Author Topic: Starter trouble or electrical gremlins?  (Read 4117 times)

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Offline Thud300

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Re: Starter trouble or electrical gremlins?
« Reply #50 on: August 22, 2016, 11:06:47 pm »
Found this video elsewhere in the forum.

! No longer available
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Offline Allmendinger

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Re: Starter trouble or electrical gremlins?
« Reply #51 on: August 23, 2016, 10:16:34 am »
carbs out. main ground removed & cleaned.......... click

voltage checked from engine ground bolt wire end to starter while button pushed - 12.8. same as battery.

time to pull starter? if so, I'm assuming that it's a bit more complicated than a car starter. ie: not just pull and replace.

the local dealer let me borrow his shop manual. which shows nothing

eagerly awaiting guidance



Offline mgoodrich

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Re: Starter trouble or electrical gremlins?
« Reply #52 on: August 23, 2016, 11:40:17 am »
I assume that you have the full service manual from the shop?

It is in section 15 (electrical section). 15-24 is the beginning for the starter.

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Re: Starter trouble or electrical gremlins?
« Reply #53 on: August 23, 2016, 05:19:14 pm »
carbs out. main ground removed & cleaned.......... click

voltage checked from engine ground bolt wire end to starter while button pushed - 12.8. same as battery.

time to pull starter? if so, I'm assuming that it's a bit more complicated than a car starter. ie: not just pull and replace.

the local dealer let me borrow his shop manual. which shows nothing

eagerly awaiting guidance

Remove the 2 bolts holding it on, and the cable, and pull it straight out...

30 YEARS OF KAW.....Rich R. (the other one..)  COG 5977  JUSTAMEMBAHNOW

Offline Allmendinger

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Re: Starter trouble or electrical gremlins?
« Reply #54 on: August 23, 2016, 05:43:54 pm »
well it appears we have our answer. got the starter off. at first glance I noticed the shaft turned very hard by hand. like it was binding.

put it in the vice hooked up the jumpers and it spun but made all kinds of noise and the shaft and wiring was kind of jumping around inside the case. then it stopped with power still to it.

I then took the cap off the other end and it was all black with what appear to be chunks melted plastic stuff. it appears one of the brushes is worn completely off. tried to attack a pic but it says my file is too big
 
what say ye?
edit: I took the 2 bolt that hold the 2 ends ins while removing it. the cap where it goes into the motor doesn't seem to want to come our
« Last Edit: August 23, 2016, 05:55:21 pm by Allmendinger »

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Re: Starter trouble or electrical gremlins?
« Reply #55 on: August 23, 2016, 06:46:29 pm »
 Youre saying the far end is still stuck in the engine? I thought there was a circlip that retained that end on the shaft...hmmm.....

Reach in and grab it with pliers, and twist back and forth while pulling, there is an o ring seal on that part they may be a bit tight, but it pulls right out

30 YEARS OF KAW.....Rich R. (the other one..)  COG 5977  JUSTAMEMBAHNOW

Offline Allmendinger

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Re: Starter trouble or electrical gremlins?
« Reply #56 on: August 23, 2016, 10:23:49 pm »
got it out. ordered one from eBay should be here sat. will update.

thanks to everyone for their help thus far. actually got a bit of maintenance done while trying to figure this. I now have a bunch of shiny electrical connections, know I don't have hydrolock etc.

hopefully it will all go back together with no issues.

thx again

Offline connie_rider

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Re: Starter trouble or electrical gremlins?
« Reply #57 on: August 23, 2016, 10:32:24 pm »
Allmendinger, I didn't do much on helping you.
But I do have a final suggestion.
Join the club and come ride with us...

You've now seen how COG folks will help non members.
We're far more helpful to COGgers. (even MOB  >:D)
And we're pretty good folks to ride with!!!!

Ride safe, Ted


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Re: Starter trouble or electrical gremlins?
« Reply #58 on: August 23, 2016, 10:37:50 pm »
Allmendinger, I didn't do much on helping you.
But I do have a final suggestion.
Join the club and come ride with us...

You've now seen how COG folks will help non members.
We're far more helpful to COGgers. (even MOB  >:D)
And we're pretty good folks to ride with!!!!

Ride safe, Ted

don't make me come down there Ted... :rotflmao:
I'm considering a go fund me account, just to get me on the road, and away from this rediculous computer....  :rotflmao: :rotflmao: :rotflmao:
I figure $60 a day would do it, cover gas, food, camping, and ...Bail... :rotflmao: :-\

30 YEARS OF KAW.....Rich R. (the other one..)  COG 5977  JUSTAMEMBAHNOW

Offline connie_rider

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Re: Starter trouble or electrical gremlins?
« Reply #59 on: August 23, 2016, 10:42:18 pm »
I already know that $60 won't do it for ya(bekuz) ya forgot somethin' important in your calculation.
   (Ya forgot to put beer in the list)....

Ride safe, Ted
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Offline Allmendinger

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Re: Starter trouble or electrical gremlins?
« Reply #60 on: August 24, 2016, 01:33:25 pm »
Allmendinger, I didn't do much on helping you.
But I do have a final suggestion.
Join the club and come ride with us...

You've now seen how COG folks will help non members.
We're far more helpful to COGgers. (even MOB  >:D)
And we're pretty good folks to ride with!!!!

Ride safe, Ted

Connie_rider, I will definitely join once I get back to work. helpful bunch you are.

I traded my beloved klr, which I put 40k miles on in 25 states, for this bike because my wife showed an interest to ride with me. she went for one ride and lost interest.

I'm more of a dual sport guy. if all goes well when I get it back together I'll keep it awhile. im not real fond of it when it's hot out.

the 2015 versys I test drove was a blast. but I've also not had a vehicle payment in 20 yrs. not sure I want one

Offline connie_rider

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Re: Starter trouble or electrical gremlins?
« Reply #61 on: August 24, 2016, 01:46:12 pm »
We're the Concours Owners Group, but we don't limit membership to Concours Owners only.
Versys and KLR's are very welcome in the club.
Many members have them, and there is a lot of knowledge available about them. (Particularly the KLR).

In  way, the KLR was probably the second most common (secondary) bike in the club.
In recent years the Versys is making quite a showing.

I didn't look at your location carefully. (apologies)
Where's home? What kind of Dual Sport Riding do you do? (ie; where)

Ride safe, Ted


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Offline Thud300

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Re: Starter trouble or electrical gremlins?
« Reply #62 on: August 24, 2016, 06:05:57 pm »
Glad the mystery is solved  :great: something of a rare failure, I think.
Returning old Kawis to riding glory since 2014
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Offline Allmendinger

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Re: Starter trouble or electrical gremlins?
« Reply #63 on: August 24, 2016, 06:38:48 pm »
We're the Concours Owners Group, but we don't limit membership to Concours Owners only.
Versys and KLR's are very welcome in the club.
Many members have them, and there is a lot of knowledge available about them. (Particularly the KLR).

In  way, the KLR was probably the second most common (secondary) bike in the club.
In recent years the Versys is making quite a showing.

I didn't look at your location carefully. (apologies)
Where's home? What kind of Dual Sport Riding do you do? (ie; where)

Ride safe, Ted

home is on the NY/PA line- Elmira

as far as dual sport riding, nothing to crazy. mostly old dirt farm roads, seasonal access roads and a few power lines from my younger days in NY/PA

definitely roads I wouldn't feel comfortable taking an almost 700lb bike on. ergos wise I'm more comfy on the dual sport bikes. did many a 700 mike day on the klr

my last trip took me to FL all 3 numbered roads i.e. 322,220 etc then BRP end to end on the way home. 2900 mi

I drive a truck for a living so I've seen most of the country from the interstate. avoid them like the plague on a bike.

these days I drive to Manhattan & back daily so when I get on the bike I try to get as far from people and traffic as possible

Offline Allmendinger

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Re: Starter trouble or electrical gremlins?
« Reply #64 on: August 24, 2016, 06:57:47 pm »
Glad the mystery is solved  :great: something of a rare failure, I think.

trust me if there is a rare failure it will find me. they usually do.

example: I once had an early 80's Toyota. every once in awhile it wouldn't start. like a few times a month.i threw all kinds of parts and time at this thing. one day at a wedding I met a retired Toyota mechanic. over some adult beverages I tell him about it.

he asked if it was made here or in Japan. I ask why. he says if it was assembled in Japan to take off the dome light cover and tighten the screw into the roof. I laughed. he said just do it.

the next morning, verified it was in fact made in Japan. the screw was loose,  I tightened it and that car started every single day for the next 3 yrs and the kid I sold it to said it was the best car ever and I think might still be driving it.

Offline Nosmo

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Re: Starter trouble or electrical gremlins?
« Reply #65 on: August 24, 2016, 07:59:44 pm »
Glad the mystery is solved  :great: something of a rare failure, I think.

trust me if there is a rare failure it will find me. they usually do.

example: I once had an early 80's Toyota. every once in awhile it wouldn't start. like a few times a month.i threw all kinds of parts and time at this thing. one day at a wedding I met a retired Toyota mechanic. over some adult beverages I tell him about it.

he asked if it was made here or in Japan. I ask why. he says if it was assembled in Japan to take off the dome light cover and tighten the screw into the roof. I laughed. he said just do it.

the next morning, verified it was in fact made in Japan. the screw was loose,  I tightened it and that car started every single day for the next 3 yrs and the kid I sold it to said it was the best car ever and I think might still be driving it.

Years ago I worked with a guy who had several cars.  The starter on one of them, (not sure what model) would sometimes hang up and he'd have to open the hood, reach down and whack it with a hammer to make it work.  One day his wife had to drive it and the starter quit, so she called him and he tried to describe to her what the starter looked like and where to hit it.  But she didn't understand.  So when he got home, he painted a big red dot on the side of the starter so she'd know where to hit it if that happened again.  It never had another starter failure.
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Offline Allmendinger

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Re: Starter trouble or electrical gremlins?
« Reply #66 on: August 27, 2016, 02:04:12 pm »
it's alive!! it appears I must have put it back together right. so far everything works.
time for a test ride. thx again everybody for the guidance

Offline connie_rider

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Re: Starter trouble or electrical gremlins?
« Reply #67 on: August 27, 2016, 02:05:11 pm »
Yahoooooooooooooo

Ride safe, Ted
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Offline HSVScott

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Re: Starter trouble or electrical gremlins?
« Reply #68 on: August 27, 2016, 04:47:29 pm »
 :great:

Offline Thud300

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Re: Starter trouble or electrical gremlins?
« Reply #69 on: August 27, 2016, 11:17:35 pm »
 ;D :great: :beerchug:
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Offline GKreamer

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Re: Starter trouble or electrical gremlins?
« Reply #70 on: August 28, 2016, 12:19:59 am »
Great job!