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Buell Forum » Knowledge Vault (tech, parts, apparel, & accessories topics) » Engine » Electrics: Starter, Ignition, Coil, Spark Plugs/Cables, ECM, "TPS Reset" » Archive through August 27, 2007 » Starter Gear change « Previous Next »

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Bluelightning
Posted on Tuesday, December 20, 2005 - 11:34 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Back a bit (found it during the ride to LaVale), my starter bolts loosened up and ended up chewing my ring gear, which has in turn started to chew up my starter gear. Are these parts relatively easy to change by themselves or will I need to get a new clutch basket and starter?
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Bluelightning
Posted on Monday, February 27, 2006 - 09:28 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

To answer my own question, I found that a ring gear from a 93 Sporty fits perfectly on my 00 clutch basket. The 1st trick is heating the old gear enough to make it expand and popping it off with a dead blow hammer, ensuring that the clutch basket itself stays somewhat cool and un hit by the hammer. The 2nd trick is how to get the new gear back on the basket. Well about 20 minutes in my handy dandy gas grill on highest setting, flip and drink another beer while waiting another 20 minutes just to make sure it's done in the middle, remove and quickly slip it over the basket. Fits perfect, tightened right up and is the same diameter and tooth count as the stock unit!!

As for the starter gear, the end of the shaft is threaded, find a good helper, thread a bolt into the starter shaft, pull it out and push back on the starter gear. have your friend remove the little ring clip from the end of the shaft and all will come off. Assembly is in reverse order. Never had to remove it from the bike!!

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