650B doesn't want to travel; e-starter locked, makes weird noise.....

jpdevol

jpdevol

Hacker of Frames,Wires and other things
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So as it often happens when getting ready for a trip, the new-to-me XS650B has been full of surprises. Thought I had it all sorted and did a 30mi shakedown run - no worries other than it sounds like a con rod little end is a bit "loose".

I go to start it to load on the trailer for Ozarks and, out-of-the-blue, the electric starter locks-up and when kicking or rolling with the rotor nut (either direction) it rolls, but makes a strange Rrr-Rrrr grinding noise (suspect gear #4 engagement??).

I ain't givin' up yet and about to pull the R side case to investigate.............

Anybody heard such a noise or experienced such weird happenings?
 
Maybe your 75 came with the same inserts mine did….. 68382542560__DF1F8AF4-2154-4DCF-9C03-95D8D35A5D08.jpeg
 
Wingedwheel said:
Maybe your 75 came with the same inserts mine did…..View attachment 241932
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LOL...it was similar....

So the first finding inside the clutch cover was the "starter gear 3" was jammed and had gouged into the case just ahead:umm:
20230502_170314.jpg


So after removing that gear - needed a puller - the whole mess flew apart and I got a glimpse of the compression spring that appeared to be between gear 3 and gear 4! Don't know how it even worked that way , but it did.

Smoothed the damage, reassembled and all works as intended
20230502_171524.jpg


On the floor below this mess was an odd object - I don't recognize it - that must have come out when the starter gear assy. flew apart.
20230502_181718.jpg

It's spring metal (all accounted for as I can tell) and the fk'dup bolt for reference is the 8mm kicker bolt.

The bike's going to Ozarks; wish me luck;):laugh2:
 
Somebody probably çrushed the hairpin bend of the spring in the vice, to increase the pressure on the gear and the spring eventually broke.. Not a good fix that one, there is a better fix, aside from buying a new spring and gear.
 
5twins said:
That piece of spring may be from one of the damper springs on the back of the clutch hub. They are known to break.
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5T, you may be right; it's about the right diameter wire. Of course, in my haste, I glanced but didn't really look closely at the damper springs. I mean, the damn thing was supposed to already be loaded on the trailer.

It's big enough wire to also be the kicker torsion spring, but it was intact. It's a really tight coil almost full circle, been chewed on some, but that must be the original shape (not bent):shrug:

That motor actually needs a full rebuild at some point in the future, but I'm a keeping fingers crossed in the short term:laugh2:
 
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