DIY: Honda XR200 Starter overhaul

My bike doesn't have a kickstart but other year model does.. so knowing issues caused by your bike starter is very essential.

Flowchart to diagnose if its the starter causing the problem:

********************flowchart will follow******************

Points of failure:
-stuck contact brushes due to dirt
-carbon brush: no contact to the armature due to wear
-cut-off wire from the carbon brush
-shorted armature windings > thank God I haven't experienced this

HEADS-UP
In my case since I did some rewiring due to battery relocation. I was able experience an issue where there wasn't enough current going to the starter. I noticed this after following my usual checks (follow flowchart). After that experience, I installed a LED that lights up when there is steady flow of current while pressing on the starter switch.

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How to dismantle starter:

 In order to gain access to the starter, we have to remove the bike exhaust.

We then take off 2 bolts holding down the starter and the (+) wire from the battery.

Using a 7mm wrench open 2 bolts from the starter. Extra careful on the O-rings, these can break depending on age but can easily be replaced with replacement parts using other starters of similar size

Just take photos if your not too comfortable in taking stuff apart.

At this point, it is now the best part to do visual inspection if you have worn brushes or you are with a broken wires. After inspection, its would also be the best time to clean the contacts and everything inside. Do not expose O-rings to chemicals that would damage it. I suggest using CARB Cleaner, its fast acting on grease and dries quickly. You can also take the contacts off of the guides after getting those nasty coil springs.

Use logic to put everything together. Remember that the bolt going thru the hole for the (+) wire to the battery should not by any means make contact the starter housing or else you will short circuit it. 

Hope this helps:)