Digging in for Starter Gear/Spring Repair

Stone Co Rambler

Stone Co Rambler

Tarmac & Terra Firma
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Electric starter works, but runs on for a few seconds after engaging and starting the engine.

Not a mission critical repair since it kicks over, just fine. I do plan to get to this in the coming months and have a few questions.

Wrong to assume this is the typical gear/spring repair that is needed?

Should I avoid the rebuild kit from Mikes XS?

https://www.mikesxs.net/yamaha-xs65...oem-447-15516-00-90468-29062-90501-15409.html

Also, what other parts should I have on hand when digging in to repair the starter?

Case gaskets, seals, etc...
 
Usually simply retensioning the spring will fix the problem. A gasket (just in case) and the aid of a scale will get r dun.
 
Wondered the same thing SJ.

Suppose there is no telling until one gets in and sees exactly what's going on.

Not having much experience with these bikes, I would suppose there could be damage to the gear given the issue?
 
Yes, there usually is some wear on the gear teeth but it doesn't seem to hamper the function. I wouldn't replace the gear unless it was about half way or more, something like this .....

yjM8tQo.jpg
 
Given the grinding sounds and other unpleasant noises that happen when I do use electric starter, seems prudent to have a new gear and other related parts on hand when I dig into this.
 
Stone Co Rambler said:
Electric starter works, but runs on for a few seconds after engaging and starting the engine.

Not a mission critical repair since it kicks over, just fine. I do plan to get to this in the coming months and have a few questions.

Wrong to assume this is the typical gear/spring repair that is needed?

Should I avoid the rebuild kit from Mikes XS?

https://www.mikesxs.net/yamaha-xs65...oem-447-15516-00-90468-29062-90501-15409.html

Also, what other parts should I have on hand when digging in to repair the starter?

Case gaskets, seals, etc...
Click to expand...
The rule of thumb on this fix has been around for several years. The conscience is the 6 lb. tension needed of the horseshoe shaped clip around the Bendix gear. Clutch Cover Gasket is definitely suggested. May be a couple of drain bolt copper washers. The inspection of the gear itself will be the deciding factor if the MikesXS starter kit is required. You did notice the photo from 5twins. That gear through the years takes some abuse. Remember this will mesh with the drive gear attached to the crankshaft.
 
Also of note in that photo is the rubber damper ring attached to the side of the gear and how that one is deteriorating. I think that ring breaking apart is responsible for the little rubber chunks you often find in your oil filters, not the front guide.
 
Follow up....

Replaced the starter gear, wishbone and return spring and still had grinding and over run.

Realized that I could tap the starter button when the bike was running and could reproduce the noise I was hearing. So I suspected the relay was the issue. I also noticed the previous owner clipped the blue wire in the double relay harness, which disabled the headlight coming on at start up. This seemed redundant since the headlight has a kill switch to allow running w/o the head light. Not sure if clipping the blue wire for the headlight relay had an effect on the starter portion?

Anyway, I popped in a new starter safety relay.....problem solved with the starter over run. And I know my gear and spring are all good as well.

Cheers
 
Agreed; that starter overrun relay isn't just a luxury, I think Yamaha kinda fixed a starter bendix design flaw with it.
 
Interesting. So the relay was added later in the model run?

Thankfully there is still a good supply of pull off relays still floating around on ebay. I waited until I found one that was advertised off a low mile bike, looked clean and was priced reasonably. I think mine was $25 w/ shipping.

Is it common for this relay to fail?

I should note the gear/wishbone, rubber ring I pulled out appeared to be in good shape, no real signs of wear.
Return spring was quite soft tho. I could have stretched it out and reused it but used all new parts with the hope I'll not have to dig in there again.

Also, I did not have the special wrench to remove clutch plate...but my air gun whipped the locknut off in a jiffy. I was careful to re torque to correct spec on re assembly.

I was enjoying using the kick-starter but it looks like I'll give it a rest for a while. The electric starter does not howl and grind anymore. It was sort of embarrassing using it when others were around as I like to keep all systems in proper order.
 
Experimented on madness with the relay removed, my thumb reaction time was not quick enough to prevent overrun, relay got wired back in. Not a common failure but it happens just like every 40 year old part...... Even my old hammer needed a new handle.
 

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