New '82 XJ650 Owner - Not starting

I recently picked up a neglected 650 in bits and pieces, hasn't ran in a year.

Took it down to frame for paint, and just put the harness in today.
All connectors have found a home except for the few up in the headlight due to the lack of an instrument cluster and tail/turn lights.

I'm not getting any click from my starter solenoid, or any response at all when I hit the starter.

It's my third street legal bike, and I've done my fair share of troubleshooting but i'm downright tired and always look over the small things. A second pair of eyes or opinions do wonders.

I'm getting voltage to the headlight with the ignition, which partially eliminates that.
It is rolling in neutral, and have played with the clutch/kickstand in case.
Starter button has been checked for continuity (In the sweet spot)

-Engine has been grounded
-Coils are grounded
-Battery posts are clean
-Positive side of solenoid is on battery
-Fuses have been checked
-Negative from the starter runs to the negative of the solenoid as shown in the wiring diagram.

I'll post more pictures if asked.



This relay clicks when I turn the ignition, or touch the metal starter relay bracket to the positive terminal.


All fuses have been checked for continuity

 

That's the starter cutoff relay, it should click and close a set of contacts that enable the starter circuit if a safe condition exists, for example in neutral or side stand up and clutch lever pulled in.

Here is a good link for isolating starter issues:

http://www.xjbikes.com/forums/threads/how-to-test-your-starter-circuit.7828/

 

Yep, the one that's fastened with masking tape.

I've read through that page, and get stopped at shorting out the starter solenoid. The 'cutoff relay' as I've recently been educated, clicks; but the starter stays dormant.

 

UPDATE - Replaced the battery with my beautiful 2000 GSXR 600's and it turned over the first time. Then after would spin the gear, not turning over. Heard this was a problem with my buddy's bike who also had an '82 650 back in the day.

UPDATE 2 - I pulled the starter and rebuilt it, all gears were in perfect condition, brushes had plenty of travel and a clean contact, no binding upon reinstallation.

The gear that the starter spins inside the case (spins freely counterclockwise as looking at the left side of the bike yet catches clockwise) also was in perfect condition, no wear. When spun with a screwdriver as a lever, it also spun the larger gear in the right side crankcase as I saw through the oil transfer hole.

Reinstalled starter and bypassed the solenoid, caught the first time but spun the second time. Didn't want to hold the screwdriver too long to weld.

 

Starter clutch is slipping.
What oil is in the crankcase?

 

The PO said the problem started occurring when he got it from the Pre-PO.

I'm not sure what it had then, but it has Lucas Semi-Syn 10-40.

Also, I still have to find out why the starter button doesn't engage the starter. but that's for another day, I've been out there for nine hours today.

 

That might be the problem.
Drain it (save it in a clean container for some other use). Refill with an inexpensive JASO MA rated oil. The vast majority of synthetic, and semi-synthetic oils are too damned slippery and will let the rollers on the starter clutch skip around.
You may find it helpful to pull the starter and spray carb cleaner in the direction of the starter clutch to help flush out the semi-syn before refilling with the correct oil. Change the filter too, or at least let the oil drain out of the filter overnight.
You should see the starter clutch not skipping, or skipping less fairly soon. After a few hundered miles go ahead and do another oil change with your preffered JASO MA rated oil.

If it still skips a lot then you will have to split the cases to inspect and rebuild the starter clutch (and replace the primary chain guide while you're in there).

 

Going to Daytona Fun Machines here in Daytona Beach later today to get some Yamalube as stated in the manual; checking to see if it's still JASO MA rated, if not i'll ask someone there for one that is. Hopefully conventional.

 

You don't need to get Yamalube. Yamaha does not make oil, but they do mark it up quite a bit.
Check the link in my signature for a link to a list of most of the JASO MA rated oils. Check out diesel oils, or house-brands. What you wnat to steer clear form are energy conserving oils.