[srad_600]

Bike was at 44k miles and was showing the typical signs of cam chain trouble associated with this bike. I replaced the tensioner with an ape one. When i went to start the bike the starter motor cranked hard for like 5 seconds then died. Now anytime I press the starter it will click and all the electronics will dim but the motor won't crank. The one time it cranked it sounded kinda diffrent from normal? More high pitched and louder I think. I'm pretty sure I installed the tensioner by the book but i obviously messed up somewhere. Can someone help me find a solution to this problem.

 

[srad_600]

Oh yeah and I checked the battery and its charge was in spec.

 

[TOrnelas383]

are you sure your timing is spot on? Are you sure the cam chain is properly adjusted?

 

[srad_600]

The timing could be off because untill last week the bike was my only source of transportation and i rode it for about 200 miles untill the tensioner came in. When i installed the tensioner i took the head cover off and zip tied the cam chain to the sprocket so i doubt the timing jumped during the install. Either way it cranked and started fine prior to me taking it apart. Not sure where to go from here.

 

[srad_600]

Alright i broke the bike down just to make sure the cam chain didn't derail. It was still in spec so i put everything back togeather. I found the source of the clicking. Its coming from the starter relay, however i checked the fuse and its still good. I checked the terminals and they read 12v but when i hit the ignition it drops to 0-1v. Has anyone had this problem and is it common to have the starter relay go bad?

 

[djmatt123]

You might try to jump the starter relay with a screwdriver across the terminals. It could be a short somewhere in the wiring before the relay.

 

[srad_600]

Correct me if im wrong but placing a screwdriver across the terminals WILL short it out. And ill have to check again in the morning but im pretty sure the starter relay is the first thing off of the battery so there shouldn't be a short in the wiring.

 

[Chocolate_Rain]

Jump the starter relay.

That will tell you if the relay is bad or the starter motor is bad. From the sounds of it, the starter motor is bad.

 

[djmatt123]

The starter relay has two sets of terminals on it, one has small wires which is the starting circuit loop and the larger wires are coming from the battery and going to the starter. What it does is when the starter button is pushed, it activates the relay and completes the circuit from the battery to the starter. When you jump the connection, you are eliminating the starter loop and the relay operation and just testing the starter motor itself. Just turn the key on, short across the terminals with the larger wires, it will arc and spark when you touch it, but it should cause the starter to crank. If it doesn't, then it's the starter motor or something in the engine, if it starts then it's a short in the starter loop somewhere.

 

[srad_600]

Thanks I understand what you are talking about now. Ill try it tomorrow and post what happens.

 

[TheSteve]

I'm having the same sort of problem. Just did a CCT install, checked all the timing marks on both cams vs the crank, got the tension set correctly. Was good to go and rode it around the block. When I tried starting it later it basically went crank-crank-crank-crank-BANG! Loud bang like hitting a truck frame with a hammer. It will crank again if the bike is rolled back in gear and it'll then make a few more revolutions before another painful bang.

After the first occurance I pulled the valve cover and checked the cam timing figuring I may have mistimed it. I did not, timing is perfect. I then checked all the starter gears looking for a missing tooth or something. Gears look perfect. Checked the starter clutch, feels fine in both directions. Pulled the starter off the engine, grounded it to the frame, and hit the start button and it works perfectly for long periods of time without fault.

I have no idea what could do this. It can't be the trans since the clutch is fully pulled in. Not the valves, not the starter or its clutch. What should I be looking for? Should I just buy a new starter?

Edit: Forgot to mention, results are the same with carbs on and off. Not a preignition problem

 

[srad_600]

Alright i jumped the starter relay and it sparked like hell and made the same clicking sound that happens when i hit the starter except it was rapid fire. So would the diagnosis be that my starter is bad or my relay? And if the starter is bad could it be repaired. I recall my old room mate had trouble with the starter on his car so he would hit it with a wrench to un jam it. Is that trick applicable to my situation?

 

[mortenmorfar]

yep try hitting it with a hammer, but even if that makes it turn over again, it will fail again, so I would order a new starter IF it works with the hammer trick.
you could also try removing the starter and connect it to a battery to see if it turns, if it does it's something else that's wrong.

 

[Chocolate_Rain]

You can also rebuild these starter motors. I have done so, it is not difficult at all.

 

[srad_600]

Yeah a rebuild sounds like a good idea. I checked my service manual though and there is no servicing info just a diagram showing how to break it down. What parts normally have to be replaced in the rebuild?

 

[TheSteve]

I tried the hammer trick and it didn't do anything. Sure sounds like something binding up hard because the starter still seems to try and turn the engine. Is there anything that could bind up and lock the engine like that?

 

[Chocolate_Rain]

Brushes. I think there are three??

Use duct tape to hold the brushes in while putting the commutator back in. The brushes are spring loaded.

 

[mortenmorfar]

I tried the hammer trick and it didn't do anything. Sure sounds like something binding up hard because the starter still seems to try and turn the engine. Is there anything that could bind up and lock the engine like that?

have you tried to turn your engine with a socket ?, pull the plugs and rotate it use the 14mm bolt on the timing cover

 

[TheSteve]

Yeah it rotates fine by hand and even cranks sometimes but its only a matter of time before it locks up again. Bump the bike back a bit and itll crank for a few seconds before doing it again.

 

[Adsuzukiboy34]

Try another battery.
I have been caught out by a battery that shows full charge, but as soon as it goes under load... Boom. Nothing