Hi folks, after much searching of the forums and pouring over similar issues with no luck, I guess it's time to post my own starting issue here. I'm stuck.

The long and short of it is: the bike won't start up at all. I had it in to a mechanic for the well known head gasket leak issue (starting and running without a problem mind you), when I got a call from them saying that the starter was kaput and would need to be replaced to the tune of $500 plus labor. Well, I took the bike back, replaced both the starter motor and relay solenoid myself for good measure (both new parts checked out fine) and still no joy.

Symptoms: with the battery charged up and on the bike, lights all come on and look good. When I pull the clutch and hit the starter switch, all the lights dim significantly, and there's a single loud *click* from the starter relay. At one point there was a loud buzzing from the relay instead of a click, but that seems to have disappeared - think that was a combination of old starter/new relay or new starter/old relay... can't remember which.

I've had both an old battery (which I know worked in the past) and a brand new AGM from Autozone on a tender, fully charged, and can't get the engine to turn over with either.

I've pulled the spark plug to give a visual check and as far as I can tell, it looks good - doesn't appear to be bridged, worn, or otherwise fouled, but gave it a quick cleaning just in case. I carried out the spark test by holding the base of the plug against the engine body, but instead of the "fat blue spark" that folks have said means things check out, I either get a very weak spark across the gap, or no spark at all. Is this indicative of a bad plug or an issue elsewhere?

That's as far as I've gotten, and I'm not exactly sure where to go from here. Any help or advice would be much appreciated!

Thank you in advance!

-Dave

EDIT: I should mention, the bike is a 2001 with about 3300 miles - 2000 of which I put on. I bought it 3rd hand, but very gently used.

From the sound of it, the starter solenoid is engaging (the "click") but the engine is not turning, which causes high current and the dimming of the lights. So the interlocks are working as they should. While I have not had to go into mine, I understand there is a washer or spacer in the starter drive system which can be incorrectly assembled, and which will cause this problem.

Is the decompression solenoid/ head unloader operating? Is there too much compression to get the starter going?

shovelbum87 wrote on 06/23/13 at 17:39:37:


I'm not really sure... how can I tell if the decompression solenoid and head unloader (or are those one and the same) are operating? Please forgive my ignorance here - I'm pretty handy with a wrench, but I haven't had much experience troubleshooting and fixing motorcycle issues.  

Ask the mech if he had the stator cover off.
You don't need to take if off for the head plug.
But if he did then that could be it.

If the stator cover was off.....the washer usually falls off the starter idler gears.  The idler gear with the clutch gets a washer on ech side, and the idle gear that the starter motor meshes with does not get any washer.  People unknowingly put a washer on the rear that meshes with the starter - then the gear is pushed out too far and hits the case when it is installed and tightened....and it locks the gear up and won't let it turn.  To find out if this is the problem take the starter out, then stick your finger in and try to rotate the gear......you should be able to turn it in one directiion easily......and the other way the starter clutch will be engaged and you won't be able to turn it.  If the dealer screwed up the washer.....they should fix it at their cost. (But I am not sure I would want them working on it anymore if their diagnostic abiliities are so poor).

You and also confirm the starter works by hooking it up while it is not bolted to the engine and seeing if the starter works when you push the button.

To see if your decompression solenoid is working.......look at the lever behind the chrome cover at the top left side on the eninge.  See if this lever moves up when you hit the starter button.....and you should hear a loud click just before the starter engatges.

winterwalker wrote on 06/24/13 at 07:10:24:

Ya know, on reading through this thread, I wonder whether the "mechanic" removed the stator cover, replaced it with the washer incorrectly installed, then decided the starter was bad when it wouldn't crank the engine. Could be, the original starter is still good.