Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech
06/2002_XT600E - starter-motor troubles... 06/2002_XT600E - starter-motor troubles...
Register FAQ Calendar Search Today's Posts Mark Forums Read
Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by Ellen Delis, Lagunas Ojos del Campo, Antofalla, Catamarca

I haven't been everywhere...
but it's on my list!


Photo by Ellen Delis,
Lagunas Ojos del Campo,
Antofalla, Catamarca



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 27 May 2012
Registered Users
New on the HUBB
  
Join Date: Aug 2011
Location: Cobar, NSW Australia
Posts: 6
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 :confused1:
Reply With Quote
  #2  
Old 27 May 2012
bacardi23's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Sep 2007
Location: XXX<-Portugal->Azores->Santa Maria (island)
Posts: 1,544
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
Reply With Quote
  #3  
Old 27 May 2012
Registered Users
New on the HUBB
  
Join Date: Aug 2011
Location: Cobar, NSW Australia
Posts: 6
Smile
Thanks, Bacardi23.

Will give it a shot n let you know how it goes!
Reply With Quote
  #4  
Old 27 May 2012
Registered Users
New on the HUBB
  
Join Date: Mar 2011
Location: Ukraine
Posts: 11
Yep ! Its starter solenoid. Get new one
Reply With Quote
  #5  
Old 6 Jun 2012
Registered Users
Veteran HUBBer
  
Join Date: Dec 2009
Location: Birmingham, UK
Posts: 126
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?
Reply With Quote
  #6  
Old 6 Jun 2012
Registered Users
Veteran HUBBer
  
Join Date: Dec 2008
Location: Denmark
Posts: 1,417
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.
Reply With Quote
  #7  
Old 6 Jun 2012
bacardi23's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Sep 2007
Location: XXX<-Portugal->Azores->Santa Maria (island)
Posts: 1,544
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
Reply With Quote
  #8  
Old 7 Jun 2012
Bobmech's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Sep 2008
Location: BOP , New Zealand
Posts: 183
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
__________________
Remember that Assumption is the mother of all f**k-ups.
Reply With Quote
  #9  
Old 8 Jun 2012
Registered Users
New on the HUBB
  
Join Date: Jun 2012
Posts: 3
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 !
Reply With Quote
  #10  
Old 9 Jun 2012
Registered Users
Veteran HUBBer
  
Join Date: Dec 2008
Location: Denmark
Posts: 1,417
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
Reply With Quote
  #11  
Old 30 Jun 2012
Registered Users
Veteran HUBBer
  
Join Date: Dec 2009
Location: Birmingham, UK
Posts: 126
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?
Reply With Quote
  #12  
Old 30 Jun 2012
Registered Users
Veteran HUBBer
  
Join Date: Dec 2009
Location: Birmingham, UK
Posts: 126
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???
Reply With Quote
  #13  
Old 1 Jul 2012
Registered Users
Veteran HUBBer
  
Join Date: Dec 2008
Location: Denmark
Posts: 1,417
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
Reply With Quote
Reply

« Previous Thread | Next Thread »

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 
Thread Tools
Display Modes
Linear Mode Linear Mode

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
3AJ starter clutch dunch Yamaha Tech 4 27 Apr 2012 04:00
starter relay awolxt Yamaha Tech 8 29 Mar 2012 09:45
Electric starter for XR650R Chipompi Honda Tech 4 4 Mar 2012 22:06
kle500 starter clutch issue, info please: Joe C90 Kawasaki Tech 0 2 Mar 2012 19:37

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now, and add your information if we didn't find you.

Next HU Eventscalendar

HU Event and other updates on the HUBB Forum "Traveller's Advisories" thread.
ALL Dates subject to change.

2024:

Add yourself to the Updates List for each event!

Questions about an event? Ask here

HUBBUK: info

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.



All times are GMT +1. The time now is 19:14.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top