Starter Question

[67GTO]

I have been having trouble with the starter on my 83 ( some times it would work, other times the starter relay would just click)

Well yesterday I took the starter apart and found out sometime in the past it was put together wrong.

The marks were not lined up on the case so the brush assy was shorting to ground. I ordered a rebuild kit

from DB Electrical. I have two questions:

1.  Is the nose seal the good updated one with the spring around it?

2.  In a past posting someone said the ring and two planetary gears can be installed wrong. Can someone
     tell me what to look for when I reassemble it?

Dan


This is the kit I ordered:
https://www.dbelectrical.com/p-8621-starter-repair-kit-yamaha-xz550r-vision-1982-1983.aspx

[QBS]

1.  Yes.
2.  See pages 4 and 5 of post 83 550rk.

[67GTO]

QBS,

  1. thank you.

  2. where? do you have a link?

thanks, Dan

[Lucky]

2.  when you pulled the nose off you saw those two gears & the pinion they turn (connected to the gear inside the engine) those 3 gears need to line up straight in the outside ring gear.  it seems like they would line up properly anyway because the housing has to line up, but this is not the case, they can be a tooth off & still be able to line up & turn.

Also, you may or may not have noticed a small steel pin loose.  it lines up the ring gear & keeps it from turning in the case. easy to miss, easy to lose, & i don't think it comes with the rebuild kit..  if this piece is absent, a section of wire coat hanger, or a pin from a needle bearing will work in it's place.

[Rikugun]

for reference...
http://ridersofvision.net/rovforum/index.php?topic=13821.60

[QBS]

Dan,
2. TechTalk, last post date was 3/31/2012.

Edit:  TIP: Upon reassembly put a small dab of grease into the bushing that the armature rides in at the brush end of the starter motor.  

[67GTO]

Thanks for all the replys!

The pin is missing, will look for a substitute.

I will line up the gears with a straight edge.

(just need to wait for the kit now)

[Night Vision]

The pin is missing, will look for a substitute.

I used a finishing nail cut to size... nails are tough as... nails

[67GTO]

Found a pin at work from a copy machine. Exact dia. just had to cut it to length.

Starter back together and works great!

Dan

[QBS]

Congratulations!  Nothing beats winning.

[Lucky]

Found a pin at work from a copy machine. Exact dia. just had to cut it to length.

Starter back together and works great!

Dan

Plus, no more photocopys of your butt...  Win!!  :)