Based on what you stated, it turns with no spark plugs. Do a compression check and make sure the compression is reasonable and not ridiculously high for some reason.

Assuming 120-160 psi compression, put plugs back in and try cranking it over clutch pulled in, this removes the load of the transmission (if any). If the engine doesn't turn over with plugs and turns over no problem without plugs, the starter is not overcoming the engine compression. This would typically imply the starter is not up to the job.

Another possibility is the starter drive binding in the outer primary cover. Loosen all the primary cover bolts about 1/2 turn or until you can move the outer primary cover slightly. Then try turning it over.

Good Luck

You also state "I have also bypassed the cables by hooking a car battery direct to starter terminal and frame ground". If the ground from the engine to the frame is bad, the frame ground may not be good enough. Try grounding directly to the engine/tranny case or directly to the starter. If it still doesn't turn over, I would go for the starter.

 

crank prob.

Springer, THANKS for the reply.
I checked the cold compression this morning, was around 100.
Taped clutch lever in, no difference.
I already put in a NEW starter cause I thought the new one that the guy put in might have been defective. I am using heavy cables from a car battery to the starter lug, and also to the ground where the starter bolts to motor. Also the outer primary cover is off, and I also tried it on without a gasket and snugged with a few bolts.............whats next?

 

Springer, THANKS for the reply.
I checked the cold compression this morning, was around 100.
Taped clutch lever in, no difference.
I already put in a NEW starter cause I thought the new one that the guy put in might have been defective. I am using heavy cables from a car battery to the starter lug, and also to the ground where the starter bolts to motor. Also the outer primary cover is off, and I also tried it on without a gasket and snugged with a few bolts.............whats next?

Sounds like the starter.

 

Two starters and good cables, time to Amp test the battery. IMHO

 

Just because the lights come on and radio may work does not mean it has the cranking amps needed to turn it over. Did you try a jump start with the plugs in? Or load test the battery? If you have a jackshaft bind as mentioned prior it would bind plugs in or out. Plus with that 1 1/2 bearing collar in there pretty hard to get that kicked sideways or getting it to bind. Cranking Amps is where I would start. Jump start, battery charger/starter hooking a car battery to it. Also open the throttle when firing sometimes they can vacume lock.

 

As mentioned, I replaced the starter already, but still have the same problem. I also bypassed the cables, hooking my car battery with quality cables to: + went to starter lug, - went to starter housing. then I ran a wire from starter lug to the terminal on the starter to pull in the shaft.
Whats next???

 

I would still be looking at the battery closely. Even good quality jumper cables are not the same as bolted cables. If you know the bike's cables and terminals are good then swap the battery with one from another bike. Just MHO.

 

I wouldn't crank it with the primary off. or you will end up with more trouble than you already have.
100 psi cranking is either because the motor isnt cranking fast enough or down on comp.
the timing could also be off enough that it is very hard to crank.
I agree sounds like a weak batt.
I would button it up and push start it and ride it a while.
or you said it started at one point get it buttoned up and ride it some. then see what happens.

 

OK>> thanks for the advice...still tinkering. My cycle mechanic friend stated that this isn't too unusual for a pre 94 bike. The ratio of the primary drive was changed after 94 to eliminate this. He also noticed the HAYDEN chain tensioner, said that wasn't helping, and recommended changing the starter gear and ring gear to a more optimum ratio. Said there is a aftermarket kit for that...I'll be chatting with the owner this weekend and determine how much he wants to dump in. Possible spring for a NEW battery and 3 NEW cables. Otherwise, I'll take my edger apart, and bolt on the PULL START CORD ASSEMBLY!!
Anyone else got any ideas?

 

i'am having the same problem.

 

You need your own thread for help.

Sent from my moto g(7) supra using Tapatalk

 

he probably solved his problem,, it was 11 years ago..