My motorcycle has an electric starter. It started clicking instead of starting. At first, I thought is was a dead battery, but later discovered it was a stuck brush. I will show you how I fixed my starter. My motorcycle is a DRZ 400 but I think a bunch of motorcycle starters are similar.

Supplies

After getting the starter off the motorcycle, I only needed to remove two screws to take the starter apart. I used a 8mm wrench to loosen those two screws. I used the plyers on a Leatherman Skeletool to pull the spring out and a stainless steel brush to remove the rust from the springs.

Step 1: What Is the Problem?

The problem was a stuck brush. There are two brushes that contact the commutator. One of the brush springs was rusted and was not pushing the brush down enough to make good contact.

Step 2: Taking the End Cap Off the Starter

Once the two screws are loose, the end cap can be pulled off the starter.

Step 3: Remove Brushes Assembly

To remove the starter brushes assembly from the end cap, remove the nut and washer from the screw that extends to the outside of the end cap. Then lift and slide the starter brushes assembly out of the end cap.

Step 4: Brush Spring Removal

Push up on the brush to expose a tab on the spring. Using plyers, pull the spring up and out. Be careful, the spring is under tension and could fly off. Once you relieve tension off the spring, you can pull it off of the post that goes thru the center of the spring.

Step 5: Remove Rust

I used a wire brush to remove the rust from the spring. I put a light coating of grease on the spring to try and prevent future rusting.

Step 6: Put the Spring Back On

Put the center of the spring back on the post and then carefully tension the spring and put the end back on top of the brush.

Step 7: Reinstall the Brushes Assembly

Reinstall the brushes assembly into the end cap by sliding the screw thru the hole in the end cap. Put the washers and nut back on the screw.

Step 8: Put the End Cap On

Put the end cap back on to the starter. Since the brushes put pressure on the commutator, you will have to place the commutator under the brushes, overcome the pressure of the brush springs and then slide the cap on. On my starter, there are lines cast into the pieces that help you line the pieces up. Tighten the two screws that hold the starter together. Once reinstalled, on your motorcycle, your starter should turn the motor over and start your motorcycle instead of just making a click sound.