Electric starter problems
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  1. #1
    Junior Member zj_hummel's Avatar
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    Hello there, I bought a 1990 TW200 two months ago. I took it apart to powder coat the frame and then put all new plastics on it. So here is the issue: I put the key in the ignition then turn it to "ON" and you can hear the starter turn over for a second. Next I will press the starter button and here rrrrrrrrrrrreeeerrrr. I was thinking it was the starter relay so I bypassed it and then I heard the same thing; rrrrreeeerrrrrr. The electric starter system was not turning over the motor. I figured it must be the starter clutch, so $94 and 2 hours later it was fixed. NOT the case. I kick started the bike on Saturday and road it 75 miles thru the mountains--wow, it was a great ride. I got to my destination and let the bike sit for 2hrs. I put the key in, turned it on, and then I heard the starter run nonstop, but it never turned over the motor. Is it the starter? The relay? Or did I mess something up when I put the bike back together? Hope you can help. Thanks

  2. #2
    Senior Member pgilles's Avatar
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    If it's always running, the starter relay may be stuck in its energized state or it's getting 12 volts from somewhere it shouldn't or your start switch is sticking/wires get shorted together. When you turned the key on and the starter spun, were you in neutral? Was the clutch pulled in? Will it spin when you aren't in neutral? How about if you don't pull the clutch in?



    Sold bike.



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  3. #3
    Junior Member zj_hummel's Avatar
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    Thanks for replying. When the bike is in neutral the starter will spin and you here rrreerrrr out of the relay. So I bypassed the relay and the starter will spin faster with no rrrerrr out of the relay. I also have pulled in the clutch, no go with that and the kick stand was up for that part. I was thinking it could be the safety ( I'm not that lucky) It will only spin when you turn the key to "ON" then push the start button. Could it be the starter or maybe the relay? Just got done looking over all the wiring to see if she was grounding out some how. Big no on that.

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  5. #4
    Senior Member pgilles's Avatar
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    ***Sorry, I think I read your post wrong. I was thinking the starter never stopped spinning. If it's just making a funny noise or not spinning fast enough to engage its teeth on the starter clutch, then go with the below post's recommendation about the battery.



    The starter relay could be sticking or the starter button could be sticking. The starter button on the handlebar could just have a piece of debris inside of it that makes it stick when pushed and never allowing the starter to stop, until bumped or knocked loose. Or the starter relay itself is sticking and preventing the starter from stopping.



    If it were the starter button stuck, then putting the bike in 1st gear and no hands on the clutch should stop the starter (the neutral and clutch safety switches would not allow voltage through the "starting ckt cutoff relay"...if you still have these safety switches intact). Or turning the key to OFF would stop it. Or if the R/W wire going to the starter button is grounding out then it'd fire off the starter.



    If it were the starter relay sticking, turning the key to OFF would do nothing to stop the starter.
    Sold bike.



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  6. #5
    Senior Member n2o2diver's Avatar
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    Sounds to me like the battery. If the battery is low it will cause the relay to make noise and the starter will not turn. Top off the battery with distilled water and put it on a slow, like 1.5amp, charger for a day.



    If the starter is spinning but it is not engaging the motor then something is wrong with the gear to the motor. Did you have the left side engine cover off at all?
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  7. #6
    Junior Member zj_hummel's Avatar
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    Quote Originally Posted by n2o2diver View Post
    Sounds to me like the battery. If the battery is low it will cause the relay to make noise and the starter will not turn. Top off the battery with distilled water and put it on a slow, like 1.5amp, charger for a day.



    If the starter is spinning but it is not engaging the motor then something is wrong with the gear to the motor. Did you have the left side engine cover off at all?


    I have replaced the starter clutch first, because I was thinking the starter idle gear was not engaging. Well I had it apart I checked to see if the starter motor was even turning over IT WAS. Its like the starter system is not turning over the motor. I can kick start it just fine.

  8. #7
    Senior Member n2o2diver's Avatar
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    If the battery isn't strong enough it will cause the problem your describing. I'd check that first before moving on.

    It doesn't take much drop in current from the battery, they are not that strong to begin with. It may spin without the load of the motor on it and I think that is what you are seeing. Charge the battery !
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  9. #8
    Junior Member zj_hummel's Avatar
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    Quote Originally Posted by n2o2diver View Post
    If the battery isn't strong enough it will cause the problem your describing. I'd check that first before moving on.

    It doesn't take much drop in current from the battery, they are not that strong to begin with. It may spin without the load of the motor on it and I think that is what you are seeing. Charge the battery !


    I just put the battery on a float charger so we will see. Thanks

  10. #9
    Senior Member PalmStateCrawler's Avatar
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    I had this problem on another bike and it turned out that the starter was turning backwards. I unbolted it and rotated the cover 180* and it fixed the problem. If you or someone else has taken the starter apart then it may have been put back together incorrectly. This drove me mad trying to figure it out but when I did it has not been a problem since. I would put money on this being your problem. Give it a shot and let me know if it fixes it.
    '13 690 Enduro R too many frickin farkles...
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  11. #10
    Senior Member n2o2diver's Avatar
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    Did you check the water level? Fill it with distilled water if it isn't already. If you are using a car battery charger be careful you don't boil it. Once you are sure you've got a good strong battery give it a go and let us know what happens.
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