2002 ET4 150cc 3000 easy miles. Had been running fine. Went to start it the other day and it makes a single "clunk" when I press starter but will not turn over or crank the engine in the least bit. What I have done so far:
1. charged the 1 year old battery - no change
2. borrowed another battery from different bike - no change
3. jumped with car - no change
4. pulled relay - no luck finding another locally - 12v applied to primary and it definitely clicks like a good little relay should and it closes the secondary terminals - no change
5. removed starter, lightly buffed brushes and commutator with 600 weight sandpaper, cleaned and reassembled. BTW brushes looked good. - no change.
6. wiring looks good. no loose connections found.
7. started to get mad
I feel the starter is getting good juice because it makes a pretty good "clunk" every time I hit the button. It is almost as if the engine is seized and the starter just can't turn it but I know that is super low probability (ran fine, oil good, no previous signs of overheating). Unfortunately, I can't test this with the kick start because the return spring broke a couple years ago. I tried to connect a jumper between the positive battery terminal and the positive stud on the starter to rule out relay or upstream wiring issues but the sparks got in the way javascript:emoticon('8)')
Is it possible the relay closes but can't carry enough current, or maybe the starter runs but is for some reason suddenly too weak..... any suggestions appreciated!
Thanks, Dorydan