starter was spinning
then replaced/attached fuel ilne
starter stopped spinning
is that correct?
did nothing elat at thattime?

 

He stated he rebuilt starter.

 

put it in neutral, clutch in, put a big wrench across the two big terminals on the solenoid. sparks starter goes.
maybe revisit that starter switch and retest the solenoid

 

yup rebuilt starter . motor turned over,noticed no fuel lines hooked up fuel lines and then no start.

if oil light is coming on your starter button is good

 

UPDATE
@Jetfixer - I took your advice and the starter motor works in the proper direction

@Polock - I tried this and it worked. The bike jumped forward when I jumped the two terminals on the starter solenoid.

@XJ550H - The starter was turning, but the engine never fired up (because the fuel lines were detached). Before I realized the fuel lines were detached, I went to press the starter switch again but then it didn't do anything. Then when I went to work on the bike later, I realized the fuel lines were detached - which explained why the engine never fired up.



I double checked the starter relay and that clicks as well when I tested all the terminals with the battery.

Is it possible this might be a grounding issue? I'm not sure where to look for the different grounds along the circuit. I'm at a loss right now because the starter engaged when I pressed the button once, but then when I pressed the button almost immediately after, the starter didn't engage.

 

First, get a new battery, an expensive one, a good battery should hold 13.2 volts, not 12, if your battery won't charge at least 12.8 or more Volts, and hold it overnight... you have a dead cell. Buy a GOOD battery, you can't kickstart your bike if your stranded!

Next, change the solenoid, buy a generic Yamaha ATV solenoid there only 30 bucks(fits big bear, Kodak etc 80s to 90s) , if you need I'll tell you which to order so the plug fits. They can burn inside and not transfer voltage, remove one problem for cheap.

After that, it may be the button, if you pull the switch block apart, and your patient, you can take the switch apart and clean it.
Hope this helps

 

the starter button grounds to the control housing and handle bars to frame. oil light coming on indicates a ground through the starter button.

there is a harness ground on the ignition coil bolt. there is a motor ground from battery to motor , then from motor to frame. the ground goes from motor to battery box under the battery

if you put voltage to the 2 pins on the solenoid connector you can test is solinoid is working plus to red wire pin neg to blue wire pin .

first take the bike out of gear so it does not jump.
pull out the sidestand relay it is under the seat near the tool tray left rear attached to frame
is neutral light on?
press the starter button.

bike has a sidestand switch to prevent bike from running or starting with bike in gear with side stand down.
bike also has a clutch safety switch which prevents bike from starting in gear with out pulling clutch.


check for voltage at the solenoid harness wire red/white wire . measure from battery ground to the red/white wire. this is done with key on.
then check for ground on blue wire . hook meter to positive battery terminal and blue wire in connector press starter button.
both tests should give you 12 volts (battery voltage)
no voltage...
is the kill/run switch on?
is there voltage on both sides of the ignition fuse.


under the gas tank there is a connector it is black . located aside of coils right side it is the connector for the right control this connector sometimes comes apart or loose.
you say you can bump start bike so you issue is with safety switches or your solinoid is junk