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Post by dodgerr4 on Jan 22, 2011 19:39:20 GMT -5
I'm trying to test a 79 engine that I picked up on CL. I got the engine all set up in my modified harbor freight stand so I could turn it over with the electric start. I hooked up the starter to a fresh new battery using jumper cables. When I did this, the starter could barely turn the engine over and only about one stroke. I took out the spark plugs and tried it again and the starter was able to turn the engine fine. I put the plugs back in but the problem was still happening. Does it sound like the starer needs a rebuild, or am I missing something? Thanks in advance.
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Post by luckyb on Mar 31, 2011 20:30:58 GMT -5
? What He Said!^^^ I just saved this bike from a trip to the junk yard by an older guy cleaning out his garage!! Hence, my member monicker!
It's a '75 with the same problem. Mine is all together and will kick start to life, but the starter seems to take alot of juice just to slowly turn over the engine. It kills the battery very quickly.
Removing this starter doesn't look that easy! Does it need a rebuild or is it something else?
Bruce
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Post by xsleo on Apr 2, 2011 12:50:44 GMT -5
If it kick starts good then just kick it. These starters are pretty reliable. Often what goes wrong is a bad seal, this lets oil inside the starter. Remove, tear down, clean, reassemble often fixes them. Sometimes the brushes and armature are worn.
Finding good working ones, on Ebay or ask around the chopper sites, you might find one.
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Post by ShakerNorm on Apr 2, 2011 13:01:13 GMT -5
If they're using a lot of power and not cranking the engine, it could be the starter - probably worn brushes.... or it could be bad wiring (check it all - mine had actually all melted!), a bad switch, or bad relay. That's about all that's in the system, so that's where to look.
My bet, however, is that you may have a weak battery. These things are hard on batteries, and they won't run without one that's reasonably well charged. It takes a lot of juice to crank over the engine, and if your battery is borderline, that would cause all your symptoms - for both of you! Most auto places can do a load test and tell you how good your battery is.
Good luck!
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azman857
Full Member
I don't have a plan and I'm stickin' to it!
Posts: 108
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Post by azman857 on Apr 3, 2011 12:40:25 GMT -5
Maybe the grease dried out in the starter. It always amazes me how little grease the factory puts in starters. Bushings needs lube too!
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Post by luckyb on Apr 3, 2011 17:13:59 GMT -5
ShakerNorm's bet paid off, I replaced the battery and made fresh pos + ground wires and she fired right up. Sometimes it doesn't engage so I'll end up tearing into it before too long. Maybe it will free up with use...
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Post by 5twins on Apr 4, 2011 14:36:49 GMT -5
Yes, there is another common problem associated with these starters that has nothing to do with the motor itself. Under the right side engine cover is a stack of gears the the starter engages through. The #4 gear in that assembly gets thrown into engagement with the motor when you hit the starter button, basically just like the Bendix gear on a car starter. This gear has a drag clip on it to slow it's rotation so it will engage properly. The drag clip gets weak over time allowing the #4 gear to spin too fast. Then it just grinds against the motor gear (or kicks back out) instead of engaging. There is a repair kit available. Yamaha updated the clip in '76 with a bigger, stronger one. Your '75 may still have the original smaller clip. Many of us simply bend the old clip tighter again if it is the new style as per the instructions here ..... 650wiki.org/index.php/12.08._Electric_start_problem_fixIf you still have the older small clip, you should probably replace it. You can tell once you get in there by where the little loop on the clip end is placed. The new larger clip won't fit in the old position .....  |
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Post by ShakerNorm on Apr 27, 2011 1:49:22 GMT -5
OK - I remember reading a thread about how to adjust the safety relay so it doesn't let my starter gears grind quite so bad after the bike has started.... Can anyone post a link so I can find it again?
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Post by xsleo on Apr 30, 2011 11:08:06 GMT -5
It's not hard to adjust the safety relay. On the older ones that just effect the starter, the later ones that turn the headlight on, the covers don't come off.
To adjust the relay, remove the cover. The one end of the spring hooks to the arm for the contacts. The other end hooks to a tab, bend the tab to loosen the spring tension.
To test I soldered wires to aaa batteries so I could hook them in series. Two batteries is about 3 volts. Three batteries are about 4.5 volts. Loosen the spring till the 4.5 volts won't trigger the relay but the 3 volts will.
This way the yellow wire only needs 3-4.5 volts to trigger the relay. If the relay takes more than the 4.5 volts to trigger it can keep the starter working after the engine starts. This won't hurt the starter but it can cause extra grinding and wear on the gears.
Leo
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Post by ShakerNorm on May 4, 2011 23:03:11 GMT -5
That's exactly what I was looking for Leo.... Thanks
I've got a 79 where the relay does turn on the headlight - but I'm going to see if I can pull the cover off to adjust it. I have the battery holder from a junk flashlight that holds 3 AAA batteries, and I can solder on a couple leads to make it work.....
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