| Author | Message | ||
     Griffmeister |
I know this is just a case of the jitters from delving into the unknown, but the service manual makes it sound much easier than it actually is. First question is about the primary cover which I think I know the answer to. Clutch disconnected, chain adjuster backed off fully and ALL the bolts out and still the cover won't come off. It wiggles a little but seems to hold tight around the clutch area. I suspect that there are at least two snug fitting dowels that are probably keeping it from just popping off. Is this it or am I missing something? The other question is that the SM says "remove sprocket cover, unbolt starter, disconnect two wires and pull starter out the sprocket side". I have the sprocket cover off and can just barely see part of the starter with what looks like a lot of stuff still in the way. There's a link at the top, two rigid oil tubes at the bottom and some wiring in the middle. Am I just imagining this, will it just slip out through the opening like the book says? Guess I just need to hear from someone that's actually been there. Any and all tips welcome. Thanks. | ||
| Skifastbadly |
I bet you've not taken out all the bolts. There are some that are kind of hard to spot especially if you never wash your bike. DAMHIK | ||
| Natexlh1000 |
Did you open the "derby cover" and remove the ramp/ball thing in the clutch hub? Sounds like you're fighting that. | ||
| Dave186 |
I had to disconnect the oil lines to get a bit more clearance, its a tight fit but the starter will come out. | ||
| Natexlh1000 |
OH! I thought he was having trouble with the primary cover! sorry. | ||
| Griffmeister |
Nate, you're right on all counts. Yes I am trying to deal with both since one precedes the other. My forehead is a lot flatter from slapping it so many times. I did not realize that the "ramp/ball thing" had to come out first, that's what it was rocking on. So the cover's off and the bolts are out and no room to move the starter. Don't know if the 08's are different from the earlier engines by much, but I can see that both upper oil lines will need to be disconnected as well as the harness that goes through there. The only other potential problem that I see is the trans vent hose. It's fairly big and not very flexible, may try and force it to the side and tie back. Looks damn near impossible to remove otherwise. Needless to say I'm not a big fan of working on small stuff with the limited supply of tools I have at home. Popped the cover back on to keep out debris and I can foresee a lot of fun in the near future trying to put it back with all the right stuff back in place. Thanks for the suggestions guys, keep your minds sharp, I may be asking more questions before I'm done.  | ||
| Bluex |
You will have a little more wiggle room if you push the vent hose as far up and behind the rear exhaust header as possible. I found removing/installing the starter power cable equally challenging! Btw, why do you need to remove the starter? | ||
| Argentcorvid |
it was a lot easier with the engine rotated, and i did have to remove the hard oil lines to get mine out. I had to get it out because I needed to replace my transmission vent hose and couldn't get to the hose clamp with the starter in there. | ||
| Mattmcc00 |
here are some pics of my recent startor motor change so you can see it opened up. might help.    | ||
| Mattmcc00 |
more     i dont recemend using a cheap chineese starter either. After installing mine i noticed i was leaking tranny oil. so... did the job again, took it all apart, and i noticed that the casting for one of the bolts was broken. Ended up using my old original starter housing and the new starter parts to make 1 functioning starter. Also make sure you check the inside of your covers for clay. clean that with break cleaner work well. | ||
| Griffmeister |
Reason for removing the starter is the drive clutch finally gave up after a few months of funny noises. Every once in a while it would sound like the engine was cranking with the spark plugs removed, then it would catch with the usual compression hitch and fire up. Last week it started getting worse, I knew I had to do something but tried to hold off as long as possible. Monday came and ended that idea, the motor just spun freely and wouldn't even engage the pinion. At this point I'm hoping it just needs the override clutch assembly as I can't afford a new starter right now. Need to remove the starter first to figure this out so here I am. Weather sucks today so I didn't get any further, maybe tomorrow or Saturday for sure I'll have that sucker out. Nice pics Matt, the top of my trans looks black and oily too. Guess I better have new gaskets ready to go back together. Thanks. | ||
| Reepicheep |
Griff... When I thought my starter had a clutch problem (it turned out to be a ground strap I forgot to hook back up) I checked and I'm pretty sure you can order most of the internals for the starter separately. So you can probably just get the part you need. | ||
| Mattmcc00 |
Don't forget to get a new starter motor gasket if your opening it up, its a rigid type. The 2 smaller cover gaskets can be salvaged but I would not recommend trying to reuse the old tranny gasket. If it doesn't seal propperly you'll have to open the whole thing up again and have to refill the oil. MMcC | ||
| Griffmeister |
Didn't have the time or gas to run up to the dealer this weekend, but a local shop was actually able to cross reference an overrun clutch assembly for the starter. It looks a little different, the driven gear is wider and both bearings are the sealed type but other than that it fits right in. The clutch is a Drag Specialties P/N 79-2101-A. Trying to balance working on the bike with other projects around the house so I just barely got the starter reassembled and bolted back in place. Had to connect the wires and spin it over just for peace of mind, works like a charm. Need a primary gasket so I can put the cover back on, ran out of time anyhow. At least I know it'll be okay. Matt, your pictures reminded me to take a couple of disassembly shots. I was able to refer to those when I put the starter back in so I didn't screw up the wiring. Found out today that Wearever Gold Brake Clean, available at Advance Auto, will take off the worst baked on oil and grease stains from your engine. If you're not planning on having any more children or living to retirement age I highly recommend it. |
