History: I bought a 2001 FE400E from new and about 1 year into owning it I had all sorts of problems with the e-start not working. I did all the normal things listed on the forum - valve clearances, improved grounding of the battery etc. So, I updated the battery to a Yuasa YTZ-7S (more CCM's) and the e-start worked reasonably during my first few rides. After that the e-start gradually stopped working altogether. It seemed the battery didn't have enough charge to turn over the motor.
I checked the electricals and the battery was being charged when the bike was running and I always keep the battery on a trickle charger when I don't ride the bike. So this ruled out the battery.
Next step, remove the starter motor and inspect. I noticed a little "slop" in the gear shaft so we then pulled the entire starter apart. What I found was alarming but not surprising now that I think back. The rear brass bush or bearing that supports the rotor was severely worn to an oval shape and there were "witness" marks where the rotor and stator had touched. As a result, when the e-start was pushed, the starter motor was engaged, torque build-up caused the rotor to "pole" out against the stator, hence not work. I believe that engine vibration due to normal operation will cause wear of this bushing.
THE FIX: Replace rear bushing with harder bronze bushing for better durability. Its only been 6 months, however so far so good. The only time I kickstart is on the first start of the day, otherwise its the button.
Hope this helps some of you.
I checked the electricals and the battery was being charged when the bike was running and I always keep the battery on a trickle charger when I don't ride the bike. So this ruled out the battery.
Next step, remove the starter motor and inspect. I noticed a little "slop" in the gear shaft so we then pulled the entire starter apart. What I found was alarming but not surprising now that I think back. The rear brass bush or bearing that supports the rotor was severely worn to an oval shape and there were "witness" marks where the rotor and stator had touched. As a result, when the e-start was pushed, the starter motor was engaged, torque build-up caused the rotor to "pole" out against the stator, hence not work. I believe that engine vibration due to normal operation will cause wear of this bushing.
THE FIX: Replace rear bushing with harder bronze bushing for better durability. Its only been 6 months, however so far so good. The only time I kickstart is on the first start of the day, otherwise its the button.
Hope this helps some of you.
