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gloft

Starter problems?

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Anyone else had to replace/rebuild their starter motor? Mine is making an ugly noise when I hit the button. If so, any words of wisdom :cry: BTW, mine is an 03 model and have had 0 problems since shearing 3 woodruff keys in the first 150 miles. I now have over 2.5k miles on the bike.

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I have a 03 wr450.

Sheared key at 2.5 miles. Upgrade to 04 parts.

About 30 bike hours later, I had to replace my starter motor.

I can't tell you what it cost, because I got a replacement starter for free.

Easy job to swap out a starter. Just make sure you disconnect your battery before you start the job.

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I heard of some motors having bad connections to the windings internally on 03's. It may be repairable. Otherwise replace the starter motor. I think you can search for the starter motor fix some guys pulled off without having to order new ones.

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i have an 04 with no problems but i've heard the 03 was just a bad year for that

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remove the cover and look at the drive gear,if its in good shape it may be your starter clutch on the flywheel slipping this is usually the 1st thing to go .i just replaced all the parts on my 03, i tried the 04 upgrades but it would not work on my bike {i'm the only one in the world} i have all new 04 parts for sale if you want to contact me

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Make sure its your starter motor making the noise! You can remove the small round cover on the shifter side, pull out the gear and run the motor without a load. Watch for small washers when removing the cover. My 03 starter clutch failed and made noise only when using the starter. I have never had a flywheel problem on the 03 and in fact it starts much better than my 05.

The starter clutch is behind the flywheel. Good luck!

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Hey postalrider, Why didn't the 04 parts work on your 03? I may take you up on the parts if I find the problem is not the starter motor but the starter clutch itself. If I end up pulling the flywheel, I may as well upgrade to the new parts. BTW, according to the manual you need a puller to remove the flywheel. Anyone have another method they will share? Thanks for the help guys :cry: This forum will make me into a mechanic yet!!

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Hey postalrider, Why didn't the 04 parts work on your 03? I may take you up on the parts if I find the problem is not the starter motor but the starter clutch itself. If I end up pulling the flywheel, I may as well upgrade to the new parts. BTW, according to the manual you need a puller to remove the flywheel. Anyone have another method they will share? QUOTE]

+1 postalrider. Why didn't the 04 parts work?

gloft,

You can use any gear puller that any local auto parts store will carry. It doesn't have to be the special Yamaha tool. Make sure you take Desracer's advice. You don't want to pull that flywheel off if you don't have to.

BTW, if you do need to pull the flywheel off, you will need to heat it up to breakdown the Loctite that is holding it on.

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the problem was the torque limiter and starter drive did not have the right clearances.i put another new case and starter and tq lmtr and as soon as i hit the button you could tell it was not right.so without even starting the bike i went back to the old set up with a new starter ,it spins much better and starts like magic,the only other change i made was from 50 to a 52 pilot,the parts i have 4 sale are new 04 case new trq limiter ,used 04 smalll cover and 2 washers.tonight a friend was looking at the small cover and seem to think it shows some wear on the brass bearing ,maybe this was my problem either way i'm done trying.if you want to buy the parts i will take $250 for it all it retails for around $340.i do recommend the buyer replaces the small cover .i think around $30. everyone on tt has had no problems ith the 04 upgrades only lucky me p.s this may not solve all your probems,i think you need to replace the clutch on the flywheel,be sure to get both parts clutch and hub it rides on.

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the problem was the torque limiter and starter drive did not have the right clearances.i put another new case and starter and tq lmtr and as soon as i hit the button you could tell it was not right.so without even starting the bike i went back to the old set up with a new starter ,it spins much better and starts like magic,the only other change i made was from 50 to a 52 pilot,the parts i have 4 sale are new 04 case new trq limiter ,used 04 smalll cover and 2 washers.tonight a friend was looking at the small cover and seem to think it shows some wear on the brass bearing ,maybe this was my problem either way i'm done trying.if you want to buy the parts i will take $250 for it all it retails for around $340.i do recommend the buyer replaces the small cover .i think around $30. everyone on tt has had no problems ith the 04 upgrades only lucky me p.s this may not solve all your probems,i think you need to replace the clutch on the flywheel,be sure to get both parts clutch and hub it rides on.

You really need to not give up on the 04 upgrade. I was one of the first to do it and had no problems. Where are you in KY. I live in Indy and head to Cinci & louisville regularily. PM me if you want some help.

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Mine fitted straight in.I put the bush in the 03 case then there was a washer or two?. The different gear and the 04 outer small gear cover.Perhaps you need someone who has done this mod to have a look for you as i have not herd of any one else having a problem.I did not need a puller as mine was sheerd and very loose.( lucky me only had to push it 7 k's.Good luck Dave

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Hey postalrider, Why didn't the 04 parts work on your 03? I may take you up on the parts if I find the problem is not the starter motor but the starter clutch itself. If I end up pulling the flywheel, I may as well upgrade to the new parts. BTW, according to the manual you need a puller to remove the flywheel. Anyone have another method they will share? QUOTE]

+1 postalrider. Why didn't the 04 parts work?

gloft,

You can use any gear puller that any local auto parts store will carry. It doesn't have to be the special Yamaha tool. Make sure you take Desracer's advice. You don't want to pull that flywheel off if you don't have to.

BTW, if you do need to pull the flywheel off, you will need to heat it up to breakdown the Loctite that is holding it on.

Be carefull about this!! I have an 03 that I replaced the starter clutch on. I tried about 4 different types of pullers and a torch trying to get the flywheel off. Nothing worked. I got the right puller (cost about $40) and hit it with an air impact gun... and bingo!

If you order a new clutch, be sure to order a new case gasket and woodruff key.

By the way.... I have never had a problem with my 03 woodruff key.

Jimbo

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:cry: My 03 Starter motor started squeeking the last ride I did, when I pulled it I checked it WAS the motor and Not the starter clutch !

Having ascertained it WAS the motor I stripped it and found lots of water/grit in the brush/commutator end of things.....a quick clean, a dab of grease and a quick re-assemble later it is fine.it turns better and has stopped making noises !

one quick word of warning tho if you do strip the starter motor, mark ALL three parts end/centre/end for alignment as if you rotate them out of line...the motor runs backwards...... :cry:

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my 2004 is staring to give me starter/batt problems. apox 5000km on it.

i will post up pictures when i take it all apart to clean it.

one think i have learned is that the wr450 properly jetted is very easy to kick start. none the less when you stall on a big rock at the top of a 100m hill, there is no way to kick no matter how easy the stroke is.

must fix soon :cry:

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I have an 03 Wr and it also seems to make a horrible noise at times when starting. I have heard of the upgrade but have not yet made that change. Mine sounds like it might be kicking back if it does not start right the first time. This may have caused damage to you starter gear or other.

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LOL Indy, i like how 'Put oil back in' is red in the description. Is there a forehead slapping story to go along with that?

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Well it may be obvious but I have heard of guys forgetting to do it or tighten the drain bolt and seize a new engine! :cry: Just trying to be thorough in my write up for the guys that are not too comfortable as mechanics and dont forget about Marcus! :cry:

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