Starter problem

[bolla]

Hi My XT600 3AJ Will not usually start by using the electric start.
I have put a new Yuasa battery on 2 days ago Battery was filled and charged for 5 hours before fitting the bike did start first time but a few hours later would not start. I put jump leads from my truck to the bike battery and still wont start just turns over and over, but if I push start it will start stright away it feels like the back wheel only has to turn half a turn and engine will fire.
I have taken the starter motor apart and looked ok and fairly clean inside.
Any ideas whats up?

[Brian Williams]

Hi Bolla, is the starter motor spinning ok. Try checking the gears behind the small cover above left engine cover. The gears might be loose on their pins, circlips loose. Or it might be the starter clutch not picking up. If its the starter clutch, you will need to pull off the CDI magnito and check the rollers in the clutch. Might just need a clean, had a KLR do the same, just pulled it apart cleaned with WD40 and it worked ok after that. Xt 600 seems similar .How was Eastern Europe trip ? Brian.

[aukeboss]

Friend of mine had the same problem. Was solved by cleaning and tightening all earth connections in the ignition system. I don´t have a real explanation, but it might be that the vibrations made by the starter motor somehow rattle the earth connections so no sparks are produced. Consider to make some additional earth connection on your electrical system, as the single one from the battery into the wiring loom is a bit flimsy.

Auke

[markzz]

Sounds like the clutch cam arrangement behind the magnito.
As Brian has said check other things eg. the gear train that drives the starter clutch cam first..
Not such a biggy.
Of course these clutch cams do chew out if they aren't lubed correctly.. Always change that engine oil and filter regularly.

[markzz]

If it is the starter clutch cam and if it is just dirty you could remove the left crankcase cover and try the dodgy method of blasting it with compressed air to.
I don't think this will truely clean it but it may remove enough buildup to get it working.
The reason I mention this is removing the magneto can be a reasonable task if you don't have a rattle gun and and at least the correct puller. I had a terible time getting min off.

[bolla]

Thanks for the replys
My problem now is that I managegd to break my engine case while fitting a kick start.