xj750 died going down the road

was riding at 35 and had a large clunk under the seat. rolled it into a drive way and rolled it backward. sounded like the starter disengaged when i roll it backwards. any suggestions. it only clicks when i push the button. but i got it to start by rolling it and poping the clutch in second. need to know if anyone ever had this happen?

 

Put it in Neutral.
Remove the Left-side Crankshaft Cover.
There are Flats on the Rotor.
Use a Wrench on those Flats and see if the Engine will Spin.

 

Rick, at the end of the post biggy got it running with a push start, sounds like the problem is with the internals of the starter.

 

Disconnect the battery.
Pull the Starter.
Loosen the two long cap bolts on the starter.
MARK the 3 sections of the Starter with lines to line-up for reassembly.
Pull the Aluminum Housing away from the motor --> Slightly <-- and look at the Brushes and Commutator. Use a flashlight.
• Brushes might need replacing.
• Carbon Dust may need to be douched from Electrical end.

 

if i have good weather tomorrow ill remove the starter. is there a rebuild kit for it? its pulling a lot of power already.

 

You should get a Tube or Tub of Synthetic Waterproof Grease.
Several Bottles of Isopropyl Alcohol from Walmart of a Drug Store.
(Remove cap. Puncture seal. Squeeze bottle squirting alcohol for cleaning.)

After you get it on the bench ...

Two long screws hold BOTH indexed ends to the main body.
MARK both ends with a Center Punch dimple or Scribe a line,)

Remove the Planet Gear end and COMPLETELY clean and re-lube everything!
You'll need to spread one Circlip to get the Planet Main Shaft out.
Keep track of washers and spacers.
Take notes. Make drawings. Take pictures.
L@@K on the ends of the shaft and inside the housing for thin Thrust Washers that like to stay stuck where they are.

Keep everything in order as you disassemble the Planet end.
Two small Planet Gears on opposed shafts.
The Ring Gear and Main Shaft.
Remove every Spacer and Thrust Washer.

Clean the "Whole-works" of the "Business-end." All of it so nice and clean a Marine Drill Instructor would have the Company check-out yours as good example.

L@@K:
Check for washers and thrust washers hiding on shafts and bearing ports.

Clean the Electric end; too.

Pull the Case away from the Motor -- slowly.
There's NO slack in the wire connecting the Brushes to the External Power Post.
Slip the Brushes off the Commutator.
L@@K for a Thrust washer - inside the Case - surrounding the port for the case bearing bushing.

With the starter exploded. Clean.
Use straight Isopropyl Alcohol loaded into a sprayer that has the Stream or Spray option. You can puncture the Seal and squeeze the bottle.
("Honey, did you see the Windex. I can't seem to find it.")

Withdraw the Armature.
Spray everything until it’s completely clean and what you are spraying ON is as clean as what is dripping OFF!

Shoot the Commutator, Brushes, Brush Housing, Electrical Lead and the inside of the Electric end Case. Clean.

Shoot WD-40 on the CLEAN windings and magnets.

GREASE the whole-works as you reassemble the Starter.

Using Top Quality Synthetic Waterproof Grease:
Everything and every surface on the Planet - Business End - gets lubed as it's reassembled.
Shafts, shaft bushing ID's, washers, spacers, gears, pivots, bushings, etc.
Grease everything. Either liberally --> for function,
OR --> smeared-on for both: Rotational forces on it ... or, to hold it from slipping as you reinsert bearing shafts into bushed ports on the case.

Spin the Planet Shaft after its re-clipped in and grease the rotating Planet Gears -- "On the Fly" ... as they rotate around the inside of the Ring Gear.

Lightly smear washers and spacers on the Electric End ... but --> don't allow the grease to contaminate electric connections and Commutator.

Get a dab of grease into the port on the Electric end; and smear the end of the shaft, which fits there.

Now, the fun and games of getting the Brushes lifted onto the Commutator and everything lined-up and back together begin.

It's like a Chinese Puzzle.

Only ... "Made in Japan" !

The MARKS you lace on the Parts BEFORE you separate the ends are really going to be very helpful when realigning the parts.

 

http://xjbikes.com/Forums/viewtopic/t=1 ... rt=30.html

 

just a quick one, you heard (or felt?) a CLUNK under the seat. I'd say its worth checking that the battery didn't explode due to a stuck starter or bad regulator? unlikely with a sprag-clutch starter like ours but if it did, the sooner the acid's cleaned up the better :?

 

Rick wrote:

Clean the "Whole-works" of the "Business-end." All of it so nice and clean a Marine Drill Instructor would have the Company check-out yours as good example. [end quote]

That would be pretty d@mn clean. Semper Fi.

Gary