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  • #21
    Originally posted by rustybones49801 View Post
    I took the starter apart last night, cleaned the contacts with contact cleaner, put it together and it is 100% better, Thanks for the advice Dave, but cables may still be in the future, we shall see.
    Keep in mind that all the crap you cleaned out of the starter is a carbon dust material from the brushes. Hopefully you inspected the brushes to see if replacement was needed.

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    • #22
      Yes, there is normal wear in the brushes that are contoured to the armature, but the length seemed good and there was tension on each brush. I didn't look up acceptable brush length at the time, kinda eyeballed it, as it was 3AM anf the gin and tonics were very tasty!!
      All these extra nuts and bolts go somewhere... oh well, I'll figure it out later.

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      • Bikerron
        Bikerron commented
        Editing a comment
        Been a good time to put a daub of grease in the end cap bearing cup for the armature, if you didn’t.

    • #23
      Using the heavier cables that davej makes is the way to go. It sends more amps to the starter and is better on the starter too.

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      • #24
        I have a set of cables ready to ship if you decide to upgrade yours. $45 shipped. Just send me a PM.

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        • #25
          Originally posted by davej View Post
          If you decide to upgrade to the larger size battery cable just let me know I make and sell them. $45 shipped in the U.S. They do help as long as the starter is OK Also just taking the back plate off the starter and cleaning out all the carbon dust, cleaning the commutator check the brushes (replace if needed) will fix starting issues and is an inexpensive and easy job.
          Im interested in a cable kit dave, will send you a pm with my info.

          Im definitely haiving starting issues also, when I hit the starter button sometimes I can only get one or 2 turns out of it. I need to check the starter also and clean it out.

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          • #26
            Originally posted by blueverclear View Post

            Im interested in a cable kit dave, will send you a pm with my info.

            Im definitely haiving starting issues also, when I hit the starter button sometimes I can only get one or 2 turns out of it. I need to check the starter also and clean it out.
            PM returned

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            • blueverclear
              blueverclear commented
              Editing a comment
              Got my wires today, great quality thanks Dave!

            • Bikerron
              Bikerron commented
              Editing a comment
              +1 on the starter cleanout. Shine up that commutator and measure the brushes length (0.20” min.) and order a kit if not to specs and put a daub of grease on those armature bearings, also.

          • #27
            Thanks Grant,Glad to help. I have more sets ready to ship for anyone that would like to purchase a set.

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            • #28
              Same problem here as well with my 02. I will check the decomp and the starter. Thanks for the info!!

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              • #29
                Sam let me know if you want a set of cables I always have them ready to ship

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                • #30
                  yes, all the above, the early RS is known for needing bigger battery cables. Also, i had problems with the brush plate in my 2004 starter motor. , it cracked inside at the 90 degree bend in the brass that holds brushes, so i replaced it with OEM, 1 yr later , same thing, so i replaced with aftermarket brush plate. now i get no, no, 0 false starts, defined as starter engages but fails to start engine.
                  if your a gear head, the starter is a piece of cake to check inside. keep in mind the visual inspection failed to find this problem, it wasnt until i played with this part until it fell apart in my fingers.
                  maybe the temperture was too low in the robot that made that part, so rather than a nice smooth 90 degree, it was a cold , stressed bend.
                  I CHASED THIS PROBLEM FOR A WHILE B4 I FIGURED IT OUT.
                  JUST BECAUSE A PART IS NEW, DONT MEAN IT IS GOOD!
                  i can remember my dad busting his knucckles while tooling,
                  saying, cheap Japanese shit, after WWII, like we DECLARE china stuff today.

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                  • #31
                    I have similar issues with my 2009.. It seems like its fighting the compression of the motor to turn over.. I’ve got a new battery but just cranks slowly.. The bike has always cranked slowly but seems ever slower than normal at present. I took the starter off and checked the brushes... was very clean inside brushes looked damn near new.. (bike only has 7500 miles). Dave I’m gonna go ahead and PM you for a set of your cables.. Is there a trick to reseating the armature inside the brushes? It’s got my stumped at the moment.. Thanks all.. -Rob

                    Comment


                    • Bikerron
                      Bikerron commented
                      Editing a comment
                      Pull the armature out of the housing and install that first into the brush plate. It’s easier to get in there to manipulate the brushes back against the springs with a screwdriver while inserting the commutator end down. Put a daub of grease in the bearing cup before starting.

                  • #32
                    cold weather and thick oil doesn't help either.......
                    not all those who wander are lost......

                    Comment


                    • #33
                      Roadstar Rob PM returned

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                      • #34
                        Oh , back to the starter brush plate problem, I FORGOT TO SAY IT IS THE BRASS THAT CONNECTS THE HOT LEAD TO THE BRUSHES, SINCE THE BRASS IS CRACKED, THERE IS PROBABLY A MAJOR VOLTAGE DROP, its important to note that you cannot really see it . It happened to OEM's on my 04, and the replacement OEM part from 2016, so it is conceivable they had a major production issue. After repetitive high voltage hot stress, they crack . its weird and you would not expect it because it is really not a "moving part". it cracks right at he 90 degree bends. Click image for larger version

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                        • #35
                          Originally posted by Bikerron View Post
                          Pull the armature out of the housing and install that first into the brush plate. It’s easier to get in there to manipulate the brushes back against the springs with a screwdriver while inserting the commutator end down. Put a daub of grease in the bearing cup before starting.
                          Thanks Bikerron- that did the trick (although not before several F bombs and a lot of trial and error).. Wound up using some duct tape and 4 mini screwdrivers.. Unfortunately bike still cranking slow... I’ve ordered a set of cables from Davej and hopeful they help..

                          Comment


                          • Duke
                            Duke commented
                            Editing a comment
                            The cables surely won't hurt, and is better on your starter.

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