Rotax 500R Starter Motor

Forums Technical Four Stroke: Help needed Rotax 500R Starter Motor

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    • #16494
      Robert Jones
      Participant

      I am having problems with the starter motor on my Saxon 500R, I have stripped it and changed the brushes but although it will turn over it is still not powerful enough to actually spin the motor over so I suspect perhaps some of the windings have gone down. What I am interested in is does anyone know if the starter motor from the 650 Rotax motor that was fitted to BMW Funduros , Aprilias and other similar popular machines. Studying various pictures on the web the starters on both 500 and 650 motors look much the same but I am unable to check the dimensions. The availability and price of the 650 version makes it very viable as a replacement over the original.
      Thanks for any help. Bob

    • #16496
      Brian
      Participant

      Hi Robert

      I suspect the 650 starter motor will not fit for two reasons, firstly the engines are not identical with the 500 being air cooled with a cam belt and the 650 BMW/aprilia engine is water cooled and has a cam chain.
      I have a BMW G650GS so I can take some dims for you and I have the Haynes manual which will have pics etc, let me know what I can do..

      500 to 650 is a 30% increase so I don’t think they would have used the 500 one on the 650s, but I could be wrong.

      A couple of potential sources:

      Diesel Dave in West Yorkshire, Bynnzi knows him, He deals in the Armstrong and Harley Davidson military bikes that used the air cooled 350 and 500 engines.

      MT Riders group who ride the above bikes http://mtridersclub.co.uk
      They have Sales and Wanted sections on their forum.

      CCM used the 600cc version of the aircooled engine in some of their R30 Supermotos. The 600 engine was a direct swap for the 350/500 so maybe you’ll get lucky. CCM also used a Suzuki engine in the R30 so beware.

      The above reminds me of when I asked my Mum what a couple was and she said “Oh two or three” no wonder my Dad divorced her:)

      Hope this helps.

      Brian

      • This reply was modified 5 months, 2 weeks ago by Brian.
    • #16498
      Brian
      Participant
    • #16499
      Brian
      Participant

      Hi Robert

      Can’t put my hands on the Haynes manual at the moment, here’s a pic from the BMW manual.

      https://drive.google.com/file/d/1lv9gSIzvaFLge9c7oYwzTdIKLjt7znd4/view

      The cover 4 measures about 64mm dia.

      Also the Harris G80 used the Rotax 500 engine.

    • #16500
      Brian
      Participant

      Hi Bob

      Found the Haynes manual and have scanned the relevant pages.

      https://drive.google.com/drive/folders/1Kk_j5_pQoNGrSnTs-mViICMhW2oPVkBe?usp=drive_link

      This has a different starter motor to the one fitted on my bike (G650GS). Quick history lesson, The engine was a Rotax design and built by them from 1993 until around 2006.From 2006 to 2007 BMW had Kymco in Taiwan assemble the last of the Rotax engine parts. When they sorted engine production out and did a mild refresh they realised, that in the meantime, they had used the F650 name for an 800cc twin, oops, an easy enough mistake to make I’m sure you’ll appreciate. You’ve got to love German efficiency. So they called the latest 650 the G650 and this had the engine made and assembled in China by Loncin. This probably accounts for the difference in the starter motors. The BMW manual extract from a previous reply was fom the G650 manual.

      Brian

      • This reply was modified 5 months, 2 weeks ago by Brian.
      • This reply was modified 5 months, 2 weeks ago by Brian.
    • #16521
      Robert Jones
      Participant

      Hi Brian,

      Thanks for all the information ,its all been very useful. I have studied the 650 motor and it operates on the opposite side to the 500 but to overcome the need to spin the motor in the correct direction it has an extra idler gear which does the trick, I will see what Diesel Dave has to offer as you never know!
      Thanks again I will keep you up dated as and when, It may be some times though.
      My Mrs used a Kymco scooter for a number of years and the build quality was superb, it was a copy of a Honda being as Kymco was originally a Honda factory and I remember a dealer in Tooting insisting they they were better built than the Honda equivalent and I’m pretty sure he was right especially after experiencing her previous scooter which was a Honda.

    • #16523
      Brian
      Participant

      Hi Bob

      Apologies if this is a duplicate post as thr first one seems to have vanished into the Ether. Probably as I put a couple of links in it.

      So look at

      Force Motorcycles part number 685-970

      Hmm £400

      Sportax Racing part number 294-358. Reduced to £270

    • #16524
      Brian
      Participant

      Bob
      Have you thought about rewinding the starter? That should hopefully work out cost effective.

      On the previous post there are three different part numbers fot the 500 starter.

    • #16525
      Robert Jones
      Participant

      Hi Brian,

      Thanks for the posts, yes that was my original plan but I discovered this company who supply the BMW 650 starter for £115 that is why I was making enquiries. There is a place I have been recommended for rewinds etc in Uxbridge but I understand one of the partners has past away, we will have to see.

      Starter Motor For Bombardier ATV BMW Motorcycle

      Thanks again

      Bob

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