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XT600e Starter issues XT600e Starter issues
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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  • 1 Post By xtrock
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  #1  
Old 25 May 2016
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XT600e Starter issues
Hi Guys

My 2001 xt600e battery just died. And I would be thankful if someone could help me to figure out the issue.

I use my bike every day for to commute to work. The last days it took always a bit longer to start up. yesterday it didn't want to start at all, so I thought it might be the battery. I jump started it with my car, and it started up straight away. Later that day it started up ok again.

But today I tried to start it up and and it hardly did anything, so I took the key out and it kept on trying to start up. So I pressed the kill switch, and it kept on trying.

Then I wanted to unscrew the cable from the battery to make it stop. After few sparks and a lot of smoke I got the battery out.

Noooow, before I replace the battery, what should I look after?

I don't want to wreck a brand new battery.

Hope my question is clear, thanks.
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  #2  
Old 25 May 2016
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Solonoid Solenoid Starter Relay Yamaha XT600 1999 2004 | eBay
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  #3  
Old 25 May 2016
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Had a riding lawnmower do that , parked it ,shut it off, went inside the house , came out 15min later and I hear this awful sound . Go over to the mower and it is sitting there spinning over (starter and wires very hot at this point) , ignition key was in the cup holder pocket not even in the ignition, motor not running but spinning away. Relay welded itself together. Glad I came back outside when I did , stuff was hot enough to almost ignite.

Your battery may not be bad if the relay was sticky and draining, just not enough to turn the starter. I'd maybe wait for the new relay to see if you need a new battery as well.
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  #4  
Old 25 May 2016
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New relay for sure. You can tap it with a hammer to get it unstuck.

They actually get stuck easier with a low voltage battery.
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  #5  
Old 26 May 2016
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Here's a thread which may help you decide whether to buy a Chinese or a Genuine starter solenoid

http://www.horizonsunlimited.com/hub...enoid-do-83312

Bob
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  #6  
Old 26 May 2016
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Thanks for all the replies

So do I understand this right?

Because the battery was getting weak, it took always longer to start up.
And because I pressed the starter button for always longer times by every start , it damaged the solenoid, causing it to give constant connection.
And this caused the battery to overheat and pop open?

I am new to this, so thanks for your patience.

So now, to fix this and avoid it to happen again.
I should get a Genuine starter solenoid and a stronger battery.

Or is the battery still maybe OK , even though it popped open on the top, if I just close it up again ?

Thanks
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Old 26 May 2016
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If you wanna do this the best way for the future buy a new battery and genuine starter relay!
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  #8  
Old 26 May 2016
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Replace both. By holding the start button longer and longer, you overheated the solenoid and caused it to warp and stick. Always use OEM. Cheap chinese solenoids will not last from what I've read on this and other forums. I have kick start so no first hand knowledge. Just passing on what I've read...
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Old 26 May 2016
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China parts are really good to have as extras when you troubleshoot and wait for OEM parts to arrive.
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  #10  
Old 26 May 2016
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GO China !!!













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  #11  
Old 27 May 2016
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Been there, don't like it.
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'84 XT600 is now bored to 2nd oversize and new OEM pistons and rings installed. No more smoking.
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  #12  
Old 27 May 2016
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Hi
So, think I found the solenoid Starter Relay, and took it out.
But it looks kind of different then the ones I saw on ebay. Like the one xtrock posted or this one, that i am considering getting

Aftermarket Starter Solenoid Yamaha XT600E 1990 TO 2002 | eBay

Or did I take the wrong part out?

I also just realized that I jump started my bike with my car the other day, while my car was running. Which possibly damaged the starter solenoid?
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XT600e Starter issues-20160527_144532.jpg  

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  #13  
Old 27 May 2016
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Its the correct part, seems like they use old relay on some of the 4pt. You can buy the original for almost same price Starter Relay Assy
3AY-81940-00-00 4KD-81940-00-00
$50.11
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  #14  
Old 27 May 2016
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Quote:
Originally Posted by OZXT600e View Post
Hi

I also just realized that I jump started my bike with my car the other day, while my car was running. Which possibly damaged the starter solenoid?
NO, It would just spin the starter a bit faster.
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'84 XT600 is now bored to 2nd oversize and new OEM pistons and rings installed. No more smoking.
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  #15  
Old 5 Jun 2016
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Thanks everyone, my bike is again up and running.
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