'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.

I got a rebuild kit for mine from ebay, didnt cost a lot.

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 ;/

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.

The old xtz660 startermotor fit aswell.

Get a "new" on ebay for sure.

Should hope so, since this is an "old" xtz :D But yes, it looks like I'm getting a newer low mileage starter :) Thanks for the help guys!

Oeh...The 600 Will fit then... doh