HOW TO: Remove/Inspect/Replace your Starter Clutch

Discussion in 'How To Guides' started by yukonerdave, Feb 27, 2011.

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  1. Sep 30, 2017 #101

    Dreamster66

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    are these the right parts from Ron Ayers?
     

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  2. Jun 25, 2018 #102

    TerryTheTillman

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    I would just like to verify that the middle gear is lubricated with engine oil?
    There is lots of documentation on the drain bolt and copper crush washer, but no mention of putting oil back in to the Middle gear...
    I've watched many you tube videos on replacing the starter clutch and no one has mentioned replacing Middle Gear Oil... I'm guessing because it is lubricated via oil channels from the engine... Just want to be sure?
     
  3. Jun 25, 2018 #103

    mabdcmb@yahoo.com

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    No special middle gear oil. It all comes from the oil pan on the bottom of the engine. Just top of the oil when your done
     
  4. Jun 25, 2018 #104

    TerryTheTillman

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    I would just like to verify that the middle gear is lubricated with engine oil?
    There is lots of documentation on the drain bolt and copper crush washer, but no mention of putting oil back in to the Middle gear...
    I've watched many you tube videos on replacing the starter clutch and no one has mentioned replacing Middle Gear Oil... I'm guessing because it is lubricated via oil channels from the engine... Just want to be sure?
    <!-- / message --><!-- sig --> __________________
    TerryTheTillman
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  5. Jun 27, 2018 #105

    TerryTheTillman

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    Thanks Mike.
    New Question:
    I think I read that someone else had experienced this, but I didn't see a conclusion...
    After successfully replacing the starter clutch (with no oil leeks :), New Oil and filter.
    Vmax started, but with one load knock. I'm hoping was a backfire? And now I seem to have a timing problem? I runs. Starter works good. Just isn't running very well. Only about 75% of its former performance :(
    Load knock happened once each time I started it testing the starter. It idles ok ( a little higher than usual). A mechanic buddy of mine suggested disconnecting the battery for a minute to reset. Does the 2004 Vmax have a computerized ignition? Any other suggestions?
    Going to try disconnecting the battery asap. I will post the results.
     
  6. Jun 27, 2018 #106

    TerryTheTillman

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    Reconnected battery, problem remains.
    Tried to start and got loud knock. Trouble turning over.
    Still sounds like timing.
    Is it possible I've changed the timing some how while changing the starter clutch?
     
  7. Jun 27, 2018 #107

    mabdcmb@yahoo.com

    mabdcmb@yahoo.com

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    Is it possible the flywhhel isnt lined up with the keyway on the crankshaft?

    Sent from my SM-G930V using Tapatalk
     
  8. Jun 27, 2018 #108

    TerryTheTillman

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    I lined up the key with the keyway with my finger in behind the flywheel, wiggled the flywheel a little until it slide on.
    I have driven the bike since then, so, from what I've read today, the key must be in place, or the bike wouldn't run at all? Is that correct?
     
  9. Jun 27, 2018 #109

    TerryTheTillman

    TerryTheTillman

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    I also confessed on another thread (Not sure if you see them all?) that the flywheel dropped to the floor while I was removing it. (I read how to stop that after the fact). It only dropped from the height of the crank shaft with the bike on its double stand...
    I couldn't see any damage.
    I got the pickup coil resistance from another thread and mine measures 104ohms at the connector under the seat. (Spec said 110ohms +/-)
     
  10. Jun 28, 2018 #110

    TerryTheTillman

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    [​IMG]

    I would be interested to find a picture of someone else’s from this angle to compare to see if it looks like it’s on correctly?


    Sent from my iPhone using Tapatalk
     
  11. Jun 28, 2018 #111

    TerryTheTillman

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    [​IMG]

    I’m going to measure from the edge of the casing where the gasket goes to where the magnets are mounted on the flywheel and then from the edge of the Stator housing, where the gasket goes, to the pickup coil and compare to see if they line up?
    Then pop the flywheel back off the crank to see where the key and slots ended up?




    Sent from my iPhone using Tapatalk
     
  12. Jun 28, 2018 #112

    mabdcmb@yahoo.com

    mabdcmb@yahoo.com

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    You should be able to verify the flywheel is lined up with the keyway by just removing the bolt and taking a look.
     
  13. Jun 28, 2018 #113

    TerryTheTillman

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    [​IMG]

    I found my problem!
    I can see where the key ended up on the inside of the flywheel by the impression that it made. I swear I felt the key engage the keyway when I put the flywheel on :/
    The key is also now very squished into the crank shaft!
    [​IMG]

    The only thing that looks irreparably damaged is the key itself...

    Hopefully, I can pop the Woodruff key out and replace it without damage to anything else?


    Sent from my iPhone using Tapatalk
     
  14. Jun 28, 2018 #114

    TerryTheTillman

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    I guess I get to be a poster boy for one more thing not to do....

    [​IMG]
    [​IMG]
    [​IMG]

    Called my local bike shop for a new Woodruff key.

    Let’s see if I’m luckier than I am stupid, and I get this thing running properly again...


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  15. Jun 28, 2018 #115

    D-Max2012

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    Glad you found your issue.. Simply chalk it up to a learning experience..
    That's what I've done with all the FUBAR's that I've encountered with my used and abused 91.
     
  16. Jun 28, 2018 #116

    Gbianchi

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    And also NICE pictures!
     
  17. Jul 8, 2019 #117

    Mightymouse

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