DL650 2008 starter problems

[Adrian80i]

Hi all,

I have been pulling my hair out with starter problems on my 08 wee.
 
It seemed like I had a flat battery, and the thing just turned over really slowly.

After swapping the battery, checking the all the relays I whacked it gently with a hammer.  I thought maybe it's sticking? And it worked! For a short while. I gently tapped it again and it worked.

Convinced something was sticking in the starter I decided to take it off.

With it sat on the centre stand I removed the two 8mm bolts holding it on. It was quite stuck in, so I need a long thin rod to tap it from the other side to knock it loose.

I then needed a bit of rag to clean up the oil that was leaking out the starter, not a lot, but best to have some card and clothe around.

There are two 7mm bolts holding the starter together, and 10mm holding the earth on..

 I undid the housing, and the thing comes into three sections fairly easily.

The rear section holds the brushes. Low and behold one of the brushes was stuck.

I took the brush out cleaned, filed, the corrosion off. Re assembled with a bit of electrical grease. A little blob on the back of the spindle as well.
 
Re assemble in reverse order, remembering the order of the washers, I have a couple left over, so if anyone has a exploded diagram that would be great.
 
Re assemble and it worked really well.

Water has clearly be seeping in through the electrical connections and corroding the brush housing, so I suspect this problem to some extent afflicts all wee storms of that era and design.

Now all I need is a spare set of brushes! Or maybe a pattern starter. The stuck brush is substantially shorter, so who knows how long it will last. 

Good luck.
A

[kwackboy]

If the magnets are intact inside then just order a new brush kit ... would be better than a pattern starter motor.
The spare washers you have left over,  are they from the where the bolt goes through the housing ? If so just put them back in one you replace the brush kit   

[Hugh Mungus]

Had similar problems on a KTM. New brushes cured the problem.
Sounds like some waterproofing would be a good idea, if it is possible?

[Adrian80i]

Where can I get a brush kit from the magnets seem fine? I thought the washers might be from between the starter and the engine, that's where I have slotted them in. There is a cable retention clip and they might have been on that, but not sure?

I used to use  damp seal on a old fiesta carb, so was going to try and get some of that.

But a spare brush kit seems like a good idea.

[greywolf]

Parts are available from Suzuki.

2. BRUSH TERMINAL SET
31130-13E00

3.BRUSH HOLDER SET
31132-33E00

4.SPRING, BRUSH
31135-31300

5.O RING
31143-49040

[Adrian80i]

Thanks grey wolf,

Shitbags. I think my left over washers are number 8. Balls

A

[Robotstar5]

Back when I was young and running my bike (GS850) on a shoestring, I couldn't afford a set of genuine brushes so spent a while filing some (considerably cheaper) Lucas Mini brushes down to fit