Motorcycle Repair: Electrical problem, starter relay, multi tester

Question
Mark,

I own a 1985 Yamaha XJ700N Maxim. I bought it new from the dealer and have not modified it in any way. It has been a good bike, is still in excellent shape, and has only 7,500 original miles on it. I have taken it to the dealer only twice. Once for a tune up and carb synchronization and once for gummed up carbs from letting it sit for three years without running it.

My problem started this year when I tried to start the bike this past spring. I put a fully charged battery in, turned the ignition switch on and hit the start button and got nothing but a clicking sound from the starter relay. It sat there until now, when I finally have some time to work on it again. I have the original Yamaha Repair Manual I bought from the dealer and started looking for solutions to my electrical problem. After running some tests using the repair manual and my multi tester I determined that my starter relay was faulty. So I went to the local motorcycle junk yard and picked up a used one for $20. I put it in and tested it and it did make the starter turn over. I thought great, problem solved, so I put the bike back together and tried it again and got nothing but the clicking sound from the starter relay again. Frustrated and pissed off I gave up for the day.

I need your help in figuring out this problem and don't want to take it to a repair shop unless I have to. I'm starting to think my problem might be with one of the safety feature switches on the bike, being as old as it is. It has a neutral switch, clutch switch, sidestand switch, etc. Would one of these switches, if faulty, not allow me to start the bike? All my fuses are good and so is the battery power. Is there some problem my bike is known for, regarding the starter not wanting to turn over? What do you suggest I do now? My email address is sanchezmark@netscape.net. Thanks

Mark  

Answer
Hi Mark,

Very good description, thanks.

The clicking of the starter relay is usually a sign of a weak battery. In your case, possible causes: the starter motor carbon brushes may be worn, starter motor has excessive build up of carbon powder and creating some resistance to turn, or corrosion/poor conductivity within wirning and multi-connectors in starting circuit, or starter button contacts corroded.

Check starter button contacts. I've had insects get in there, die, and cause similar problems. The safety switches are likely working properly and not the problem.

Check all connectors, clean well (if necessary), and apply dielectric grease to all.

Remove the starter motor and disassemble. Remember where shim washers come off and return them to their respective places. Check brushes and wiring terminals. If you get stuck, email me.

See microfiche parts at:

www.bikebandit.com

Click "OEM Parts" and then select your MC from the menus that follow.

Check your email address for repair info files.

Respectfully,
Mark Shively