Gentlemen:

My starter stopped working, but I could hear the solenoid clicking. Using the wonderful flow chart prepared by one esteemed member of the forum, I determined that the problem was the brushes in the starter, so I obtained a rebuild kit from Stockers. Ethan was right, replacing the brushes on the starter while it is still mounted on the engine was not easy, but is possible. I got the brushes in and the starter buttoned up carefully. All seemed right, however, when I attempted to start the bike, the starter just makes a nice whirring sound, and fails to crank the engine. I am guessing that I missed a cue on the reassembly process, or perhaps the sprag gear is not engaging, but I really have no solid clue or knowledge of such things. Any suggestions or ideas? Thank you in advance for your time and attention to the issue. My thoughts are to again remove the back of the starter, pull the brushes, have a looksy and to reassemble again in hope of reaching success, but that is a rather lousy plan. Thus I look to the forum for wisdom.
—Randy

someone here had managed to rebuild the starter so it actually turned the wrong way. No idea how that was done.
What´s a bit tricky when replacing the bracket with the brushes is to push the brushes back in their guides while pulling the complete assy over the rotor. But if you managed to put on the end cap and all marks match it should be alright.
While the starter is on the bottom right the starter sprag clutch is behind the flywheel so on the left engine side. Maybe you have a chance to locate the noise.
If the above won`t lead anywhere I wouldn`t really know what to try except to remove the starter completely and see if it runs on the work bench. If it does it´s likely the starter sprag clutch.

G.

Hi ,The end cap on the starter is 180 degrees off,I done the same thing,same whirring,(spins backwards).Easy fix. Jay

Just thought of something,the cap is 180 degrees off in relation to the windings,so if your power lead connection is in the wrong spot,you could have the whole centre piece 180 degrees off,(take bolts out,hold end cap stationary and rotate centre barrel 180 degrees,put bolts back),otherwise just take bolts out spin end cap 180 degrees,put bolts back.

Shouldn't matter which way you do it though. lectrickity does funny things eh Jay.

Jay,Thank you so much for the tip. That's great news! I think I can manage the rotation. I am in your debt. Next time your in San Francisco, I'm buyin'

-Randy.

Hey Randy,Something else just occured to me.It has been a fair while since I had the same problem,but I can remember at the time thinking that I may have had the whole centre barrel section on backwards,I'm Just not sure now if it was that or the end cap that fixed the problem.If you had that removed when you worked on the starter then that is another possibility.Sorry if I have caused you any confusion. Jay