QuestionI have a 1981 Yamaha 650 Maxim. I've it for 3 years now with no trouble. It won't start on it's own now, I have to push start it. I just put 2 different brand new batteries in it and it hasn't helped at all. I haven't had any problems with any lighting. Just won't start on it's own. It's going to cost me $185.00 to have the starter rebuilt. But I would like to start with the cheaper possibilities first. Any suggestions other than the cylinoid? And is there a way to jump the cylinoid with a wire or something to see if that is my problem. Also would you happen to know what the cylinoid looks like on it? I live in Indiana in U.S. Also, I don't see how it could be the starter because it just one day wouldn't do ANYTHING when I hit the button. Never any weird or funny noises up to that point. No grinding or anything like that. THANK YOU SO MUCH for your time in trying to assist me in this matter. Jason
AnswerStarter systems are usually fairly easy to figure out. Look at the wiring drawing in your shop manual while you read my description below.
If you don't have a shop manual you should get one - your bike is an antique and you will have a hard time finding a shop that will work on it. The sad fact is that a lot of the mechanics working now are too young to remember bikes this old and aren't interested in learning about them so that they can do a proper job since yours may be the only one they see this year. This means that you will have to do most of your own work, and working on a bike without a good shop manual is just not worth the headaches. (My bikes are from the same era - that's why I fix them myself.)
I recommend that you get two manuals - a Factory Shop Manual and a Haynes or Clymer. That way when you don't understand the explanation in one you will probably figure it out when you have read the other too. If you spend some time on Google you might even find a factory manual available for free download.
The starter system actually consists of two circuits, the starter motor circuit and the starter solenoid circuit.
The starter motor circuit is usually a heavy wire from the + terminal of the battery to a stud on the solenoid, another heavy wire from the other stud on the solenoid to the starter motor and the return path from the starter motor to the - terminal of the battery via the engine block and the heavy wire that connects the block to the - terminal of the battery. If any of the wires is broken or disconnected or the starter motor or solenoid is defective the bike won't start.
The solenoid circuit consists of the low current terminals of the solenoid, the neutral switch & the clutch lever switch (between the solenoid and ground), the start button (between the solenoid and battery +) and the wires that connect them. Some circuits also include diodes to prevent the neutral light from coming on when the clutch lever is pulled in.
To troubleshoot the starter system you will need to connect the negative lead of a voltmeter or test light to a known good ground point (motor mount bolts are usually good) and check for voltage by touching the positive lead to the points mentioned below.
- The first thing to do is to determine if there is voltage between the starter motor and ground when the START button is pressed.
If there is voltage and the starter motor does not turn the starter motor itself is probably at fault.
- If there is no voltage at the starter motor, check the voltage at the high current terminals of the solenoid (your shop manual should tell you where it is, or you can follow the heavy wire from the battery +).
There should be voltage at the terminal that is connected to the battery all the time and voltage at the terminal that is connected to the starter motor only while the START button is pressed.
If there is no voltage at the solenoid terminal connected to the battery + either the battery is dead or the heavy wire that connects them is faulty.
If there is voltage at the solenoid terminal connected to the starter motor but not at the starter motor, the heavy wire that connects them is at fault.
If there is no voltage at the solenoid terminal connected to the starter motor the fault is in either the solenoid or the solenoid circuit.
A word about the solenoid: The solenoid is really just a relay,. If the solenoid circuit delivers voltage to the solenoid a coil inside it becomes magnetic and pulls a steel part into position so that the contacting piece attached to it connects the high current terminals. This allows the circuit that controls the solenoid to carry much less current than the starter motor requires so thinner wires can be used and the START button will last much longer.
- From the wiring diagram, figure out which low current wire is + (connected through the START button)and which is - (connected through the clutch switch and teh neutral switch), then check for voltage at that wire when the START button is pressed.
If there is voltage at the low current + wire and not at the high current terminal that is connected to the starter motor, the solenoid is probably at fault.
If there is no voltage at the low current + wire the problem is in the solenoid circuit.
- By following the solenoid circuit in your wiring drawing you should be able to determine when there should be voltage at the appropriate points. If you have come this far, the likely suspects are the clutch switch, the neutral switch and the START button.
