starter locking up in my 1150, its on a second rebuild, time for new one?

[asbjones]

From what you describe 'starter motor spinning but engine not' sounds like your starter clutch has failed.

is that inside the starter? or behind the alt cover?

[asbjones]

The starter clutch is on the back side of the rotor under the stator cover. It's a pain to get off so really read up on it before doing any work there.

ah! didnt see this, I will look into this...

[Suzuki mad]

Oh NO.

is that inside the starter? or behind the alt cover?

Behind the alternator cover and behind the alternator itself

[tom203]

From what you describe 'starter motor spinning but engine not' sounds like your starter clutch has failed.

Sure sounds like this- no fun! but lots of recent posts on here on how to attack rotor removal.

[asbjones]

so I put the starter back in and cracked the left side stator cover open and I can see the starter clutch, I hit the start button and see the small gear spinning and what looks like the starter clutch outer housing not spinning, so should I pull the cover completely off and check it up close? I saw in another thread something about small connector bolts might be broken, is this what happens sometimes? thanks guys!

[tom203]

Dive in! the smaller gear (an idler) gets turned by starter motor which turns a large gear on rotor- when all is well, this large gear thru the starter clutch turns the crankshaft. Yes, there some little parts in there that fail.

[asbjones]

something is sticking

so I got my 1150 ready to fire up again after dealing with no spark
and low and behold Im back to dealing with my starter sticking and staying on...

pulled the ignition fuse and it still stays on

my starter button looks good inside, the spring looks good too

changed the solenoid to a brand new unit awhile back, swapped from the old one to the new and starter still sticks

looking at my diagram I see a starter interlock switch in my harness, Im going to try to locate it and check it out

I was even thinking of directly hooking the starter up to 12v and see if it sticks, but somewhere it keeps getting power to keep spinning

effing stumped again!

[hjfisk]

Is the starter solenoid hanging up and not releasing?

[blowerbike]

jump across the solenoid and if it cranks and stop when you stop jumping it then the problem is before the solenoid.
the interlock is the clutch lever switch..won't cause this.
also i believe the side stand switch is for the light only...no mechanical function.

on the other topic...
was your ignitor bad?

[UncleMike]

also i believe the side stand switch is for the light only...no mechanical function.

Confirmed, or at least it's only ever operated the light on my bike.

[asbjones]

on the other topic...
was your igniter bad?

yes igniter got fried or crapped out...

[chef1366]

Are you sure you are running an 1150 starter and idler gear? 1100s will not work.

[asbjones]

Are you sure you are running an 1150 starter and idler gear? 1100s will not work.

Yes, same parts that were always in there, ive put a few thousand miles on this bike since owned, always started easy, till one day the starter stuck

[asbjones]

I did some checks today...

negative lead was off the battery because the starter was in a stuck position from last time I tried to start it

if I touch the negative lead to the battery it sparks and the starter spins

I disconnect the positive lead going to the starter from the solenoid relay, then reconnect the negative to the battery

hit the starter button and the relay clicks everytime I hit the button, I can now reconnect the negative to the battery and hit the starter button and the starter spins

if the bike does'nt start right away the starter makes a popping sound and shortly after the starter sticks on

I quickly disconnect the battery lead and it stops

Is the relay sticking on? or is the starter drawing to much power?

[chef1366]

I did some checks today...

negative lead was off the battery because the starter was in a stuck position from last time I tried to start it

if I touch the negative lead to the battery it sparks and the starter spins

I disconnect the positive lead going to the starter from the solenoid relay, then reconnect the negative to the battery

hit the starter button and the relay clicks everytime I hit the button, I can now reconnect the negative to the battery and hit the starter button and the starter spins

if the bike does'nt start right away the starter makes a popping sound and shortly after the starter sticks on

I quickly disconnect the battery lead and it stops

Is the relay sticking on? or is the starter drawing to much power?

It has to be one of these
A short
Bad relay
Starter button