Motorcycle Repair: electricl problems, yamaha xt600e, motor brushes

Question
hi,i own a yamaha xt600e 1999 model,i am having problems starting ,i have just replaced a starter relay due to failure and this cured the problem for a few weeks.now after leaving it standing for a few days it will not start,when the starter button was pushed there was intermittent firing the it gave up ,now all i am getting is a clicking noise from the relay,i have made a connection direct from the battery to the starter motor and the engine will start,all the lighting is working fine and when i have push started the bike it runs fine.any help would be very appreaciated.thanks mick

Answer
Hi Mick,

When this happens, adequate electrical current doesn't flow from battery, through conductors, to starter motor. The reasons may be:

1) Loose connections at at battery, relay, chasis ground, or starter, starter button, and safety switches: (side stand/clutch/neutral). Must be clean and tightly fastened.

2) Corrosion in conductor or components. You may not see corrosion concealed by wiring insulation.

3) Burned or pitted relay or starter button contacts.

4) Weak or defective battery.

5) 1,2, or 3 above with the ignition switch.

6) Worn starter motor brushes or excessive buid-up of carbon powder inside starter motor.

7) other

Never jump start a motorcycle with a car or truck. Voltage is the same, but current is much greater with the larger motor vehicles. May fry electronics and battery.

Check the above and advise.

Respectfully,
Mark Shively