83gs550e New Starter Engaging While Eng Running

[GQROD]

" With the starter clutch spinning around the crank faster than the actual starter can turn would it activate the clutch and spin the starter at the speed of the motor?
I could be wrong but I still think it's the starter clutch. "-posted by chef1366 ( thanks again for the help i appreciate it-ROD)

According to another site a "freewheel" clutch is used on motorcycles and farm tractors specificly to prevent the starter from being turned too fast by the engine ( on a Bendix system the engine would be turning the starter at 15,000 to 20,000 rpms) if it were to be engaged while the engine is running.

Granted this makes sense!!- that the starter clutch could cause the starter to spin, however in a freewheel clutch the starter would be spun at it's original rpm,

but it does not explain why it is burned out? or the battery boiling? and the cables being heated to the point where the insulation melted slightly.

The jeep forum touches on something important that has not been considered-"feedback" as the cause of the relay being triggered while the engine is running. ( visit site it's good reading )

So my only conclusion is the relay ( which has not been replaced since i got the bike ) is bad, but does not test as bad. Electrical tests all show it working as intended.

However mechanical failure can cause this and lead to the motor burning up by pulling too many amps unrestricted.

Hope these long winded expalanations can help those who may run across this problem or hopefully prevent it.

Thanks again everyone for your help.

[chef1366]

If your boiling your battery you have a bad R/R.

[GQROD]

Thanks chef I just replaced it with a unit from Duaneage but i'll check it. Voltage showed normal so i didn't suspect it.

The boiling happened when the starters died, i thought it was due to the starters pulling too many amps for too long, didn't dawn on me to check the r/r.

[GQROD]

update

Took out the starter, shook it, and heard pieces inside loose. Could be the brushes. I turned the starter by hand and it froze momentarily-likely the loose parts jamming.

Sent it off for a replacement.

Ordered the starter interlock switch the plastic piece was too far gone.

I will be replacing the starter relay, i believe this is the culprit, i'll also add a high amp switch to be on the safe side. Not necessary with a new relay but you just never know.

Wired the sense wire from the honda r/r to the rear brake light on the Brown wire ( this is the color for this model the 1983 gs550e ) to see if the readings are higher.

Tested the r/r using the stator papers guide but i may need a better meter cause i saw no decimal point to indicate 1.0 volt or .50 volts on the diode portion of the test. Just a 1 and on another reading it read 536/ don't know what that is.

Don't think the r/r is bad though since the output has been steady and consistent.

Could not finish testing it until the engine is running again, don't want to put the cover back on to push start it.

The boiling battery i feel came from the starter pulling too many amps for too long because at the same time i noticed the battery boiling i saw the melted insulation on the cables from the starter relay and they felt hot. I figure if it's the r/r boiling the battery then it would happen all the time which it doesn't.

Great points brought up by all which allowed me to hone in on the problem.

I'll update once the new starter and relay are in.

Thanks again everyone for your advice i do appreciate it.

[GQROD]

Update 11/13/08 Starter

Got the new starter back, installed it, bike started great idles fine and ran very strong.

Rode for 2 miles without a problem. Still have to ride it farther to make sure.

However i am hearing a light clicking noise from the left side that gets louder as i rev it higher to about 5000 rpm. Don't know what this is.

The rotor is on tight and the starter clutch is new, so i don't know what this noise is unless it's valves? it made this same noise when i first i got it.

However before taking starter out this time it was not making this noise. Any ideas anyone?????

I still have to install a high amp battery cut-out switch between the battery and the starter solenoid to avoid accidental engagement of the relay while the engine is running. ( don't wan't to blow another starter! )

R/R is putting out slightly higher voltage now more consistent through out the harness at over 12.5 volts.

Seems putting sense wire on brake light does give you higher voltage at coils than putting sense wire on battery. Bike pulls harder now. Without over charging.

Replaced the oil hoses coming from the cylinder heads to the case, the old ones were SHOT!! and leaked everwhere.

So a big thank you to everyone who has helped through out the last few months with your advice i would not have been able to get this far without you and this great site.