1982 Seca XJ550 engine noise

This bike ran fine last year. I had to pull the carbs off to rebuild them over the winter (it was having idling problems), and then I had a problem with the starter relay. I've replaced that, and now it's make a sound that's best heard that described; see below. It's not there initially upon starting the bike, but you hear it starting and going up in pinch at the 9 second mark. I did pull off the starter and inspect it, since I had the starter relay problem that cranked the starter until the battery died, but it appeared fine.

A lot of online postings regarding noise reference the cam chains. Far as I know though, the bike has a self-adjusting tensioner. And yes, the oil level in the bike is fine. The oil isn't that recent, but I've put few miles on it since the last oil change.

I look forward to your input on diagnosing the issue.


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The cam tensioner is not self adjusting, but it's easy to adjust. There is a nut you loosen and that allows a spring to tension it, then tighten the nut again (more or less). So, it locks in position once tension is set.
I don't know if that's the noise, but that sure is a strange thing.. starter not disengaging? no idea.

 

I'm more concerned about the noise that I don't hear.
Namely the valves. When did you last check clearances?

As to the noise we all hear: I think the starter clutch isn't disengaging. That is a distinct electric motor whine.

 

It is pretty easy to tell if the starter clutch is the issue as the starter will output a lot of voltage as it is spun. And, if it is just the starter clutch not free wheeling and the solenoid is opening as it should you can measure the voltage on the large cable that goes to the starter (should be zero when running) and it will be scary high and changing with RPM.

The other scenario is where I usually confuse myself a bit, but I am thinking today anyway if the solenoid sticks while the bike is running the starter will continue to spin, but now it spins at a no load speed - unless it can spin fast enough to sort of catch up to the free wheeling starter clutch. The no load speed would be considerably faster and could make some strange noises as you are hearing. The test for that would also be easy as the large cable that goes to the starter would be near 12V when it should be zero and should not change with RPM.

 

^^^ Agree it sounds like starter clutch is stuck . You might pull the starter and reinstall starter for giggles just to see if it makes any difference.

 

Yeah, the consensus appears to be that the starter clutch is engaged. I did try removing the plugs and rotating the crankshaft back and forth, hoping the clutch would let go, but that didn't help. Anyone have any other suggestions that might help free it up?

 

Did you do the voltage checks to be sure? I wouldn't worry about trying to free it up until it was proven it was stuck and not free wheeling.

 

Yep, I checked the output terminal of the starter relay (the one that goes to the starter), and turned the key and pressed the button. Once I stop pressing the button, the voltage goes down to zero.

 

I'm actually having the exact same issue.
Did you figure it out?
I'll check the voltages tomorrow on my side to make sure, but it does feel like the starter clutch is stuck.

Would it make any difference to remove the starter engine and squirt in some oil there?

Here is a link to the noise my bike makes, I get it going at ~35 seconds
bit.ly/3hsAJxw

 

if your starter is still engaging after start up, its internal with the start clutch assembly as these gentlemen have mentioned, or your start solenoid is internally bad allowing battery voltage to keep starter engaged. pull the main wire from starter off the solenoid, and use your hand to touch it to its terminal and start the bike, then remove it manually from the solenoid. if it keeps making that noise, its internal with starter clutch assembly.

 

Indeed, I understood that part.
What I'm wondering is what I can do about the starter clutch?
As I understand it, it is quite the job to get access to the starter clutch to try and fix it which I'd rather not do unless there is no alternative to try first

 

Yes, if I remember right its a case splitter...

Most starter clutch assemblies on bikes work with a few gear rings and some plates that act as a one way slipper gear clutch, when it wears, usually have two symptoms. Either stays engaged, or just spins with no engagement. Yours sounds like the first. All are metal to metal parts so no clutch/brake pad like materials were used. When metal clutches wear only thing u can do is replace the metal gear plate and spring assemblies.

 

:'(
Thanks!

 

https://www.bikebandit.com/oem-part...-starter-clutch-xj550h-j-k/o/m147107sch225096

Pay attention to #9 thats the wearable one way metal clutch setup
2 rings, springs pins and rollers

Could be collapsed springs, worn rollers etc...

 

So is this pretty much the approach I need to take to fix my stuck starter clutch?

 

The Virago starter clutch is nothing at all like what you have, so that video is of no use to you.
What you need is the service manual for yor machine. The details of how to replace the starter clutch are covered there quite well.

 

Just to throw this out there when you think the starter is still spinning is the oil light staying on? I had an instance where my diode block was faulty and the oil switch was sticking and this caused the starter to spin. Switched out the diode block , stop spinning then I got the oil switch unstuck. I mentioned this because it is a simple check and fix just requires you to meter out the diode block with your meter set to diode check you will find one that's a dead short and there is one resistor in there for the oil light as well. the bad diode will be adjacent to the resistor reading on the diode block

 

I'm digging out the starter clutch, but when I get to here, I'm unsure how to proceed. The manual doesn't help either. If anyone here has done this, please steer me towards the information on how to remove the starter clutch. Thanks.

https://imgur.com/vRFOX9m

https://imgur.com/QbYiOEP

 

See my thread on the "dreaded starter clutch" I have just two of these now ....you have to split the case , it is not as bad as it sounds . Some claim it can be done through alternator opening ...I played with it about 10 minutes after I split case just to see ....what a joke that was , I have pictures posted on my thread as well.

 

Jetfixer - are you referring to this? https://www.xjbikes.com/forums/threads/dreaded-starter-clutch-replacement.130190/ Unfortunately, I don't find the details sufficient to actually do the work.

 

This is the full detail of tearing down the engine and restoring the starter clutch for an xj750 or 650 . The link you had was for the XV Virago starter ...I have done these as well .