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XS 650 Starter Bendix Repairs
The Yamaha electric starter is not usually the problem when you hear a skipping and grinding noise when using the electric starter on a XS650. In the top image below, the starter bendix gearset is not engaged, the gear set is manually engaged in the bottom image. These are replaceable with an updated quality set availabe from a Yamaha dealer by removing the primary cover and clutch basket assembly on the right hand side of the bike.
The starter bendix gear in the disengaged position, with the bendix spring holding it toward the outside.
Gear is pushed in with a screwdriver against the bendix return spring to show the engaged position. When it is in, it engages a large mating gear machined into one of the righthand crankshaft cheeks.
Top gear on these two bendix drives is the gear that wears, gear number 4. Notice the worn down width of the top gear #4 on the right bendix drive set, and the normal gear #4 on the left bendix gear drive set.
The gears slide right off the assembly. Number 3 on the left, and the worn gear #4 in the center above, it is the gear with the alignment clip snapped on it.
The original early #4 gear clip fit into a recess in the cases, the later clip is wider and is installed in the new position to the right of the original location above. The bendix gear quality was upgraded around 1979, so a good early model gear may still fail early. The OEM Yamaha late model gears are available at a deep discount from Mikes XS.
Click below to see the original Yamaha service manual info:
http://www.650motorcycles.com/StarterReductionGears.jpg
Gear number 4, two in the above images but only one required per motor.
New starter gear #4 on the left above, jumping out, worn out and grinding bendix gear above right.
650 Classic Images & Info: Click Here!
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