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Post Info TOPIC: Starter motor repair, using fazer Starter motor


Super Guru

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Starter motor repair, using fazer Starter motor
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I have been asked a lot about this lately, so I thought I would re post my old solution to a cheap starter motor repair.
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Hi

I have been doing a lot of maintenance on my bike lately, and have spent quite a few pounds. Now my starter motor has packed up, shredded gears, done the sprag and large idler gear, then turned my attention to the starter. A new starter from Yamaha is over £300 +, pattern part from china £120, as I have spent so much and am on a budget, I done some research and found this....http://www.dirtybiking.co.uk/features/tech_stuff_2005_starter_rebuild.htm

 

I found a starter on ebay for £20 with free postage, when the part was delivered I put both on the bench and reflected on Adrian's article. I really found it hard to get myself motivated to do that much work, and started to look at them closely, what I noticed was that they were very similar. I spent the next hour trying to think of ideas, then had a eureka moment.

The only difference of the starters was that the fazer one was 12mm longer and the mounting bracket and spigot for the electric were different and in the wrong place (would hit the cylinder head), what I came up with is this. I took the back part of the ttr starter off, and swapped it with the fazer one, drilled out holes 12mm from the centres of the original ones, so that the starter could move back 12mm. Then I cut of the old holes, took a file to the raised bit's and replaced them later with washers, to make the correct position. I had to file a bit of the back of the starter to get the bolts to fit properly, this is obvious if you have a go at this. Then I bolted the modified ttr one onto the back of the fazer starter and fitted it to the bike!

Once I had worked out what to do, the actual work took 30mins

I have nearly got the rest of the bike back together and will let you know what happens next, ie if it STARTS!!!!

Here are the photo's of the work.

 

starter 003.jpg

starter 018.jpg

starter 020.jpg

starter 021.jpg

starter 024.jpgg

starter 026.jpg

If you are going to do this, PLEASE MAKE SURE YOU TAKE THE STARTER GEAR COVER OFF AND INSPECT THAT THE STARTER PINION GEAR IS WORKING ON THE WHOLE SURFACE OF THE IDLER GEAR. If it isn't, you will have to adjust the fixing holes and move the starter motor inwards a bit!

Anyway if this starts the bike, it is a very cheap way of fixing a starter and does not take too long.smilesmilesmile.

Hope that you at least enjoy my report, if nothing else.

Cheers

Steve

 



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good on y steve i like a bit of fetteling to save a few pounds but usefull to all our ttr members maybe you can sort a few out for your stock for people not able to do this but still like riding their ttrs but not fixing them cheers john

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Great work!! People will love this!

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z1g


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This is handy to know, as starters here are a few hundred dollars ($360 from memory)..


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Great post..! Thanks for that, i might keep an eye out for a cheap one ., its only a matter of time on a 94 im guessing...?

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The original starters will outlast the bike. It's only when a worn sprag is ignored that you get problems no

A great guide from Steve and it may just have motivated me to have a go at adapting a couple of Fazer starters I have gathering dust here!

Brian



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An even easier route to a second hand starter is to find a starter from a YP 250 Majesty { a scooter i think} and swap the end/back plates from one to the other and you have a starter for a a TTR. I have succesfully done this and they are bought cheap 2nd hand. I posted it on the site here somewhere when i did it at the time. You just swap the back plates over and it is done. couldn't be easier.

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1996 TTR 250 OE, 1996 YAMAHA WR 200, 1990 YAMAHA FZR 1000,2001 HONDA DEAUVILLE 650, 2005 TTR 250, 1998 Honda CR125R( in pieces) 1994 Kasawaski KX 250.



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Just bought one to try out, thanks for re posting that.

Steve



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