| Author |
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Zac4mac
| | Posted on Tuesday, July 10, 2012 - 08:29 am: | 
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The small gear is the starter gear.
It is part of an assembly consisting of that gear and another, larger one, connected by a "friction clutch".
I suspect "something" came out of the friction clutch when you removed the small gear.
Not sure how you got it out, the "teeth" on the piece of plastic should keep it in place.
I pulled on the one I have apart and the gear slid on the shaft a little but wouldn't come off.
I didn't try to turn the motor tho to see if the teeth would line up.
Good luck with her trip to the dealer...
Zack |
Zoolander
| | Posted on Tuesday, July 10, 2012 - 08:50 am: |
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I'm not understanding what this key and keyway look like. I did not see anything come off of the starter gear. If it's something that could have fallen off by itself then maybe I missed it when the cover was off.
Thanks for all the help and suggestions. We'll see what they say. |
Sparky
| | Posted on Tuesday, July 10, 2012 - 03:09 pm: |
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The video of you turning the crank counterclockwise shows the small starter gear on the left also turning. So if the engine is running does that mean that the starter will also be turning? I thought that is what the sprag clutch is supposed to do - prevent the starter from turning when the engine is running.
If you removed the sprag clutch from the sprag clutch housing at all during this episode, I submit that you installed the sprag clutch into its housing backwards. That would explain the freewheeling noise and non-cranking while trying to start. |
Zoolander
| | Posted on Thursday, July 12, 2012 - 11:06 am: |
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Whoever guessed that I installed the starter gear in backwards, wins!
I'm a little confused by who calls what what, but apparently I installed the big ring - which i know as the starter gear - onto the sprag clutch backwards( the one that is attached by the 6 bolts). Sparky, I think you nailed it.
It fires up now seemingly without any problems. I still haven't had a chance to go for an official test ride but that will come this weekend.
Thanks for everyone's help. Even though I couldn't figure it out, I sure did learn a few things. You guys were great. |
Baf
| | Posted on Thursday, July 12, 2012 - 08:19 pm: |
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Is your stator in good condition? Mine was marginal when I changed rotors, then it crapped out 400 miles later.
Not blaming the rotor in the slightest - just noting that it isn't a miracle fix, if your stator is already on its way out, then it's on its way out. |
Zoolander
| | Posted on Thursday, July 12, 2012 - 10:11 pm: |
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I've wondered if this is truly "the solution". Only time will tell I guess. My stator looked good (posted on "call for stator pics" thread). I think I'm good for a while. (nervous laugh) |
Bossanova
| | Posted on Tuesday, July 31, 2012 - 06:57 pm: |
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So got a question also...
I have mine tore down to fix "free wheeling" starter issue. My question is, does the FRICTION CLUTCH (#15 on page 37 of the '09 Parts Manual) spin freely on it's shaft in both directions? Please tell me it does- looks like a PITA to remove since you can't just slide it off to replace it. I know I will need to replace the SPRAG CLUTCH (#13), HOUSING (#14) and possible the 53T GEAR (#16) since it appears galled on the surface where the sprag clutch engages. With the stator removed on the bench, I can free spin the 53T gear in any direction. This leads me to believe that that stuff needs replaced.
Any additional info would be appreciated.
BTW, Zoo's in your vids, you are spinning the big 53T gear clockwise freely. Did it engage when you spun it CCW? |
Zoolander
| | Posted on Tuesday, July 31, 2012 - 10:06 pm: |
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Boss,
The starter gear (53T gear) did not spin the other way.
I hope you figure it out, I wish I could help. |
Bossanova
| | Posted on Wednesday, August 01, 2012 - 05:10 am: |
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The starter gear (53T gear) did not spin the other way.
Thanks Zoo. Don't happen to remember if the Friction clutch (the gear that actually engages to the starter motor) spun freely in either direction? It is the most forward gear that is on a shaft, and it is trapped unless you remove the lower part of the gear train for the rear cylinder.
edit- added a short vid of what I'm asking.
http://www.youtube.com/watch?v=5o3mamHjYE4&feature=plcp
(Message edited by bossanova on August 01, 2012)
(Message edited by Bossanova on August 01, 2012) |
Bossanova
| | Posted on Wednesday, August 01, 2012 - 10:54 am: |
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edit- double post
(Message edited by bossanova on August 01, 2012) |
Sparky
| | Posted on Wednesday, August 01, 2012 - 02:56 pm: |
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Boss, you've got a bunch of the parts removed. I'm pretty sure that all the parts involved in that gear train have to be installed in order to determine what is/is not working.
If you could put the parts back on and try the simple crank rotating bit that zoolander did in his vid, maybe that'd help us. In zoo's case, the sprag clutch (goes on the back of the rotor) was put in backwards causing starter freewheeling instead of catching when pushing the Start button. |
Bossanova
| | Posted on Wednesday, August 01, 2012 - 05:42 pm: |
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Sparky, Yeah I'm positive the sprag clutch is bad. I have already ordered it, the housing and the 53T gear (and nut). I just don't want to go to the trouble of buttoning it up if this friction gear needs replaced also. I just got back from HD and the mechanic seemed to think that the gear was supposed to spin freely in both directions.
I am inclined to think that the Friction Gear is a set up that is designed to "disengage" in the event of a sprag clutch failure that might permanently engage the gear train from starter to rotor. |
Bossanova
| | Posted on Monday, August 20, 2012 - 12:55 pm: |
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 Feel kinda dumb asking but...
This was in my oil drain pan when I poured the oil out of it. Where does it belong?
Looks familiar but it's been over 3 weeks since I disassembled it for the new sprag clutch (and EBR Rotor). |
Zoolander
| | Posted on Monday, August 20, 2012 - 09:40 pm: |
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it covers the ignition bolts at about the 2 O'clock position and routes the wire that lays over the top of it.
I believe I have the monopoly on dumb things for this thread. |
Bossanova
| | Posted on Tuesday, August 21, 2012 - 10:21 am: |
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Yeah thats it- Thanks Zoolander. Must of fell off the wire during the removal.
One more question- Only one of the cover bolts has a copper washer. The IPC shows it installed up around the 12 o'clock position, but is not clear. Which hole gets it? |
Sparky
| | Posted on Tuesday, August 21, 2012 - 02:07 pm: |
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quote:Only one of the cover bolts has a copper washer. The IPC shows it installed up around the 12 o'clock position, but is not clear. Which hole gets it?
"NOTE
The fastener with the brass washer threads into the torque sequence position eight"
Position eight is approx an inch below and to the right of where the upper locating pin is. |
Bossanova
| | Posted on Tuesday, August 21, 2012 - 08:59 pm: |
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Wow thanks Sparky. |
