Fixing starter motor problem (with pics)...

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...specifically for a 1994 Honda CB500 but I'm sure the principle may apply and help for other bikes.

Sorted last weekend but posting now as wanted to make sure all was working (for now).

Problem I had was hitting the starter there would be just a click from the solenoid. Dodgy battery you'd think. However, put bike in 2nd and rock forward and then hit starter (clutch in) and fires up. So that'd be a starter issue then.

Did a google and found this CB500 forum entry and this thread on here. I guess this thread is just adding some more info and pictures.

Starter on the CB500 is on top of the engine so easy to get to. Those underneath the engine may require some extra work (the Varadero XL125V appears to weld itself to the engine).

Need small hands as access is awkward. Other threads say take unscrew +ve terminal first. I didn't as too much of a faff. Couldn't get socket onto one nut so had to resort to old fashioned spanner. It's the nut with the -ve connector. All nuts so far 10mm.

https://i1113.photobucket.com/albums/k503/mapidd/Biking/CB500/2014-04-03-998_zps86f75eea.jpg

Then a little tap with a rubber mallet and wooden stick from the other side...
https://i1113.photobucket.com/albums/k503/mapidd/Biking/CB500/2014-04-03-1000_zps06aa60a1.jpg

...and then wiggle and jiggle to get out (might improve your foreplay technique)...
https://i1113.photobucket.com/albums/k503/mapidd/Biking/CB500/2014-04-03-999_zpsd6f5ffa4.jpg

...then can get at +ve connector under rubber boot...
https://i1113.photobucket.com/albums/k503/mapidd/Biking/CB500/2014-04-03-1001_zps466351b7.jpg

Then take inside and take apart. Two long screws (nut head, size 7mm). Take off the end where the power connects, opposite the pointy out cog thing (technical mechanics terms there).

The commutator part looks a bit dirty...
https://i1113.photobucket.com/albums/k503/mapidd/Biking/CB500/2014-04-03-1004_zps87e536ab.jpg

...and the brushes (bushes?) a bit worn with uneven wear...
https://i1113.photobucket.com/albums/k503/mapidd/Biking/CB500/2014-04-03-1002_zps1de79f5c.jpg

The CB500 thread says Haynes manual states standard length of brushes is 12mm, service limit is 8.5mm. Only read that after I'd taken apart and reassembled. Outside the case...

https://i1113.photobucket.com/albums/k503/mapidd/Biking/CB500/2014-04-03-1006_zps0f9c8cdb.jpg

I cleaned out the case for the brushes. Lots of carbon dust. I'm thinking dust gets in the springs and stops them springing.

Anyhow if you have some degreaser or acetone (old school nail varnish remover) I'd use that to clean. Then a mild piece of emery found and cleaned up the copper bits...

https://i1113.photobucket.com/albums/k503/mapidd/Biking/CB500/2014-04-03-1007_zps5c19d516.jpg


Then as Haynes manual says reassembly is reverse of disassembly. Prior to screwing motor back together I put some red rubber grease round the seals for the motor parts and also round the seal that goes into the engine (as I had it available).

When wiggled and jiggled motor back found it best a two person job (I'm sure can be handled single handed). One person to put bike in gear and rock back and forth. The other to push motor back into engine. There's no sudden click or snap just the holes for the bolts suddenly line up.

Then to test. I'll admit slight hiccup as forgot bike in gear and stand down. So when hit starter got sweet fa. A quick slap on the back of the head for being stupid, into neutral and started on the button. Has started on the button every time since. The battery also seems less stressed. So I'm also thinking the starter before cleaning was drawing more amps from battery than was healthy.


I'll probably have to do this again as brushes were worn. Nice to know it's an easy fix.

I'm left with the inner glow of doing a job, not cocking it up and ending up with an improved bike. Also saving myself at lease £30+ labour. That based on an hours labour, that's about the time it took me. A competent mechanic doing this sort of faff regularly could probably get that down.

HTH
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...and the whirlwind is in the thorn trees, it's hard for thee to kick against the pricks...
Gibbs, what did Duckie look like when he was younger?

[covent.gardens]

Owning a CB500 I find this interesting, shame there aren't more of those how to's with pics.

[Teflon-Mike]

Much like the Benley e-starter, only you gave to remove the sprocket off the starter shaft from inside generator housing first.

May be worth mentioning; if you are going to strip and clean a starter, particularly on older bike; get new brushes as a matter of course.

Apart from wearing out; the flexible braid between the brush and the contact can go 'thin' with age, corrosion, use. I have actually seen a braid so thin that when testing, the amps the starter draws have made it glow like an electric heater element!

They are also bedded into the carbon, and some-times vibration can see the carbon crack around the braid, very slightly, but enough to give a poor connection.

Is a satisfying little job though, and so nice when the starter spins the motor over so much quicker and easier and QUIETER.
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My Webby'Tef's-tQ, loads of stuff about my bikes, my Land-Rovers, and the stuff I do with them!
Current Bikes:'Honda VF1000F' ;'CB750F2N' ;'CB125TD ( 6 3 of em!)'; 'Montesa Cota 248'. Learner FAQ's:= 'U want to Ride a Motorbike! Where Do U start?'

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[_mjs_]

Nice easy job ain't it?

I predict your drum brake will start binding on next... the magic trick is a blowtorch on the little pivot that pushes the shoes apart
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Previous Bikes: 2006 Honda XR125L > 2003 Yamaha DT125R > 1996 Honda CB500
Current bikes: 1997 Kawasaki ZZR 600 E5 > 2006 Honda Varadero XL125V