I know I had posted about the starter not catching well and making clunky sounds. Today after installing the Mikuni carb I gave it the old "college try" and I may have made the problem worse, or easier to diagnose.

It would catch for maybe 1/2 a revolution, the engine would put-put for a half second and then the starter would disengage from the engine, spinning free. After 5 minutes of stubbornly trying to make it catch (usually hitting the button twice in rapid succesion, holding on the second time would help) the button became completely un-responsive, not even a little click that it gives when the battery is too low.

It seems to be its an electrical issue, solenoid maybe? Electrically everything else on the bike is fine, Battery is charged to 12v on my multimeter.

 

Fully charge to battery - an automatic battery charger is best, charge until the green light comes on. If the battery is liquid filled you can use a hygrometer battery tester to check. I don't think 12 volts is fully charged - you need perhaps 13 or more. I am not certain as i use an automatic charger and just go until the green light comes on.

With a fully charged battery, disconnect the small green wire from the solenoid. Now when you push the start button you should be able to hear and/or feel the start relay give a gentle click. If not then the button or the relay or the wire between them is faulty.

There is a procedure in the factory service manual 99484-** to test the solenoid. It is tested without being removed from the bike. That test would be the next step. ** is either 78 or 85 depending on the year of your bike.

It is possible that the problem is with the starter bendix, but that test waits until these are done; and i will not be able to help with it.

But it sounds to me like a low battery.

 

Turn on your headlight and see if it is really bright. If it is not that bright you need to charge the battery.
If you get no sound of clicking at all but the headlight is bright then most likely you have overloaded the starter by repeating the pressing start button over and over again without allowing it to cool off.
15 seconds of holding down the button will overheat things.

In this case look at the solenoid and the relay breaker for the starter.
It sounds like you have a low battery as long as you heard clicks.
No clicks...... suddenly........ makes me thing you overheated the system.
In any case charge the battery overnight and try again.
pg

 

2nd piniongear,you need starting amps,dont worry to much about volts right now, remember i said to charge the battery and have it load tested? tryin to start with a week battery is gonna do nothing but hurt the starter and entire electrical system,

 

Thanks all, my biggest hurdle in life is that I tend not to be methodical enough. I am more and more in the project/wrenching mindset than the riding one at this point though and just need to find a day with enough time to troubleshoot.

I will get the battery inside and on the charger tonight. COuldn't afford an automatic one but I have a nice multimeter to let me know when to take it off. Its a little 1amp charger I got at autozone when I got the bike.

I went outside again to try it out, the lights all shine bright and horn works but the starter button is still unresponsive.