2003 WR450 Starter Clutch Upgrade - Which Idler/Clutch?


3 replies to this topic
  • mrgem

Posted January 23, 2014 - 08:07 AM

#1

First, let me acknowledge that this discussion has been flogged thoroughly here and on other sites. I just need the definitive info on the correct parts. I apologize in advance for "beating a dead horse."

 

I've just purchased a 2003 450 that seems to be in fine shape. Just found out that it has already had the "locktite fix" TSB applied -- but from what I've read here, there still exists a danger of the back bacfiring and destroying the starting system.

 

So, after reading no less than a half-dozen threads on the subject, I am ready to commit to doing this fix -- which will cost me more than 200 bucks in parts. The problem is that there are 2 different part numbers used to identify the "Damper Assembly," and it depends on which thread here you read. There is also a contradiction between some sources and other about the use of a bushing.

 

I am using Partzilla's web site to confirm and price the parts needed and there is some inconsistency.

 

The earliest posts on this subject (from 2004) say that the correct dampener/torque limiter is: 5TJ-15560-00-00. When you go to the 2004 WR450 fiche, that is the part identified. However, it does not show that dampener as using the solid bushing -- part number 90380-10002-00. Interestingly enough, that part DOES show as being used on Partzilla's later WR250 fiche -- but only for 2008 and later models .And it is used with a DIFFERENT dampener -- part number 5TJ-15560-01-00.

 

Can someone here give me the LAST word on which parts are correct? I'd like to take this bike on a desert ride in a couple of months and I really don't want to have to push it if the woodruff key gets sheared.

 

TIA



  • DeepPurplishBlue

Posted January 23, 2014 - 02:37 PM

#2

You need the 2004-up damper, 5TJ-15560-00
You need the 2004 damper cover,  5TJ-1549B-00
You need the 2004-up thrust washers, 90201-105A8-00

and you need a bushing that gets driven into the 2003 side cover.  This gets you out of buying the
2004-up side cover.    Bushing part number:   90380-10002-00

Nothing else is required for the upgrade. 

 

Have done it 4 times now on different bikes



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  • mrgem

Posted January 23, 2014 - 06:27 PM

#3

You need the 2004-up damper, 5TJ-15560-00
You need the 2004 damper cover,  5TJ-1549B-00
You need the 2004-up thrust washers, 90201-105A8-00

and you need a bushing that gets driven into the 2003 side cover.  This gets you out of buying the
2004-up side cover.    Bushing part number:   90380-10002-00

Nothing else is required for the upgrade. 

 

Have done it 4 times now on different bikes

 

Thank you, sir. 



  • mrgem

Posted January 24, 2014 - 07:46 AM

#4

You need the 2004-up damper, 5TJ-15560-00
You need the 2004 damper cover,  5TJ-1549B-00
You need the 2004-up thrust washers, 90201-105A8-00

and you need a bushing that gets driven into the 2003 side cover.  This gets you out of buying the
2004-up side cover.    Bushing part number:   90380-10002-00

Nothing else is required for the upgrade. 

 

Have done it 4 times now on different bikes

Again, thanks for the prompt and concise response.

 

Just as an FYI, RonAyers.com's parts display indicates that the 5JT-15560-00-00 dampener has been SUPERCEDED by the 5JT-15560-01-00 part.






 
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