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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 27 May 2012
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06/2002_XT600E - starter-motor troubles...

Hi, was wondering if anyone had experienced similar troubles to me and my XT600? After starting it the other day, I couldn't get the starter to disengage! I turned the ignition switch to the 'off' position and the engine stopped, but the starter kept trying to start the engine, without any input from me. So, I turned the key to the off position and removed it, and still the starter kept on trying to start the engine. So, I removed the battery. Success. That worked. However - the battery was hot and I could hear the fluid boiling away inside.

Something must be shorting somewhere - perhaps. But where? I could pull everything off and not find anything obvious. Any ideas?

cheers
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  #2  
Old 27 May 2012
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Tested and proved!
Your Solenoid (also know as Starter Relay) is the culprit.. temporary fix: hit it with a hammer on its side to see if it disengages but ultimately you need to get a new one!

ebay link:
http://www.ebay.co.uk/itm/Relay-yama...item35bc89cd7e


Vando
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  #3  
Old 27 May 2012
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Smile

Thanks, Bacardi23.

Will give it a shot n let you know how it goes!
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  #4  
Old 27 May 2012
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Yep ! Its starter solenoid. Get new one
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  #5  
Old 6 Jun 2012
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This has happened to me once, when the battery was almost dead, never happened before, or again since. Is it possible a starter solenoid once engaged, can stay that way after the starter button is released, due to a dead battery? Or am I looking at a new solenoid soon too?
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Old 6 Jun 2012
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Yeb, its more likely to happen with a flat-ish battery.

I wouldnt be to worried about riding it afterwards, actually I did, untill I eventually sourced a new relay

Last edited by Jens Eskildsen; 1 Jul 2012 at 08:18.
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Old 6 Jun 2012
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Yes to the first question and Yes to the second aswell.... it can't hurt to keep one of those for replacement later on and it's not that expensive!


Vando
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  #8  
Old 7 Jun 2012
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The genuine Yamaha starter solenoid(relay) for a 2001 4PT XT600E is part#4JG 81940 00, which in 2005 was superseded to part#4JG 81940 10, then in 2006 was again superseded to part#4JG 81940 12.
So there must have been problems with them.
Powersports Plus.com have the Geniune Yamaha latest superseded one, part#4JG 81940 12 for US$49.14 plus shipping.
Bob
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Remember that Assumption is the mother of all f**k-ups.
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  #9  
Old 8 Jun 2012
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great info on the part numbers. hey guys i just purchased a starter relay on ebay for usd17.00. source is ems global direct, Manufacturer Part Number: 4KD-81940-00-00. referenced to fit all xt600's. mine is a 97 xt600e. physically they look the same. hope it works !
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  #10  
Old 9 Jun 2012
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The one I currently have is from some sorf of yamaha atv. Looks the same, but the positive and negative poles are reversed, meaning, where the negative was on the stock relay, is where the positive mounts on the new relay.

Just a little heads up, if its not an oem part for the xt600
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  #11  
Old 30 Jun 2012
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Quote:
Originally Posted by bacardi23 View Post
Tested and proved!
Your Solenoid (also know as Starter Relay) is the culprit.. temporary fix: hit it with a hammer on its side to see if it disengages but ultimately you need to get a new one!

ebay link:
Relay yamaha starter solenoid TT ttr xt 225 ttr225 tw XT600 XT 600 YX radian SR | eBay


Vando
I'm now having trouble in that when I hit the starter button, it cuts power to the bike completely. No lights, no neutral light, no horn, nothing, completely dead.

I assumed the main fuse had blew, so went digging for it and found it was mounted on the starter relay, and the main positive feed from battery to rest of bike is obviously through the plug connector into the starter relay.

The fuse hadn't blown, it was obviously just a bad connection, as soon as I moved it the bike's electrics came back to life, and I could start the bike.

There is obviously a bad connection between the main positive high amp cable from the battery, to the main positive feed to the wiring loom, via the fuse.

So I now need to buy a new starter relay unit, but on the one Vando has posted, where does the main fuse go?
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  #12  
Old 30 Jun 2012
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This is what my starter relay looks like



It would seem that lots of Yamaha bikes use an identical looking relay

yamaha starter relay | eBay

I assume this is just Yamaha's parts bin standard, and I could buy any one of these identical looking relays and it will be the same???
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  #13  
Old 1 Jul 2012
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Yeb, seems like it. Have this in mind tho':

Quote:
Originally Posted by Jens Eskildsen View Post
The one I currently have is from some sorf of yamaha atv. Looks the same, but the positive and negative poles are reversed, meaning, where the negative was on the stock relay, is where the positive mounts on the new relay.

Just a little heads up, if its not an oem part for the xt600
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