Monster 750 starter removal...

[johnnymotocros]

Hi,
I recently adquired a 99 750 Monster, and a week after riding it, the starter got weaker and weaker, and finally "died".
I, being a mechanic ( aircraft ), wanted to fix it myself, and looked for guidance here and in other sites, did not find much...
So, I will post my findings and photos for others to use in the future.

*First, the starter gradually got weaker and weaker, until it did not have enough torque to crank the twin.
* Did a voltage-source test to check for available DC voltage to the starter terminal ( while cranking ), got about 11.5 volts which is about normal. So the starter is the problem.
* Tried to remove the starter backplate ( without removing the starter ), but the engine case is too close and one of the starter long bolts does not come out. ( It other engine models you might, I heard )
* The starter is held by three bolts, one outside the case, and two inside the case, behind the left engine-case, so , YES, you will have to remove the left case.
* Lean the bike to the right, against a wall or something to keep the engine oil inside the case, or drain the oil.
*To remove the case, you should use a puller. I got one from Pep Boys for $12.00 ( Steering Wheel Puller ), and two 1-1/2" bolts which fit in the thread of the small center access plate in the cover.
*You will need to remove the clutch slave, and it`s rubber boot to get access to a bolt hidden behind the boot.
* Remove the stand.
* Remove the shift lever.
* With the puller, the cover came out very easily.
* To reach one of the starter bolts, you have to rotate the small gear in front of it, and you will find that one of the holes on it, alligns perfectly with the starter bold.
Remove the starter voltage cable.
* Remove the lower oil line in front of the starter to allow the starter to come out.
* When disassembling the starter, note and mark the position and allignment of all the starter parts, because once appart they rotate freelly.
* I found the brushes worn completely, and found lots of oil residue all over inside the starter ( ? ).
To be cotinued... I will post photos tonite...

[vtwin]

I managed to pull the backplate off, without having to remove the whole of the starter. Bike is a 99 996sps.

If you have oil inside your starter, check the o-ring at the gear end.

I've posted my ordeals with the starter at my blog.

[johnnymotocros]

Thanks VTWIN,

I will check the O-ring.
I got the starter brushes from our local shop, from a used starter with a burned rotor. I got lucky today. The guys in our local shop are The Best !
I looked at other air cooled ones, and same as mine, it`s imposible to remove that long bolt without removing the starter, so you are lucky.
Anyways, it`s not really hard to remove the left case. I am about start reassembly. I will take pictures to post them later.
JT