Er6 -- Starter Motor

[TongueThaied]

My ER6n is at about 2 1/2 years and 40,000 Kilometers. It appears the starter motor is dying. What happens is that when I try to start it I get a click (similar to what you get when that battery is a little too weak to kick it over), but the starter motor does not run. The battery is new and fully charged. I click, click, click several times, and then it will catch and start normally. This occurrence started out probably 5K km ago and was periodic. Now it is almost every time. Soon, it won't start at all, so I need to get on the stick and do something about it. It has all the symptoms of a dead section on the armature, where rapid clicks (attempts to start) may be jigging it just enough to get passed the dead spot (I have experienced this in cars). Or, I suppose it could be the brushes? Something else?

The ER6n parts catalogue lists brushes that can be purchased separately and some other parts, but the armature is not listed as a separate part. If the armature, is the problem, the whole starter motor will have to be replaced.

Has anybody else out there had to change an ER6 starter motor at this stage of the game? Anything I may be missing before I go buy an expensive part? If I have to buy a new one, I guess I'll have the old one rebuilt and put it on the shelf. I really don't have the time for a rebuild right now, and I seriously doubt that any Kawasaki shops in this country would have the skill, know-how and parts to do it.

I live in Phitsanulok and the nearest place for parts is 100 km away in Nakhon Sawan, which is a pain. Because of the periodic nature of this problem, if I went to Nakhon Sawan, purchased brushes and put them in and it starts up just fine, I would have know way of knowing if the problem will reoccur five starts later, when I'm back in Phit'lok.

What about the diagnostic software every shop has (but many do not know how to use)? Should it be able to detect the fault and isolate the exact problem?

I would appreciate any thoughts.

[monty]

Sounds more like the starter relay gone bad. Maybe burned contacts.

Other members maybe know how exactly the setup is on your bike.

Starter motors usually don't go bad that fast!

With a bit of luck it will not be to expensive!

Sent from my GT-I9001 using Thaivisa Connect App

[thaicbr]

How longs the warranty on Kwakers?

Maybe video it on your phone when it happens. Then you have proof.

sent from my Wellcom A90+

Edited August 22, 2012 by thaicbr

[TongueThaied]

Thanks, Monte. I wondered if there was a relay in there somewhere. Now, if only I can figure out a way to test it! Maybe the diagnostic software at the Kwacker shop can isolate it.

The annoying thing is that the damned shop, 100 kms away, doesn't seem to stock any parts beyond the usual consumables (filters, etc.). That means either take a guess and preorder parts or make two trips (with a bad guess being wasted expense). I am also considering telling the owner that he is the Kwacker shop and should stock the parts -- then demanding that he preorder every potential bad part at his expense -- if he wants my continued business.

Most things I can troubleshoot, but with electronic components in the loop and without diagnostic software, troubleshooting some things is impossible.

[thaicbr]

Thanks, Monte. I wondered if there was a relay in there somewhere. Now, if only I can figure out a way to test it! Maybe the diagnostic software at the Kwacker shop can isolate it.

The annoying thing is that the damned shop, 100 kms away, doesn't seem to stock any parts beyond the usual consumables (filters, etc.). That means either take a guess and preorder parts or make two trips (with a bad guess being wasted expense). I am also considering telling the owner that he is the Kwacker shop and should stock the parts -- then demanding that he preorder every potential bad part at his expense -- if he wants my continued business.

Most things I can troubleshoot, but with electronic components in the loop and without diagnostic software, troubleshooting some things is impossible.

Or just take a trip to Kawa rama 9. They got the lot.

sent from my Wellcom A90+

[TongueThaied]

Thanks, Monte. I wondered if there was a relay in there somewhere. Now, if only I can figure out a way to test it! Maybe the diagnostic software at the Kwacker shop can isolate it. The annoying thing is that the damned shop, 100 kms away, doesn't seem to stock any parts beyond the usual consumables (filters, etc.). That means either take a guess and preorder parts or make two trips (with a bad guess being wasted expense). I am also considering telling the owner that he is the Kwacker shop and should stock the parts -- then demanding that he preorder every potential bad part at his expense -- if he wants my continued business.Most things I can troubleshoot, but with electronic components in the loop and without diagnostic software, troubleshooting some things is impossible.

Or just take a trip to Kawa rama 9. They got the lot.sent from my Wellcom A90+

Hmmm, one 800 km round trip for a sure thing, or several 200 km round trips with loads of aggravation. It's a definite thought. I may just ride down to Nakhon Sawan early (on the way to Bangkok), ask them to hook it up to diagnostic, then see if they have the parts. If not, sawadii krup, and on to Rama 9!Do I need an appointment for Rama 9? If so, do you happen to know their phone number? I was only there once for a badly needed tir, and they told me I would have to wait four days. I found another shop.First things first, though. I found the relay and it's easily tested; I'm going to test it this minute. Edited August 23, 2012 by TongueThaied

[Hili]

OT: does anyone have the number of KAWA RAMA 9? The one i do have theres an automatic answering machine and if pressing to get connected with the right department it cuts the line?? They also not replied on an email i sent.

[TongueThaied]

It was indeed the starter relay, thank you very much Monte! It was hard to believe the starter could have gone out. I have never had a starter go out except on cars with over 100,000 miles. I should have thought of the relay. The good news is that the starter relay is about the easiest part on the whole bike to get to (unlike the ABS unit). I tested it, it was bad. I telephoned Kwacker in Nakhon Sawan and they will order and post it to me. All pretty painless.