HEADS UP!!!

Site upgrade in progress... Core site functions are working, but some non-critical features/functions will be temporarily unavailable while we work to restore them over the next couple of weeks.

Please post any bugs you encounter, but before you do, check to see if it's already listed.

Thanks for your patience while we work to improve the community.

Sign in to follow this  
Followers 0
momudder

2003 starter help

13 posts in this topic

Does removing the gear that drives the flywheel prevent my cases from being broken? My starter motor is screeching and i did a search on this site to fix it. This was described to track down where the problem is but it was unclear if it was also a way to prevent damage from an un updated starter.

Share this post


Link to post
Share on other sites

That is great info for when i do the upgrade but will removing the gear protect me for now?

Share this post


Link to post
Share on other sites

I also had starter problems.I have done the upgrade last year after my flywheel key broke.My starter acted like the battery was flat.The battery checked out o.k.ON removing the starter i found the brush end metal bearing to be worn.Sorry not a yamaha part but we can sell you a new starter $450 aus the parts guy said with a smile.I bought a bearing at the local bearing shop for $ 2.90 and had a mate turn it to fit on his lathe and also put a new set of brushes in and it runs a treat.You can remove the starter from the exhaust side by pulling the muthler loosenig the headers and turning up the rmoving the oil pipe.

Share this post


Link to post
Share on other sites

remove the small round cover (near the starter, two bolts) and take out the idler gear inside. make sure you don't let any parts drop inside and your good to go. you'll have to kick start now but that's easy enough. if you want, you can remove the battery and save a couple pounds. tape up the wires real good and make sure they don't touch the frame (ground).

Share this post


Link to post
Share on other sites
Does removing the gear that drives the flywheel prevent my cases from being broken? My starter motor is screeching and i did a search on this site to fix it. This was described to track down where the problem is but it was unclear if it was also a way to prevent damage from an un updated starter.

I should have added more to my earlier post. Yes,a quick fix to dis-able the stater mechanism is:

1. remove the two 8mm bolts that hold the side cover on (cover is about 3inches in diameter)

2. remove the cover, the center shaft,both washers (outside and inside),bearing and gear-----most of this will come out as one piece.

This will protect the starting system from being damaged.

Share this post


Link to post
Share on other sites
I also had starter problems.I have done the upgrade last year after my flywheel key broke.My starter acted like the battery was flat.The battery checked out o.k.ON removing the starter i found the brush end metal bearing to be worn.Sorry not a yamaha part but we can sell you a new starter $450 aus the parts guy said with a smile.I bought a bearing at the local bearing shop for $ 2.90 and had a mate turn it to fit on his lathe and also put a new set of brushes in and it runs a treat.You can remove the starter from the exhaust side by pulling the muthler loosenig the headers and turning up the rmoving the oil pipe.

Hi i just read your post and I just got a gret deal on a 03 450. The deal cam about because of the same problem you describe. The starter just produces a relay type clicking sound, like a dead car batt. The mechanic says that its the brushes..

Do you think you might be able to help me prevent paying this guy the 400+labour by telling me some detailed information on your fix?

ta in advance...

Ben

Share this post


Link to post
Share on other sites

I burned through a starter on my 03 wr450 also. They're junk and too small for trying to crank over the 450. The starter on my DRZ400 is almost twice as big in diameter as the one on the WR and it's got 50 less cc to crank. More evidence on the starter being to small is that the ATV 450 motor with electric start has a bigger diameter starter on it then the WR450. Yamaha must have seen a reason to "upgrade" the starter when it designed the ATV.

Share this post


Link to post
Share on other sites
Hi i just read your post and I just got a gret deal on a 03 450. The deal cam about because of the same problem you describe. The starter just produces a relay type clicking sound, like a dead car batt. The mechanic says that its the brushes..

Do you think you might be able to help me prevent paying this guy the 400+labour by telling me some detailed information on your fix?

ta in advance...

Ben

Some of the 03 starter motors had bad brush installations. Take the motor apart and try to solder the connections some motors came with poor brush installations. :banghead:

Share this post


Link to post
Share on other sites

i just spoke to a yami dealer. He said a new set of brushes would cost 22.50. I might just go for those.... If it all works out this just might be the deal of the century. thanks for your information.

Share this post


Link to post
Share on other sites

While you have it apart it's easy enough to check the rear bearing.Its a easy job to replace the brushes.

Share this post


Link to post
Share on other sites
I also had starter problems.I have done the upgrade last year after my flywheel key broke.My starter acted like the battery was flat.The battery checked out o.k.ON removing the starter i found the brush end metal bearing to be worn.Sorry not a yamaha part but we can sell you a new starter $450 aus the parts guy said with a smile.I bought a bearing at the local bearing shop for $ 2.90 and had a mate turn it to fit on his lathe and also put a new set of brushes in and it runs a treat.You can remove the starter from the exhaust side by pulling the muthler loosenig the headers and turning up the rmoving the oil pipe.

Having the same problem. Are you talking about the bush in the back housing near the brushes or the bearing in the front housing near the drive cog??

Thanks. just got the bike and it has the dreaded started motor probs!!!!!!

Share this post


Link to post
Share on other sites

Does anyone know if the YFZ starter does in fact have more output and reliability than the WR??? It looks like a conversion could be done by replacing the left crankcase cover and the YFZ starter. The cover is taller in the starter area to allow for the larger diameter and includes a badly needed additional breather spigot. The starter mounting appears to be the same as the WR. I am not sure if all of the starter gears will swap, but the starter gear #3 and sprague (one way hub) have the same part numbers. The other issue is if the stator will exchange.

If anyone has done this, please jump in.

Don E

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!


Register a new account

Sign in

Already have an account? Sign in here.


Sign In Now
Sign in to follow this  
Followers 0