Starter trouble

[John A]

My wife's 02 Stone that I put together from salvage has been reliable. I caused a starter problem by making a tab to keep the tank bag from hitting the starter button. I made it out of aluminum that bent in and pushed on the button. She didn't notice until the starter leaked smoke and stunk. She called me, I was on airport shuttle duty and I met her at home and put on a spare starter so she was able to catch up with her Women on Wheels friends. About three hours later she called again and the starter wouldn't turn it over so I went and got her with a trailer, she was only fifteen miles from home at that point. Last night I checked battery voltage, 12.8. I expect there is some heat damaged wireing and relay. So my plan is to inspect all that, and put on a new starter relay. I'm also going to install another relay so the factory wireing only has to activate the new relay which will run the solenoid from the battery. I spose I better pull the starter and peek at the ring gear too. My question is does anyone have any tips or suggestions?

[Sasquatch Jim]

 You lost all the smoke!  Just put some more smoke back in and it will work again.

[guzzisteve]

When Guzzi started using the metal switches they would run the starter when wet, I fixed a few by making waterproof.
My 1st Sp did the same thing w/tank bag, was better on LM3, quit using one 10yrs ago.

[John A]

You lost all the smoke!  Just put some more smoke back in and it will work again.

Can I make my own smoke or do I need the extry special store bought smoke for starters?

[Wayne Orwig]

So what does it do now when you try to start it.

[John A]

The bike does what its supposed to, the spare starter I put on appears to have a bad [new] solenoid so I ordered a new starter from Euromotoelectrics. I'll take the starters apart and build up one to set on the shelf. The ring gear looks like it'll last so aside from a burnt up starter theres no damage.

[Kiwi_Roy]

appears to have a bad [new] solenoid 

Check it's not out by 180° so the input terminal is wired to the armature, don't ask.

[John A]

Check it's not out by 180� so the input terminal is wired to the armature, don't ask.

Thanks Roy, it never would have occurred to me that it was even a possibility !

[LowRyter]

speaking of starters. I ordered one and found that I likely don't need it. 

I paid $67 for it.  It looks very nice.