I was out for a ride a last weekend and the bike wouldn’t start after my coffee stop.

Once I got the bike back to HQ I found continuity between the Low Tension terminal and the body of the starter motor/solenoid assembly. I’ve removed the starter ( what were they thinking ) and disassembled it. The continuity is somewhere between the LT coil that pulls the plunger forward and the casting.

I can’t see how I would go about removing the coil from the solenoid body. Any thoughts?

I ordered a rebuild kit (which I’ve realised now that it’s on the bench won’t fix the problem) but I’ll fit it anyway, and a manual push cover for redundancy, which will get me riding again but I’m keen to sort out the short circuit and restore the handlebar switch functionality.

Any advice on fixing this would be most welcome.

https://www.ebay.co.uk/itm/204824552985 ... R5bz8dyCZA.
Fit another one complete.

It should have continuity.

_________________
Mithered ta death.
92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR

Instant short circuit the moment I press the start button?

....but there is zero resistance between the LT +ve cable terminal & the Starter body. I would expect to see some resistance as the current (should) needs to flow through a lot of copper to find earth.

When I press the starter button I can hear the click of the LT relay, then all electrics (instruments & lights) turn off. That would indicate to me a short circuit which is confirmed by the lack of resistance between the LT +ve terminal & the starter body.

It looks like I would need to push the coil out of the casting from the gear end but it doesn't look obvious how to do it. Once the coil is out I figure the source of the short circuit will be evident.

Should be circa 0.4 ohms.

_________________
Mithered ta death.
92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR

I've taken the starter/solenoid assembly apart, fitted a rebuild kit on the solenoid, done all the checks shown on page 5-16 of the manual which were all ok, cleaned the armature, brushes, coil etc, re-assembled it and then bench tested it, and it spun up fine.

I then installed it back on the bike, hit the starter button and got a fast click/buzzing noise with power disappearing from the instrument etc. So, pretty much the same problem on the bike. I tried the manual plunger I installed in place of the solenoid cover which has the same effect.

Where to from here?

Dukinfield.

_________________
Mithered ta death.
92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR