Starter motor brush kit for Kawasaki KFX400 and Suzuki LT-Z400

Starter Clicks But Won't Crank? 5 Checks Before You Buy a New Starter

You press the start button and hear a click, or nothing at all. The instinct is to order a new starter motor. But a no-start is often caused by a relay, a worn brush set, a starter drive or a bad cable, all of which cost a fraction of a starter. Use the symptom to find the part.

Prefer to read? The full guide is below.

Check 1: No click at all

The starter isn't getting a signal. Check, in this order:

  • Battery charge and terminals
  • Main fuse
  • Kill switch or lanyard (outboards and PWC)
  • Neutral / safety switch
  • Start button and the starter relay

On outboards the starter relay is a common failure. Examples: Mercury 4-terminal relay 89-817109A2, Yamaha 40–90 HP relay 688-81950-10-00, Johnson / Evinrude / OMC relay 240-22013. See all solenoids and relays.

Check 2: A single click, but the engine doesn't turn

Press the start button and measure the voltage at the starter's main terminal.

  • About 12 V reaches the starter and it doesn't turn: the starter is at fault (brushes, armature or a seized unit).
  • No voltage at the starter: the relay, solenoid or cable is at fault.

Check 3: Rapid clicking

This is almost always a flat battery or a poor connection. Charge the battery, then clean and tighten both ends of every main cable, including the earth. A new starter won't fix a weak battery.

Check 4: The starter spins, but the engine doesn't

If you hear the starter whine but the engine doesn't turn, the starter drive (bendix) isn't engaging. The drive is often sold on its own:

See all starter drives.

Check 5: Slow or intermittent cranking

With a healthy battery and clean cables, slow cranking often means worn brushes. On many ATVs and motorcycles you can fit a brush kit instead of a complete starter:

If the commutator is burnt or the armature is damaged, a brush kit won't help. Replace the starter. See all starter brush kits and starter motors.

Symptom → part

Symptom Most likely cause Where to look
No click Battery, fuse, switches, relay Solenoids & relays
Single click, no crank Starter or relay (voltage test decides) Starter motors
Rapid clicking Battery, cables, earth Charge and clean first
Spins, no crank Starter drive (bendix) Starter drives
Slow cranking Worn brushes or a failing starter Brush kits

FAQ

Can I just replace the whole starter to be safe?
You can, but if the fault is the relay, a cable or the battery, the new starter won't fix it. Do the voltage test first.

How do I know which brush kit fits?
Match the part number on your starter, or the starter's make (for example Mitsuba), against the listing. Brush kits are specific to the starter model.

Still not sure? Send us your symptoms, your part number or a photo before you order. Choosing a new starter? Read How to choose the right starter motor and our outboard starter guide by brand.

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