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Discussion Starter · #1 ·
I have two 83 650 Interstates. I've recently learned that a 500 starter might work better. 10 min. break helps, but still its an embarrassing issue! Could the starter be wrapped somehow to keep eng. heat away? Thanks for your thoughts. Bucko rolls!
 

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I believe that they are exactly the same starter. The 650 just has more to turn and everything needs to be in tip top shape. That includes the battery.



If you haven't removed and cleaned your starter, that would be the first thing. Get all the carbon dust out, clean the commutator bar, lube the bearing, and consider a "Positive ground" fix.



This fix involves running a copper strap or braid from the ground brush to a hole that you drill in the rear case. It provided a positive ground for the motor to use. The current grounding is thru tabs on the brush plate being squeezed into contact by the assembly bolts. Sometimes they get corroded and don't make good contact.



There should be a thread under General Discussion - Quick Reference topic detailing the process. It isn't hard to do, I've done several. You just need to make sure that the strap or braid doesn't interfere with anything inside. Think twice and drill once. It does make a difference, by the way.



There is also the trick of first cranking with the kill switch off, then flip it on after a second. That saves the sprague clutch from getting kicked back and stressed.
 

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My Gl650 used to give me fits when starting. I too had to cross my fingers, do the kill switch trick etc. A real pain and potentially damaging to the starter clutch. I did the ground strap fix and the starter really spins the motor with no problem. It never kicks back now. When the motor is warm I don't even hear the starter turn, the motor just jumps to life. The starter is easy to remove and reinstall, and the ground strap fix is easy to do.
 

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My Gl650 used to give me fits when starting. I too had to cross my fingers, do the kill switch trick etc. A real pain and potentially damaging to the starter clutch. I did the ground strap fix and the starter really spins the motor with no problem. It never kicks back now. When the motor is warm I don't even hear the starter turn, the motor just jumps to life. The starter is easy to remove and reinstall, and the ground strap fix is easy to do.


Even just cleaning it up inside and a bit of emery on the plate edges that have the brushes on works wonders.They are the part that seems to get clogged with old carbon and corrosion causing bad grounding.Of course on the outside you should emery the bare contact areas as well so when it's fitted it grounds well.



More info here,



http://globalcxglvtwins.hostingdelivered.com/viewtopic.php?f=8&t=208
 

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Discussion Starter · #6 ·
Thank you guys very much for the advice. One contributing factor could be that where I park them is relatively dry as far as simple rainfall but not sweating dew point humidity. Here in Oregon and WA. at least in the western sections it rains alot, probably somewhat similar to England. From past trips I know Missouri can be humid! Thanks again; bucko rolls
 

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Here is a short list on what needs to be done ...



Cleaning & servicing the starter is a 20 minute job for me with experience. You should be able to do it in 1-2 hours.



You need to:

*The day before spray down the screws with penetrating oil to give it a chance to work in to the threads.

*Keep track of where everything came from so it goes back together exactly the way it came apart.

*Disconnect the battery

*Take out the two bolts that hold the starter in place

*Disconnect the hot and ground wires to the starter

*Put a large flat blade screw driver between the starter and the engine and gently push it out of the engine. No oil will leak out.

*Take the snap ring off the gear

*Remove the screws holding the motor together. If they don't unscrew easily grab the screw shaft near the threads with a vice grip to break it loose.

*Carefully pull it apart and look for the tiny o-rings between the two end caps and the main body. They break easily.

*Make sure you don't miss the sequence of parts and washers. Scrape the ends of everything with your fingernail to make sure there aren't any washers that you missed. They tend to stick and basically become invisible.

*Clean everything spotlessly clean not using anything metal. A Scotch Brite pad works great.

*Do not clean the brushes.

*Don't use carb or brake cleaner cleaner on the armature & main body as it could damage the insulation.

*When everything is clean lightly lube the end caps so everything will spin smoothly.

*When reassembling be sure not to put any side force on the brushes. Pull brushes gently back to put the armature back in place.

*Be careful of the o-rings. If you break one you can use silicone caulk of almost any type.

*Put the starter back in and enjoy your new starter.
 

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My '82 GL500 was sluggish starting. I removed the starter and took it apart. Inside it was full of carbon and rust. I wire brushed the rotor, cleaned everything else with a rag, oiled the bearing and put it back together. Bike now starts quickly. So just as others have said, clean it and make sure all electrical connections are shiny and free of rust/corrosion.
 
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