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CMaD

03 WR450 starter sticking

6 posts in this topic

I just got an 03 WR450 and the starter has stuck (I think) on it a few times. When I go to push the start button it just clicks, then I'll move the motor a little with the kick starter and then it will turn over with the starter. When I move the motor with the kick starter i hear the starter let go or something. Do I need to open it up and do some greasing of something. Dont know if the 04 starter upgrade thing has been done either.

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I just got an 03 WR450 and the starter has stuck (I think) on it a few times. When I go to push the start button it just clicks, then I'll move the motor a little with the kick starter and then it will turn over with the starter. When I move the motor with the kick starter i hear the starter let go or something. Do I need to open it up and do some greasing of something. Dont know if the 04 starter upgrade thing has been done either.

It is easy to tell if the 04 starter upgrade was done. The starter clutch gear cover on the 04 has a raised bump where as the cover on the 03 is flat. If this mod has not been done do it immediately or completely remove the clutch gear assembly and only use the kickstarter.

If you do not do this it will only be a matter of time before you suffer the dreaded woodrift key shear on the flywheel.

As to the starter working intermittantly it almost sounds as if the brushes may be sticking. You may want to overhaul the starter motor. Pay close attention to the brushes and make sure that they move freely in the brush holders. A good cleaning is usually all that is required but this may be a good time to replace the brushes.

Good luck.

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Have you been riding my bike CMaD?

Seriously I just bought an 03 WR450 and I'm having the exact same issue.

I ordered a new set of brushes. I'll let you know if it fixes the problem when I get them in.

Mine does not have the 04 starter mod...yet.

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willy_fitz- When you refer to the 'starter clutch gear cover' is that the idle gear cover? The starter clutch is bolted to the back side of the rotor, correct?

Reason I ask is my stator/rotor is fried, appears 2 of the bolts that go through the rotor (appear to hold on the starter clutch) sheared off and bounced around the rotor causing the stator to fail. I am now wondering if the woodruff key wasn't the initial failure...

RMJ

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You are correct in this is the idle gear cover I was attempting to describe.

The starter clutch is actually part of the idler gear assembly . On the 03 model it was basically a one-way bearing. When the bike backfired, the bearing would cause a lockup of the starter and the rotor leading to the woodrift key failing. I just sold my 03 WR so I no longer have the manual to look at the drawings to see what you are describing but if you closely examine the taper on the main output shaft and see any scoring, you did have a woodrift key failure.

Hope this helps.

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