HOW TO: Remove/Inspect/Replace your Starter Clutch

[DMAN999]

I used this guide to do pull my flywheel and replace my Starter clutch and it went Great.
I used a different puller though.
I borrowed the AutoZone OEM/Harmonic balancer puller kit (Part Number: 27019)
http://www.autozone.com/loan-a-tool.../oem-harmonic-balancer-puller-kit/555524_0_0/

And bought 3 - 8mm x 1.25 x 110 mm class 10.9 bolts (stronger than grade 8) from Advance Auto:
http://shop.advanceautoparts.com/p/...85110/9060219-P?searchTerm=dorman+8mm++x+1.25
And bought washers to match from Lowes.

I did tie my flywheel puller to my crash guard and frame as advised by a post I saw on this forum.
And I'm glad I did, my flywheel literally jumped off my bike and would have flown across the garage if it wasn't tied to the bike.

No compressor or Impact Wrench was needed.
I put a 1/2" ratchet on it with a 2' foot pipe for a cheater and slowly turned it then tapped it with a 3 lb. hammer, then turned it ,then tapped, then turned again.
And then the SHOTGUN went off !!! It popped off with a lot of force and a Huge Bang.

And I bought this Ideal Engine Parts 6 roller HD starter clutch for $69.99 with new bolts included:
http://www.ebay.com/itm/Heavy-Duty-...2-1982-2007-/381785581545?hash=item58e431a7e9
NOTE: The Bolts included with this HD starter clutch were too short to be properly peened.
Be sure to use OEM Bolts instead.
91317-08014-00

I bought the stator and middle gear cover gaskets and crush washer from Ron Ayers:
http://www.ronayers.com/oemparts/a/yam/500442faf8700209bc78ee32/crankcase-cover-1

 

[blaxmax]

Good to know tying to the bars, thanks for that.
I have always used a harmonic balancer puller. Makes any clutch or crank removal a breeze.

 

[Boogieman]

For anyone curious about part numbers, the middle gear cover gasket is part number 3JP-15461-01-00. The stator cover gasket is part number 3JP-15451-01-00.

 

[VmaxingPauly]

Gentlemen - please watch video - give thoughts - Starter or Starter Clutch - https://www.youtube.com/watch?v=tNLd6XKmvro

 

[ga_max]

Sounds like starter to me. My starter clutch is going and the bag of rocks sound is a very accurate description of the sound it makes. But I'm not an expert and did not stay in a Holiday Inn last night.

 

[Dorney]

The starter is ingaged all the time so I would say it's the clutch.

 

[Boogieman]

VmaxingPauly, that's exactly what mine did, it gets worse as it gets colder. No box of rocks, just spinning starter. I think if not fixed you will eventually get the box of rocks syndrome, but as it is now, you've caught it early. Your starter should be A-OK, just the damn pesky bolts on the starter clutch have backed out.

I've been working on mine tonight.

I'm halfway done, I'll finish in the morning. I followed DMAN999's guide. That autozone puller works damn good. I actually just used the bolts that came with it. It ruined the flange on the 3 bolts, but it does work. A washer would have probably saved the bolts, but as cheap as bolts are I'm not too concerned. I tightened the 3 bolts into the holes in the flywheel about as tight as they would go.

I tied around the three bolts on the puller and tied them off to the frame. I used a 1/2" drive and put a 30" 3/4" galvanized pipe over it for a cheater. Tightened the center big bolt on the puller a bit, smacked it with a big ball peen hammer, tightened some more, hammer, etc. till it popped. The flywheel kept trying to turn, but once the ropes got tight enough it didn't turn anymore.

All in all, that autozone puller is f'in amazing and it's only $20 to buy it.

I did put the same heavy duty clutch on that he did. I've been using my bike as my daily ride to work so no time to wait on parts if the original was broken. I think the original was OK, but I just couldn't' risk over 3 days downtime.

 

[VmaxingPauly]

Well - I fixed my issue today. Went with a electric impact wrench and it did the trick - would like to thank everyone who has posted to this thread - helped me shit loads to fix this issue with confidence. The fly wheel jumps off the shaft - so if you make this repair - tie it up to the bike. :worthy:

 

[one2dmax]

Do I see a crack in the old housing? Right side of the clutch (left clutch in the picture)

 

[VmaxingPauly]

I didnt see any cracks - but all three bolts where loose and the clutch was floating so there was signs of wear but nothing I felt was a even minor issue. So I cleaned up a smoothed out so very small areas and mounted the new heavy duty clutch with new bolts and red locktite and peened each bolt in two places on it's exposed area.

 

[bkuberek]

Help Please!

I have ruined the beginning of the threads inside the flywheel shaft when using the crows-foot puller :bang head:. The puller was thin enough to go inside the hole and I didn't think to put something thicker in there. See pictures. Fortunately, it just the beginning and I am hoping I can rethread. What is the size tap I need to get in order to fix the threads? :ummm:



Thanks

 

[DMAN999]

Help Please!

I have ruined the beginning of the threads inside the flywheel shaft when using the crows-foot puller :bang head:. The puller was thin enough to go inside the hole and I didn't think to put something thicker in there. See pictures. Fortunately, it just the beginning and I am hoping I can rethread. What is the size tap I need to get in order to fix the threads? :ummm:

Thanks

That sucks !
I'd take the Bolt that goes into that shaft with me to someplace that sells taps and match it.
The puller from Autozone comes with a tip that works well so I'm glad I used that one.

 

[[email protected]]

Not sure what the size is.

You may want to check if any auto part stores near you have a to loaner program with a thread chaser kit in stock.

I have a kit with SAE and metric restoration taps, dies, and files. It has paid for itself over the years

 

[bkuberek]

Thanks guys. I will stop by a few places see if I get lucky!

 

[sufidancer]

Hi vmaxers, I need a new woodruff key for my magneto/flywheel .
Any good source for this part? I wonder if a hard ware store would sell it.

any info. Oh and when you put it on is there a particular tip on where it should be?

 

[DMAN999]

Hi vmaxers, I need a new woodruff key for my magneto/flywheel .
Any good source for this part? I wonder if a hard ware store would sell it.

any info. Oh and when you put it on is there a particular tip on where it should be?

Key, Woodruff
90280-05029-00
http://www.ronayers.com/oemparts/p/yamaha/90280-05029-00/key-woodruff

 

[Boogieman]

delete please

 

[bkuberek]

So I did fix my starter clutch. Like others sad, removing the flywheel was harder than I thought. Sean makes it look too easy on his view

Regarding the bolt that holds the flywheel, it is a 12mm X 1.25

Best,

 

[rzubonja]

Hello all,

i recently upgraded my starter clutch with the XVZ/Royal star bearing + gear
New 6. holes needs to be drilled in the rotor.
I forgot to make pictures of the finished product, but you will get the idea

 

[one2dmax]

Yep, that's one of the heavy duty conversions we offer.