Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech
'94 XTZ 660 Starter motor hardly turns even without load -- rebuild or replace '94 XTZ 660 Starter motor hardly turns even without load -- rebuild or replace
Register FAQ Calendar Today's Posts
Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by Hendi Kaf, in Cambodia

I haven't been everywhere...
but it's on my list!


Photo by Hendi Kaf,
in Cambodia



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 4 Jun 2014
Registered Users
HUBB regular
  
Join Date: Jun 2010
Location: Trondheim, Norway
Posts: 51
'94 XTZ 660 Starter motor hardly turns even without load -- rebuild or replace
Hi!

I own an XTZ 660 with starter motor problems. I have eliminated the following methodically:
  • Grounds are good
  • Power is getting through
  • Solenoid is good
  • Starter clutch is good
If I take the starter motor cover off and remove the gears between the starter and the crank, I can turn the starter without load. However, even without load, the starter will barely turn at first and then spin up slowly. It is also hard to turn using my fingers. I need advice on which action to take, and/or how to diagnose this further. I recognize my options are:
  1. New starter motor (£350ish + import taxes).
  2. OEM Brush kit + rebuild (£70ish).
  3. Wemoto brushes, not sure how many I need, but they're £10 a pop.
  4. Used starter motor (varies, but seems to be cheap)
  5. Combination of 4 + 3 or 4 + 2
Any and all help on what to do next is greatly appreciated.

I'll try to make a small video of the problem.
Reply With Quote
  #2  
Old 4 Jun 2014
Registered Users
Veteran HUBBer
  
Join Date: Dec 2008
Location: Denmark
Posts: 1,417
I got a rebuild kit for mine from ebay, didnt cost a lot.
Reply With Quote
  #3  
Old 4 Jun 2014
Registered Users
HUBB regular
  
Join Date: Jun 2010
Location: Trondheim, Norway
Posts: 51
Hi Jens!

It turns out this is the exact same starter engine that they put in the XT660R/X/Z, and seemingly also the MT-03. The part number for the entire starter is 3SX818900000.

Ebay seems to have quite a few of these starters with young age and low mileage for less than a OEM rebuild kit.

So I am leaning towards getting a used one in good condition and not risk wasting time on a possibly FUBAR starter (it's been making bad noises for years according to the previous owner).

Edit: the current unit also makes a nasty rattling sound when it gets up to speed. I suspect the bearings/bushings are shot ;/
Reply With Quote
  #4  
Old 5 Jun 2014
Registered Users
Veteran HUBBer
  
Join Date: May 2013
Location: Wisconsin, USA
Posts: 827
Those motors like to run until there is literally nothing left inside. Our 660 is the same one and has a good track record but the bearing goes out, lot of abuse if the motor ever backfired. If it's caught early on the first signs of weakness you can rebuild it, but if it's been making noises for years, the armature is ground up and won't ever work right again. I'd just get a used one of the lowest mile donor motor.
Reply With Quote
  #5  
Old 5 Jun 2014
Registered Users
Veteran HUBBer
  
Join Date: Dec 2008
Location: Denmark
Posts: 1,417
The old xtz660 startermotor fit aswell.

Get a "new" on ebay for sure.
Reply With Quote
  #6  
Old 5 Jun 2014
Registered Users
HUBB regular
  
Join Date: Jun 2010
Location: Trondheim, Norway
Posts: 51
Quote:
Originally Posted by Jens Eskildsen View Post
The old xtz660 startermotor fit aswell.

Get a "new" on ebay for sure.

Should hope so, since this is an "old" xtz But yes, it looks like I'm getting a newer low mileage starter Thanks for the help guys!
Reply With Quote
  #7  
Old 5 Jun 2014
Registered Users
Veteran HUBBer
  
Join Date: Dec 2008
Location: Denmark
Posts: 1,417
Oeh...The 600 Will fit then...
Reply With Quote
Reply

« Previous Thread | Next Thread »

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
Trying out a replacement starter clutch from Ideal Engine Parts for my '94 XTZ 660 andrerav Yamaha Tech 0 14 Apr 2014 01:56
BMW 800GS, Triumph 800XC or Ténéré XTZ 660? joasphoto Which Bike? 41 17 Apr 2013 00:13
Yamaha XTZ 660 (3YF) Starter Clutch Prob! Dyce Yamaha Tech 3 4 Mar 2013 19:45
Looking for 1995 yamaha xtz 660 tenere engine. tvytas Yamaha Tech 0 26 Apr 2012 18:34

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now, and add your information if we didn't find you.

Next HU Eventscalendar

25 years of HU Events
Be sure to join us for this huge milestone!

ALL Dates subject to change.

2025 Confirmed Events:

Virginia: April 24-27
Queensland is back! May 2-5
Ecuador June 13-15
Germany Summer: May 29-June 1
CanWest: July 10-13
Switzerland: Date TBC
Ecuador: Date TBC
Romania: Date TBC
Austria: Sept. 11-14
California: September 18-21
France: September 19-21
Germany Autumn: Oct 30-Nov 2

Add yourself to the Updates List for each event!

Questions about an event? Ask here

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

Adventurous Bikers – We've got all your Hygiene & Protection needs SORTED! Powdered Hair & Body Wash, Moisturising Cream Insect Repellent, and Moisturising Cream Sunscreen SPF50. ESSENTIAL | CONVENIENT | FUNCTIONAL.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.



All times are GMT +1. The time now is 10:51.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top