startermotor
 

Help, I have a 1991 3wr xt 600. The starter motor won't crank the engine on the thumb switch. If I connect the starter motor directly to the battery it works fine. I have also tested the starter motor solenoid (relay?) and that is ok too. I have tested the sidestand switch, the clutch switch and the buttons on the handle bars (start and engine kill switches) and they are all good. Is the operation of the starter motor in any way controlled by the cdi unit under the seat?? Also where can i get a wiring diagram for the starter circuit ?? Clymer is of no use for this problem. Any help would be much appreciated, taking the left hand side panel off and jumping the starter is a pain especially in the dark!!! Thanks Paul. Sydney.

I know it might sound bloody obvious but it may need to be in neutral and the neutral light on also the clutch switch may also go past the contact point.I had exactly the same problem once with my DR you could try shorting the sidestand and clutch switches or try moving the clutch lever in and out while pressing the starter

Finally sorted out starting problem with the help of an excellent wiring diagram from www.xt600.de. The problem was rusty connectors on the starter motor relay. It is situated underneath the solenoid where it can get nice and wet!! I cleaned the connections and moved the relay up into the battery compartment where hopefully it will stay dry and clean. The bike now starts on the button. I hope this is of some use. Paul