Starting problem
Posted: Wed Feb 16, 2011 1:32 pm
On a few occasions lately I turn the key to start the bike and I only get a clicking sound from the under seat electrics. It is intermittent - if I wait a while and try again it can work.
Three months beforehand I had put in the Motolectric Starter Upgrade Kit and a new battery. any ideas?
Sept UPDATED all things I did in this thread to get it going:
1. Since I did the Motolectric Starter Upgrade the starting had been fantastic and when I did that I got a new battery and the connections at the battery and Starter were excellent. But, I learned later (see 9 below) that a new Motolectric upgrade can lead to a Sprag clutch failure if the Sprag clutch spring is nearly finished.
2. Since the Solenoid clicked when the starter switch was pressed then I learned the power was getting through. I checked various wire connection points, but not very well, actually (see 8 below)!
3. I undid the starter button, sanded the points and sprayed with electric cleaner. Later, I did the same for the kill switch - good to do, but not the problem.
4. I learned that if the Solenoid clicks and there is no motor turnover, then it could be a defective starter motor (connections, worn brushes, etc) or burned-out main contacts in the Solenoid. So, I took the cap off the starter to learn that the brushes were okay. But anyway, I replaced the brushes and the brush holder plate from a maintenance kit (Stockers Starters) - good to do, but not the problem.
5. I did some multimeter testing on the Solenoid and found too much Ohms (resistance) between the main contacts (partly burned out). So, I replaced it. Now, the motor turned over - good.
But, still the starting was intermittent, so there was another problem!?!
6. Hmm, in this process I stupidly created a fire from a backfire up the carb throat to a rag with fuel on it - spreading to fuel I had spilt on the bike and floor. Oh, now some water had gone down the carbs.
I turned the motor over with the starter and spark plugs out and changed the oil. See other post "What not to do - fire". 
7. Since I was doing all this work, I thought I would put in some new Dyna coils, but connected them to the wrong cylinder (stupid)
- corrected that.
8. More carefully, I re-checked the wire connections and found a really bad wire at a connection point from the alternator. Also, the wire from the Digiplex to the battery negative was dropping off at the Digiplex connection . I fixed those wire connection 
. The bike still was only starting intermittently ! More, more , more, what now ?
9. Sent my Digiplex in for analysis and was told it was irreparable!
. So I got a replacement . Still intermittent starting and NOW I notice an increasingly clear clunking noise near the back of the motor when trying to start the bike . From research I realised that it could be to do with the Sprag clutch and I learned that a bad sprag also clutch prevents starting .
10. I replaced the Sprag clutch . Yep, that got it. 
Starting regularly - perfect 
. Haaaaaaaaaaaaa :-)
Thanks everyone for your help on this one. It was a big and long learning curve for me. I learned a lot about the electrics and starting components. It seems I had multiple problems. All this was hard from my knowledge level - where I had never worked on bike starting systems, so I had to work out a lot of things including finding more about logical testing procedures. But, if I can do this, anyone can, right?! Sometimes, I was ready to give up and had breaks in the work while away for work, waiting for parts, 'fire' and repairs. I made it harder for myself by putting Dyna coils on wrongly - but anyway, I kept going and now the thoroughbred is performing again - rewarding me with beautiful rides :-) and having had an electronic overhaul.
While I was at it I also finished off my job to upgrade to 17 inch wheels (I had done the back wheel, so now the front wheel is done too) :-)
Three months beforehand I had put in the Motolectric Starter Upgrade Kit and a new battery. any ideas?
Sept UPDATED all things I did in this thread to get it going:
1. Since I did the Motolectric Starter Upgrade the starting had been fantastic and when I did that I got a new battery and the connections at the battery and Starter were excellent. But, I learned later (see 9 below) that a new Motolectric upgrade can lead to a Sprag clutch failure if the Sprag clutch spring is nearly finished.
2. Since the Solenoid clicked when the starter switch was pressed then I learned the power was getting through. I checked various wire connection points, but not very well, actually (see 8 below)!
3. I undid the starter button, sanded the points and sprayed with electric cleaner. Later, I did the same for the kill switch - good to do, but not the problem.
4. I learned that if the Solenoid clicks and there is no motor turnover, then it could be a defective starter motor (connections, worn brushes, etc) or burned-out main contacts in the Solenoid. So, I took the cap off the starter to learn that the brushes were okay. But anyway, I replaced the brushes and the brush holder plate from a maintenance kit (Stockers Starters) - good to do, but not the problem.
5. I did some multimeter testing on the Solenoid and found too much Ohms (resistance) between the main contacts (partly burned out). So, I replaced it. Now, the motor turned over - good.
But, still the starting was intermittent, so there was another problem!?! 6. Hmm, in this process I stupidly created a fire from a backfire up the carb throat to a rag with fuel on it - spreading to fuel I had spilt on the bike and floor. Oh, now some water had gone down the carbs.
I turned the motor over with the starter and spark plugs out and changed the oil. See other post "What not to do - fire". 7. Since I was doing all this work, I thought I would put in some new Dyna coils, but connected them to the wrong cylinder (stupid)
- corrected that. 8. More carefully, I re-checked the wire connections and found a really bad wire at a connection point from the alternator
. Also, the wire from the Digiplex to the battery negative was dropping off at the Digiplex connection . I fixed those wire connection . The bike still was only starting intermittently ! More, more , more, what now ?9. Sent my Digiplex in for analysis and was told it was irreparable!
. So I got a replacement . Still intermittent starting and NOW I notice an increasingly clear clunking noise near the back of the motor when trying to start the bike . From research I realised that it could be to do with the Sprag clutch and I learned that a bad sprag also clutch prevents starting .10. I replaced the Sprag clutch
. Yep, that got it. Starting regularly - perfect . Haaaaaaaaaaaaa :-)Thanks everyone for your help on this one. It was a big and long learning curve for me. I learned a lot about the electrics and starting components. It seems I had multiple problems. All this was hard from my knowledge level - where I had never worked on bike starting systems, so I had to work out a lot of things including finding more about logical testing procedures. But, if I can do this, anyone can, right?!
Sometimes, I was ready to give up and had breaks in the work while away for work, waiting for parts, 'fire' and repairs. I made it harder for myself by putting Dyna coils on wrongly - but anyway, I kept going and now the thoroughbred is performing again - rewarding me with beautiful rides :-) and having had an electronic overhaul.While I was at it I also finished off my job to upgrade to 17 inch wheels (I had done the back wheel, so now the front wheel is done too) :-)
