Xt600e 03 help

[cali2304]

Hi

I bought my first xt this year and have been thrilled with it so far, absolutely love it.

However the bike now won't start after a few months of riding it, all I here is a single click from the starter solenoid and the starter motor doesn't budge. I've cleaned the contacts in the wiring system and did find some corroded connections which have been replaced and the connections to solenoid, battery and starter motor have been cleaned too. I've also checked the neutral switch, side stand and e start/kill switch and found that the o ring connector to the neutral switch had snapped off. This was replaced and I've now got a working neutral switch and light!

Managed to start bike started first time better than it ever has since I've had it, once I'd done these repairs. Let it run for about 30 minutes, restarted it again about 10minutes later no problems.

Problem solved however when I came to it again a few hours later I thought I'd give it one last try to make sure it was sound for work the next day, unfortunately it was just that same clicking noise and has been since....

The battery is reading 12.8v after been charged over night and is was new about 3-4 months ago, spark plug is clean and I've put new fuel in too.

Am thinking its either electrical, problem battery or an issue with the starter motor?

I did check the battery and it dropped about 2v when I clicked the e start but am not 100% sure what am looking for

Does anyone one have any ideas on how to fix this or have any suggestions?

Thanks

Matt


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[Jens Eskildsen]

Check the batteryvoltage after sitting a day or 2, this isnt your main problem tho.

The problem is the starter relay, thats making the clicking sound when it tries opens the curcuit. They corrode/get sooted up inside. Change it, and as I said, make sure the battery is fine aswell.

You can get a cheap one on ebay: Motorcycle Starter Relay Solenoid Fit Yamaha Grizzly 660 YFM660 2004 2005 | eBay

The positive and negative pole is reversed compared to the stock, and you need to use the stock mountingrubber. But the connector ect is a direct fit.

[DiverBones]

Wow, that is so cheap I've ordered one just to have as a spare.

[Bobmech]

Certainly cheap alright.
Makes you wonder what the quality is like & how long they last (compared to the genuine ones)?
Has anyone had problems with these, or are they as good as genuine?

Bob

[DiverBones]

I look at it from the point of view that if I need it I want it now. At that price I don't mind if it sits on the shelf unused. But, agreed, what to do if I do need to fit it. Is it a temporary fix till I get an original? Can it be trusted long term?

[xtrock]

You get what you pay for, if you need parts to find out whats wrong with the bike its ok. But i would never buy parts like this for the long travels, better to buy a used one original. Its a reason why the still work after 20years, electrical is not something you buy every year so why save 20 bucks..

[cali2304]

Ok so I tried a new solenoid and still got the same problem, a click but not starting. Having looked at the black cable from the solenoid to the starter motor there's some corrosion on it so am going to replace that. If that still doesn't work can I assume it's the starter motor that's gone bad??

Many thanks

Matt


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[xtrock]

If you measure with a meter you will know where the power stops.

[cali2304]

Ok thank you, what should I be looking for? Is there a way to check if the cable is bad before taking the starter apart?


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[xtrock]

I read that you had 2v when trying to start, either the battery is not good or starter is blocked. Remove and check the startermotor if your battery is 100%.

[cali2304]

Yea the battery is good I also tried a new one. I am thinking its the starter motor as it made a sound like a spring going bad and it has only started once since. Thank you for your help and I'll let you know how I get on


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[Jens Eskildsen]

You can hold a big wire from + of the batteri, directly to where the wire bolts on the startermotor. This will bypass the starter relay. It will spark becuase of the high current, but thats okay...just a heads up

It might be good to check the startermotor anyway.

[Bobmech]

Here's a link to a voltage drop test basic tutorial.
It shows how to locate the fault.
You just need a digital voltmeter.

https://www.youtube.com/watch?v=paw80mS_Kxg

Bob

[lslabe]

I had the same problem, so I ordered this kit, and I also made new thicker wires from battery to the starter (30mm^2)

Starter Kit Fits Yamaha Motorcycle XT600 595 90 95 XT 600 | eBay

It now starts every time...

Did you try to hit the starter motor with a hammer, it sometimes works. Just dont hit it too hard tho

[xtrock]

Problem was the startermotor, rebuild kit is on the way. Here is kit for this bike: Yamaha XT 600 E 99-03 Starter Motor Repair Kit Parts at Wemoto - The UK's No.1 On-Line Motorcycle Parts Retailer