Starter motor issues

So long story short I got this bike a few years ago for very cheap. It was meant to be a parts bike/engine swap, but almost everything is there for a full bike. Right now the wire harness is spliced all over and a lost cause (Not sure what the previous owner did). I have mocked up a basic wiring harness with all the required components (TCI, Voltage regulator, starter relay, etc.) I have everything setup on my bike and cannot get the starter motor move, it just clicks. I know the starter relay is working, I have spark to the plugs, and I have cleaned and tested the starter motor off the bike with a battery. Electrically everything seems to be working. I am just needing some help/guidance on what else could be going on.

 

Grab some jumper cables and directly attach the positive from the battery to the terminal on the starter motor.
This is what the solenoid is doing.
If it spins... Good. If not then the starter motor needs a refurb.

PS: this takes for granted that the negative from the battery is directly attached to the engine and you just touch the terminal on the starter motor and don't attach the clamp.

 

I have tested the starter motor and it is working. I'm ordered a rebuild kit for it anyways as gaskets are worn out. After doing some trouble shooting last night I found out the engine is seized....so I'm going to put some penetrating oil on the pistons to see if that will help it. Didn't really want to rebuild the top end and new rings, but its looking that way.

 

Ouch! That's a bit of a larger job.

 

Seems a 50/50 mix of Acetone and ATF is often recommended for this, and if no joy a new / used motor may be a better route than rebuilding

 

This actually my parts motor for my Seca. I just wanted to see if I can make my parts bike run. Im going ro troubleshoot and see if I can get it turning over, if it does I may just buy some new rings and hone out the cylinders

 

If possible check, I'm not sure how without a boroscope mind you, that the primary drive chain isn't locked with corrosion.

This is something a fellow xjr had happen when he finally got his bike running. It just seized up with a crunched up primary drive chain.
Hmmm. Mind you if you pull the head and barrels you'll be able to spin the crank to see easily enough.

 

I do have question hopefully you all can answer. In order to take off the cylinder head assembly does the crankshaft need to be TDC? This thing is pretty seized and wanted to open it up to see what's really going on. I want to try and tap the pistons to see if anything will budge. If I do pull the cylinder head will that mess up timing?

 

No but you will have to time the engine should you get things moving again. Just a matter of reading the factory manual as it will get you right back on the money.

 

Well last night I got the engine unsezied. Pistons and cylinders actually looked pretty good. Might just clean everything up and put everything back together and test how well she will run. Might make new rings and honing the cylinders a winter project.

 

If you’re in there, you will definitely want to lap the valves and replace valve seals too in my opinion

 

I'm with Dan on this, at the least lap the valves in. If there's any corrosion on the seats they're going to leak and possibly burn making an even bigger mess to clean up down the road.

 

Thanks for the advise! I will definitely lap the valves. I will do an inspection of the seals. If they are bad I will replace them. Since this is just a cheap parts engine I don't want to put too much money into it. I would rather put money into my other engine that is currently in pieces.

 

Oh, gotcha. I missed that part. Then make sure to do the valve job on the main engine as part of the “while yer in there” list

 

Oh I will. I bought a full rebuild kit seals, 0-rings, gaskets, dowels. Had a couple kids and moved, so had to put projects on hold for a few years. Now I have a little bit of free time and want to get these bikes running again. It's been years since I have rode a bike.

 

Okay I need some help. How fo you remove the valve seals ? I cant get a needle nose on them snd don't want to scratch of the bore for the valve .

 

I sacrificed a set of long nose pliers.
Map gas torch and a bit of fiddling.

 

If it works it's worth it.

 

Google for 'valve seal pliers' and you'll get something like these...
https://www.auto-doc.ie/energy/13638429

 

Don't let my Ex see those!