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My starter has been working intermittently for the last two or three weeks, and has finally quit outright...
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Does the starter motor turn and not engage the engine OR does the starter motor not spin at all?
If the starter motor spins but doesn't engage then you may have a sprag clutch problem or broken starter shaft.
[quote]I've measured the battery voltage on several different occasions, and I was always getting upwards of thirteen volts. I've checked the connections, and they appear to be fine and un-corroded. Just to be sure, I put the battery on charge, and when it showed a full charge I tried again. Still nothing. [quote]
No load battery voltage should be 13.2 volts. You need to check battery voltage while cranking the starter to determine if the battery capacity has dropped. I'd be very suspicious of a battery that dropped to 10V or less in the first 5 seconds of cranking.
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When I measure the voltage at the solenoid, it drops to zero when the starter button is pushed. Otherwise, it's about two volts (???). Shorting across the terminals has no apparent effect.
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The voltage across the solenoid should drop to zero when cranking, so that's probably OK.
Two volts without cranking says there's a high resistance across/through the starter motor which may indicate worn/broken/stuck brushes, a burned commutator, broken brush tension spring(s) or several other things.
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Here's my question: I've found a place here in town that will renew the starter for around a hundred dollars. Can I be absolutely sure that the starter is the culprit before pulling off the carbs and draining the coolant and all that nonsense? Based on the comments that I've read regarding other members' starter problems, I have to guess that my solenoid is not the problem here, but it would be nice to be sure.
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You can't be sure about the starter until you remove it from the bike and take a good look at the brushes, commutator and brush plate.
There are two different starters: Taigene and Nippon Denso.
The brushes should move smoothly in the brush guides but if they're sticking you can blast the crud out with brake cleaner. Don't use the non-flamable brake cleaner since it may damage insulation.
If the brush tension springs are hitting the brush guides (or are close) then you need new brushes.
I think the Kawasaki EX500 brushes are supposed to fit the Taigene for about $35 and Triumph has replacement brushes for the Denso (unless I've got that backwards.)
If it's not the brushes then a $100 repair is basically 1-2 hours for labor, so that isn't a bad price.
Jim
