Hi, l had the same symptoms as you with my 400 for the past 2 years. Always having to jump start from cold. I was using a cheap battery with supposedly 130cca. I've just bought and fitted a Yuasa and guess what, started no problem after not being run for at least a month. Try a Yuasa YTZ7S !!!

gordonian,


I suspected the battery at first, but I took it back to the battery store and there they verified the battery is good, and showed me with their tester unit that it had 150cca. and the battery had sat inside, off charger, over night.

Hi 60ratrod,
The only other things that I did was to fit a new brush plate in the starter motor and I ran a larger cable from the start solenoid directly to the starter motor. I also fitted a new exhaust cam and shimmed the valves. This didn't improve the starting really. I'm also running auto cam chain tensioner.

so the mcct didn't help with the cranking speed. and now the battery cable terminals are getting really hot, so I'm thinking that it's the brushes as previously mentioned. I would say it might be corrosion, but back in December I went through every single connection in the start circuit, except for the ignition switch and the start button on the right grip pod, and cleaned them and applied dielectric grease. I even did the main battery ground on the back side of the engine under the tank. I may also look into making new battery cables, incase there's a short or corrosion inside the wires that I can't see.

and I found the p/n for the brushes and got them on order from partzilla. so if my luck holds with them, I should have the brushes before the end of this week.

final update?
 

so i ordered the brushes, and of course they had to be the wrong ones. but i didn't find that out until i yanked the starter out after doing some metering to see if there was a voltage drop. i tell you what, that thing was gnarly inside of it. so after cleaning the crud out and scrubbing the brushes and brush contacts on the motor, i think i got it finally! and of course there will be photos:rolleyes:

http://i159.photobucket.com/albums/t...ps29zmawmk.jpg

http://i159.photobucket.com/albums/t...psmm09ttke.jpg

http://i159.photobucket.com/albums/t...psiknicrxm.jpg

http://i159.photobucket.com/albums/t...psni3rxslp.jpg

http://i159.photobucket.com/albums/t...psni3rxslp.jpg

Sorry for late reply, this is the numbers for the brush holder and the brush from Hondahttps://uploads.tapatalk-cdn.com/201...5efaf83d6d.jpg

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