I have a 1981 XS650 that I ride to work regularly. Towards the end of summer the starter was turning slower and I was beginning to have to use the kickstarter to get the engine started. Since the battery was a few years old I assumed that was a problem and bought a new one. The starter turned even slower so I took the battery back and had it checked,they charged it overnight and then tested it and declared it ok. I brought it back home and then the started wouldn't turn at all. I have removed the starter and it spins fine outside the motorcycle. the battery I bought spins the starter of my Honda 350 like a champ. I put the starter back in and ran jumper cables from a car battery directly to the starter and it will not turn the engine.It turns over and starts with the kick starter without a problem. So ,is it possible that there is an issue with the starter that it will not turn under load?
You know that your engine and your battery are both working fine and results are unchanged when you bypass your switches and wiring harness, so that leaves the starter motor as the source of the trouble. Refer to the factory manual (a free download from http://www.biker.net) and have a look at the starter motor. New brushes and a clean commutator might be all it needs.
I am trying to analyze and am trying to take this a step at a time instead of my normal method of taking things apart and hoping I stumble across the problem. It has been a month or so since I had last messed with it but I think I had hooked the ground to the kickstarter lever.I guess I want to positively eliminate the electrical system before I start pulling engine covers off to check gears. I have zero experience with starters, I usually hand them to a mechanic and ask him to check it out. I secured the starter in a vice and connected a battery to it to make it spin.
It seems the problem is in the starter. I ruined one of the long machine screws taking the starter apart. Everything looked fine inside no crud the brushes were still about 50% ,my multitester is just a cheapo so I could not do all the tests. long story short I could not locate another machine screw of proper size so I bought a new starter. I installed it and wonder of wonders it works. Now I have to wait for the snow to go away.
r80rt: :)This is a splendid write up, THANK YOU!!!!
Dec 26, 2015 16:54:05 GMT -5
mashermoto: What the what is this shoutbox for? Or should I shout, WHAT THE WHAT IS THIS SHOUTBOX FOR!
May 12, 2016 22:22:21 GMT -5
motormike: Good Day ...just a FYI.. Wild Cat is this Labor Day weekend. Still go'n on. A few 650's still make the scene. Various rides at different skill levels each day.. awards dinner sunday eve. BS in the park'n lot after dinner.
Aug 23, 2016 7:57:01 GMT -5
lsettle: First post in over 6 years!
Aug 28, 2016 19:45:17 GMT -5
kardon: Wow quiet here, where did they all go.
Oct 7, 2016 2:18:13 GMT -5
gggGary: XS650.com LOL
Feb 16, 2017 20:49:02 GMT -5
buell88: Anybody have any idea who built the xs650 tracker used in the Draggin Jeans Ad on Pipeburn?
May 16, 2017 16:24:09 GMT -5
joshua: The regulator/rectifier unit I got from Mikes PMA has closer hole spacing than original. Are we supposed to mill the holes to fit?
Jun 7, 2017 19:25:58 GMT -5
joshua: My bad. I found the bracket they supplied to mount the rectifier/regulator... Uh oh. How is this meant to work? Which way is it meant to mount? Looks like I have to use some spacers or something. Good instructions would be nice.
Jun 7, 2017 22:09:52 GMT -5
craig8johnson: Not sure if this is the right spot or not but oh well...
Jul 11, 2017 18:04:15 GMT -5
craig8johnson: I'm checking the charging system. I'm afraid I might have fried the last battery. With the solid state regulator (after market) what should it be charging at. The book says, I think, 15 volts. I'm hitting 17 when revved. Is that too high?
Jul 11, 2017 18:06:19 GMT -5
gggGary: Yes 17 volts is too high, about 14 volts is max, sounds like you don't have the right regulator or it's wired wrong.
Jul 13, 2017 6:54:33 GMT -5
dean: Just saying Hello, new member who is going to fix up a 79 XS650 that has seen its better days. I will definitely have lots of questions coming up.
Jun 23, 2018 16:45:32 GMT -5
tt650: Trying to breathe life into a 1980 that's been stored (indoors) for 25 yrs. Air filters are dry rotted. Have cleaned carbs but she only runs briefly on choke then stops. Need jet setting info and other ideas that might help her idle and rev.
Jul 3, 2018 19:15:19 GMT -5
trix13: Hey everyone! New to the forum and am fighting those gremlins!! New charging system, ignition switch, coil and fuse box. Resistance is higher than normal on the ignition pick up so I'm trying to find one. No such luck yet.
Aug 16, 2018 8:50:48 GMT -5
trix13: Also, even though all of my connections are clean, I cannot seem to find out why , when at higher rpms, I hit the signals and the rpms pulse with the signals...hahah. same with the brake light. I appreciate all input!!
Aug 16, 2018 8:55:08 GMT -5
bob99: how do I post a question. I am new to the forum
Jun 6, 2019 10:52:10 GMT -5
adlpc: Hello all! Been enjoying your edifying posts and discussions - and as a fan of the XS650 since my early teenage years happy that I now own a 1980 Special which I plan to turn into a vintage half faired racer. Thank you all for being here!
Oct 1, 2019 0:58:56 GMT -5