Starter Clutch problem
Posted October 06, 2010 - 08:48 PM
After getting the bike on Tuesday, starting it up, and riding it up and down the street a few times I got down to some mods. First up, along with a larger gas tank, was the Baja Designs dual sport kit. I want to be able to ride to the trails - so getting this bike street legal is one of my top priorities.
I did the stator modification recommended by Baja Designs, and after getting everything put back together I have a problem that can be traced back to pulling the case cover to do the stator modification - only problem is I can't figure out how to fix it.
Basically, when using e-start, the starter isn't engaging the starter clutch. When I hit the button, I can hear the starter "free-wheeling". To verify that this is what is occurring, I pulled the torque limiter out and hit the button. When I do this I can see the starter spindle spinning and making the same "free-wheeling" sound. Put the torque limiter back in, tighten everything up, same problem.
So for some reason the starter spindle (not sure if that's the right word for it) isn't engaging the torque limiter. Everything else checks out, both the starter clutch drive gear / rotor and the idle gear turn freely in one direction but not in the other, which I'm pretty sure is correct.
It almost feels like the torque limiter is falling out to the left, if that makes sense, which then puts it too far out to engage the starter.
Thoughts? I'd hate to have to take this to the dealership before I even get a chance to really ride it.
The image below shows where I think the problem is - the points in red.
Posted October 10, 2010 - 05:34 PM
Posted October 10, 2010 - 09:24 PM
Posted October 11, 2010 - 09:13 AM
I'll check that tonight when I can crack it back open.
Posted October 11, 2010 - 12:44 PM
Edited by dang420, October 11, 2010 - 02:32 PM.