Starter not engaging on 03 WR450
Posted July 25, 2004 - 05:14 PM
Anyone else have this happen?? Anyone know a fix?
Posted July 25, 2004 - 05:25 PM
Posted July 25, 2004 - 06:02 PM
Posted August 12, 2004 - 06:04 AM
SORRY for taking so long to get back with you! We had to wait on the correct flywheel puller to arrive and then I've been on vacation!
We swapped out the one-way clutch assembly on my bro-in-law's 03 WR450 and we were SHOCKED at what we found. When we took the one-way assembly out it literally FELL APART!! Check out this photo of the one-way clutch:
It's difficult to see in the photo but the parts that made up the assembly are sheered and rough on certain sides and the spring that holds them all together was wadded up in the casing. We collected all the parts and confirmed that nothing fell into the motor while taking it out.
I would recommend installing the longer flywheel bolts while you have the assembly out. We didn't change ours out (didn't want to wait on the parts and we had a big ride the next day) but our bolts looked good so we reinstalled them.
The '04 one-way assembly (spare) I had is identical to the '03 part (they didn't change it in '04) and it completely resolved his starting issues.
Posted August 12, 2004 - 07:49 AM
Posted August 12, 2004 - 08:20 AM
Anyway, I think there have been a few on here that have had the same symptoms we've had but overall, I think they've been fairly reliable. I believe Yamaha expects this part to wear out because the manual says to inspect it occassionally and "replace as necessary." Yamaha's marketing department would call that CYA.
Posted August 12, 2004 - 08:42 AM
Posted August 12, 2004 - 09:31 AM
What I mean is, one cause of the woodriff keys shearing was the engine would backfire, and the thrust from the backfire would shear the key. Well the factory fix is to Loctite the flywheel and torque flywheel nut on there super tight. This fixes the problem with the key sheering, but your bike is still going to backfire once in awhile. What is going to absorb that thrust, and prevent other parts in your bike from breaking?
Just wondering. I upgrade my 03 with 04 starter parts right away. In the 04 parts, the starter gear now has damper built into it which I assume is to absorb any thrust from a backfire.
Posted August 12, 2004 - 09:40 AM
Posted August 12, 2004 - 06:01 PM