I have not yet completed the suggested Primary Nut fix. I have just purchased required gaskets and I believe I almost have all the info I need.....almost. I know that the nut on the ignition side is a 26mm and requires either a deep socket or an offset wrench, what size is the primary nut itself, and can you complete the fix (Loosen, Locktite, and Tighten) without removing the clutch basket? :thumbsup: It also sounds like this would be a good time to dig into the starter gear bolts to make sure they are tight as well?

Yes check the starter gear bolts, and the P/Nut is 27mm.
You may need two 27mm sockets, as my 26 mm socket would not fit the rotor nut.
Neil. :thumbsup: :ride: :ride:

Neil Claydon said:

Thanks for the tip...can you tell me if it is necessary to remove the clutch basket?

obrianmcc said:

No you can leave the clutch alone, but I decided to check the centre nut, and it was just barly finger tight.
In fact I checked the P/N the rotor nut and starter gear bolts as well and they were all below the specified torque as was the P/N and clutch centre nut.
Neil. :thumbsup: :ride: :ride:

I have a 2003 400E and the primary nut wa loose . Needed 27mm for both sides as stated above. You need a left hand tourque wrench.(left hand thread)

SwampDigger said:

Very good point.
I have 3 reversible torque wrenches, and none of them worked in reverse.
I ended up using an old flexy beam type, that has been gathering dust for the last 30 years.
Neil. :thumbsup: :ride: :ride:

OK...Tell me if I'm on the right track...I've been studying the diagrams on Ron Ayers...

1) You have to remove the "Stator Assembly" and the "Magneto Rotor" in order to access the "Starter Clutch Set" to check the torque of the starter clutch bolts?

Sound right?

obrianmcc said:

Sort of.
Remove the generator cover, and the starter gear bolts are visable.
I removed them one at a time, degreased the thread and the bolt, and loctite'd them in place.
Neil. :thumbsup: :ride: :ride:

Neil Claydon said:

Excellent, Thanks for your help Neil!!!