New Starting Problem

[Flaggo60]

1981 GS650G, 80,000 km. I just noticed a new glitch thats appeared. Cold starting is fine and instantaneous. Lots of juice to turn the motor over. Run the bike for a while ?til its warm and then shut it off for a few seconds (or, worse yet, stall it at a light) and the starter barely has enough power to spin the motor even one turn. Leave it and go back in ten minutes and all the electrical power is back and the motor spins fine with the starter. Lots of juice.

The battery is fairly new and was charged with a tender all winter and I put in a new Electrosport stator. The R/R is the original- I have a replacement if I need to change that.

Any thoughts folks?

Cheers,
Ted

 

[JTsGS650]

My thought would be to pull and inspect the starter.

 

[Macguyver]

My thought would be to pull and inspect the starter.

+1 on this. Check the starter to make sure the commutator and brushes are clean, then very very lightly grease the commutator with dielectric grease and reassemble.

While you are in there, check the starter gear to make sure it is not showing signs of binding.

I would then check the starter wiring to make sure none of it shows any signs of overheating, then clean the connection points, dielectric grease them, and reassemble.

Sounds to me like it may be a dead spot on the commutator, but let's hope it is just dirty connections.

 

[Flaggo60]

Thanks, guys, I'll take a look at that. Perhaps there is something expanding in the heat that stops the function of the starter until it cools and contracts a bit. Its the original starter and its almost thirty years old so it definitely could be dirt or wear. I have a spare starter motor so I think I'll swap it in for the other and then take a look at the original.

Cheers,
Ted

 

[1_v8_merc]

I have the exact same problem on my 82 650!

I cleaned the entire harness, brand new battery pulling
perfect voltage, brand new starter relay/ solenoid, and still have this
problem!

Seems like it does it more when it's hot out, but generally has a weak
crank even in somewhat cold weather, and likes to stall out at lights for
some reason and always barely starts back up!

Popped the starter cover and it seems VERY smokin hot for
some reason!!! Brother said he saw some light smoke coming from it.

 

[Flaggo60]

I have the exact same problem on my 82 650!

I cleaned the entire harness, brand new battery pulling
perfect voltage, brand new starter relay/ solenoid, and still have this
problem!

Seems like it does it more when it's hot out, but generally has a weak
crank even in somewhat cold weather, and likes to stall out at lights for
some reason and always barely starts back up!

Popped the starter cover and it seems VERY smokin hot for
some reason!!! Brother said he saw some light smoke coming from it.

Mine has almost twice the mileage as yours (approx 48,000 miles) and this is the first time it has ever happened. The one difference is that I put a new Electrosport stator in last fall and rode it only a few miles before I put it up for the winter. All the mileage before this has been with two stock Suzuki stators. I did see another recent post where an Electrosport stator seemed to be cooking a bit as well.

This aftermarket stator is supposed to be better and more powerful than the stocker, hope they?re right. In the meantime I?ll be checking the starter motor.

 

[1_v8_merc]

Okay guys, took out my starter tonite.

The two bolts that hold it on were a pain to get to, hadda use a swivel head, with an extension.

Yanked the starter out, took it apart further, and OMG, the smell was AWFUL!!!!!
I think I'd rather shovel cow manure all day than smell that starter again.

Here's some pics, they might be large......









--------

And here's how far I had to push the carbs up, just to GET the starter motor out.



------------

Alright guys, this starter just doesn't look repairable to me!

I'm probably just better off getting one out of a junkyard or buying a new one.(which is a little pricey)

 

[1_v8_merc]

Alright, re-edit......looks like I CAN salvage this starter hopefully.

Hit it with some carb cleaner and contact cleaner, got it pretty clean.

------

Sorry, didn't mean to hi-jack your thread!
Just jumped on this today, and thought I'd post the pictures up.

 

[gs road racer]

Take it to an auto shop that rebuilds starters they'll turn it down and replace the brushes and good to go I think...I've seen worse. Just a precaution but when you replaced the stator did you check the starter drive on the back of the rotor? Good idea to do so they are bad for bolts loosening and destroying associated parts. You'll need a puller for the rotor......