A reliable 961 starter motor? Calling all Hog Jockeys.

Clive · Jun 11, 2021

cliffa said:
Good news Clive, but that's interesting as you'd think the resistance of any brushes would be negligible. I know yours were cracked (weird) but surely they were still passing current?

the one was split wider than normal and not moving well in the carrier and the other was split in half where it meets the commutator. The brushes are actually wider than each sector on the commutator so I think they should create current in more than one winding on the armature. That is my guess but it now turns over like the starter on a proper motorbike!

cliffa · Jun 11, 2021

Clive said:
the one was split wider than normal and not moving well in the carrier and the other was split in half where it meets the commutator. The brushes are actually wider than each sector on the commutator so I think they should create current in more than one winding on the armature. That is my guess but it now turns over like the starter on a proper motorbike!

Wow, that's a pretty elementary mistake. Glad it's sorted anyway. I guess you don't need a replacement now?

TonyA · Jun 12, 2021

Clive said:
Got my replacement brushes machined up and soldered in which, was a bit tricky trying to get a soldering iron with enough capacity to do the job and be small enough to fit in, but put it all together and it spun up and started the bike like never before. If I didn't have a replacement on order I'd make it a bit more permanent and be quite confident about the fix. So a nice ride into work this morning (as good as it can be for Birmingham) Yeahh!

You can't argue with great results !

Clive · Jun 19, 2021

Well DB Electrical in the USA came up trumps! Worked out just a bit over £200 including postage, took ONE WEEK! and came with a test report sheet. Still debating whether to at least paint the end silver but there again if it comes out a slightly different shade of silver it might as well be black. I suppose it kind of fits with my modded intake look.

Current starter with my fettled brushes still starts it first time no stalling even when hot. Is this what it feels like to own a proper motorbike?

A reliable 961 starter motor? Calling all Hog Jockeys.

TonyA · Jun 19, 2021

Clive said:
Well DB Electrical in the USA came up trumps! Worked out just a bit over £200 including postage, took ONE WEEK! and came with a test report sheet. Still debating whether to at least paint the end silver but there again if it comes out a slightly different shade of silver it might as well be black. I suppose it kind of fits with my modded intake look.

Current starter with my fettled brushes still starts it first time no stalling even when hot. Is this what it feels like to own a proper motorbike?

View attachment 80509

Black should look good.

Bernhard · Jun 19, 2021

TonyA said:
Black should look good.

Mmmmmm........shall we have gloss black, enamel black, matt black . . . decisions, decisions. . . . .

Clive · Jun 19, 2021

Bernhard said:
Mmmmmm........shall we have gloss black, enamel black, matt black . . . decisions, decisions. . . . .

Repaint the rest of the bike to match it??????

von tripper · Jul 12, 2024

TonyA said:
Lastly , You don't need to remove the clutch basket or any primary drive gears when removing and installing the new starter . You will need a ground down 5/16" or 8mm ball allen to get to the rear mounting bolt. Look it up in the search history , look at the picture its easy to make it on a grinder.

hi can you give a link to find this picture plz ..... iam getting square eyes trying to find it thanks

cliffa · Jul 12, 2024

von tripper said:
hi can you give a link to find this picture plz ..... iam getting square eyes trying to find it thanks

Welcome to the 961 forum.

This should help. You need an M8 ball ended Allen (hex) key for the upper bolt. Use Loctite when putting them back in.
Once you have the gear lever off and have removed all the screws, carefully remove the cover, as the gaskets can normally be re-used.
While you have it open, check for any looseness in the starter ring gear and also the clutch basket. If you contact Stu Bodycote at Motorvated Ltd., he will sell you a much improved gasket for the starter motor.

A reliable 961 starter motor? Calling all Hog Jockeys.

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