GN250 click click click

[sigg]

Hey team, thought I'd seek some advice instead of throwing my toys like I have been.

She's a '93 Suzuki GN250. I got it for cheap the other week and am keen to fix it up.

After I rode it the other day we could start it fine, however, when starting her up later the only thing I hear is a click (of the solenoid?). I replaced the battery with a new Mottobatt this morning. It push starts fine.

I've done some reading today and I've figured out the following:

I've double checked all the battery connections. I've used a multimeter to test voltages at the battery (12.5V), before the solenoid (12.5) and after the solenoid (11.5V). I connected the wires thus bypassing the solenoid to no avail. Fuse is fine and I cleaned up the spark plug. I think the charging system is OK, the multimeter read 13.52V at 2,500rpm but showed little difference when reved to 5,000rpm. I tried to jump the old batt from my car, again to no avail.

Now from what I've read its likely that the problem is either the cable to the starter, the connections or the starter itself? Am I on the right track? If so, how do I get to the starter? Take the fuel tank off?

Also, is there a way that I can double check the ground from the battery?

Thanks!

[Drew]

Sounds like the starter is bung. The voltage drop from one side of the solonoid to the other, is just what you're losing in the starter motor I think.

They can be refurbished, if you're patient and careful. Or a quick fix if the windings aren't fucked is to simply pack the brushes in the starter motor a bit.

[sigg]

How do I get to the starter then? Take off the fuel tank?

[Drew]

How do I get to the starter then? Take off the fuel tank?It's hanging out the front of the motor. Cylider kinda thing, sort of where the motor meets the frame.

[fridayflash]

could be the common to gn's starter (sprag) clutch problem..get a price for the part from suzuki i guess, although the part is common to other applications as far as i know, so if you could get a part number you may get a better price at an engineering supplies crowd.

[bogan]

Is the ginny starter mounted on the front? I seem to recal it might be.

Anyway, the next step is to measure the voltage getting to the starter motor, so connect your voltmeter across the cables at the starter motor itself. You should see 11.5V, same as what the battery is dropping to. If you see a lot less its a wiring problem, if you see that much, it'll be brushes or the motor itself, or something else mechanical maybe...

[Drew]

could be the common to gn's starter (sprag) clutch problem..get a price for the part from suzuki i guess, although the part is common to other applications as far as i know, so if you could get a part number you may get a better price at an engineering supplies crowd.
A buggered sprag clutch usually lets the starter spin like mad, without turning the engine over in my experience.

[Drew]

Is the ginny starter mounted on the front? I seem to recal it might be.Yarp, but you made me wonder so I google imaged that bitch!

[sigg]

Thanks for the help guys. I'll test the starter tomorrow. I read somewhere that people connect the jump leads directly to the starter? Would this be wise? It would give me a definitive answer if its doable...

[mossy1200]

Tap starter with hammer (not smash) then try again.

[Drew]

Thanks for the help guys. I'll test the starter tomorrow. I read somewhere that people connect the jump leads directly to the starter? Would this be wise? It would give me a definitive answer if its doable...
Yep. There is a thick cable going to the body of the starter. Hoof a jumper lead onto it, and then the other one to a solid grounding point.

If it turns over that way...I'm stumped.

[hayd3n]

loose starter lead, had that on missus ginny

[neels]

^^^^^^^

Loose connection somewhere, or it's run out of brushes.

You can test the starter by sticking a lead from the terminal that has the big lead connected to it (it gets its ground from the engine) to the battery positive, if it turns it's a connection problem. Just don't touch lead bits of the battery terminal, they're pretty soft and melt easy, and make sure it's in neutral.

[fridayflash]

A buggered sprag clutch usually lets the starter spin like mad, without turning the engine over in my experience.

hmm..yeah you could be right..i seem to recall a few wank symptoms on the mussus gina..like spinning, clicking and serious labouring like it had a crook battery or connection etc.
armstrong starter was faultless tho...

[jellywrestler]

Yep. There is a thick cable going to the body of the starter. Hoof a jumper lead onto it, and then the other one to a solid grounding point.

If it turns over that way...I'm stumped.

if you're going to do this make sure the positive is connected to the power terminal on the starter firmly first then select somewhere easy on the chassis to connect the negative, somewhere where you can touch it on and take it off with ease.
that's Positive first then control it with the earth connection.

[ducatilover]

Starter is at the front by the engine mount, 2 8mm head bolts on the RHS IIRC.
Tap it gently with a hammer as said before, if it works, you have fucked brushes. I suspect it's brushes anyway.
If you're patient, when I next raid my parts at my other house I can see if I still have one of the GN starters there :2thumbsup

[sigg]

Starter is at the front by the engine mount, 2 8mm head bolts on the RHS IIRC.
Tap it gently with a hammer as said before, if it works, you have fucked brushes. I suspect it's brushes anyway.
If you're patient, when I next raid my parts at my other house I can see if I still have one of the GN starters there :2thumbsup

Thanks mate, we'll see how I end up.

Hammer didn't work neither did direct leads or jumping directly to the starter. Took the starter motor apart and took a photo of the brushes, to the rookie eye they don't look in the best shape but what do you guys think?

http://postimg.org/image/5llts9f53/ (1.1mb)

[peril 787b]

What state is the commutator in? (That's the segmented wide copper ring on the end of the armature (shaft in the starter) that the brushes contact with)

[sigg]

It was pretty black, cleaned it up with some fine grade sand paper and scraped some shit out of the grooves. Reckon the brushes are OK? One is significantly shorter than the other..?

[sigg]

Got a new starter from the wreckers. Problem solved. Thanks team.

[ducatilover]

Good to hear it bro :niceone: