Need Help! Starter disengages and grinds after Stator repair

[parrothead71]

1983 XVZ12TK

 

About 2 months ago I had to replace my stator because I thought I was having charging issues. I carefully took the cover off taking note of how each of the gears were positioned and then put each one of them exactly as before. Replaced stator, oil, gasket. After reassembly i hooked up the battery and tried to start the bike. Immediately the starter turned over but before the bike started one of the gears disengaged with a gear grinding. I can start the bike but if it doesn't kick off right away the gear disengages. I have taken it back apart 3 times. I even have taken apart one of my parts bike to compare the two thinking I reversed a gear or over looked something. But I can not find any way any of the gears could be installed wrong, I then swapped the starter thinking that maybe the starter was getting ready to bite the dust but the starter that worked perfect of the parts bike does the exact same thing. When the starter spins the motor everything sounds normal. There is no binding or grinding. Has anyone ever made this error? Any ideas on what I have done wrong. I have spent over 30 hours taking it apart, putting it together over and over and I have had it.

 

I love this bike but have to get this fixed. I am beyond the point of spending too much time and $$ .If I can not fix it soon I am either selling or going to take a LONG and expensive road trip to find a reputable tech that knows how to work on this bike. There are no reliable mechanics that are WILLING to work on a bike this age. Add the fact that something is wrong after I worked on it won't help them jump at the opportunity to fix it. Any help is appreciated. PLEASE SOMEONE HELP!!! Chris

[bkuhr]

check out this thread

http://www.venturerider.org/forum/showthread.php?t=53772&highlight=starter+clutch

 

Have not messed with mine at all, so no first hand info.

[Snaggletooth]

Hey Chris,

 

Ok, if I'm following you on this the noise is only during the cranking over of the motor, but not after it starts. Right?

 

If that is the case I'm putting money on the starter engage clutch failing.

 

They make a terrible racket when the three bolts work loose or the clutch body cracks letting the three dogs chatter on the boss of the 72 tooth ring gear that is drivin by the idlers for the starter.

 

The only fix. a new engage clutch and 72 tooth ring gear......or Dano has a upgrade for a bit more $$ which it the final answer for life of the bike. I installed the upgrade in mine after replacing two engage clutches.

 

Do not even try to rebuild one. It's a waste of time and money. Do it with all new parts or the upgrade.

 

Any questions......feel free to ask. Been through it.

 

Mike

[Rocket]

1983 XVZ12TK

 

I even have taken apart one of my parts bike to compare the two thinking I reversed a gear or over looked something. But I can not find any way any of the gears could be installed wrong,

 

 

PLEASE SOMEONE HELP!!! Chris

 

Maybe swap the rotor assy, from the parts bike & try it. It may, have a better starter clutch on it. It will be a low cost test, at the least.

[parrothead71]

Thank you sooo much for the quick replies. I'm certain this is the problem. Tomorrow I will pull the clutch off of the parts bike to test but will certainly order the mod to fix it right. there is no way this is a coincidence that it went out after reassembly. I must have damaged it removing the engine cover the first time I tore it down. Until now I never really thought about how the gears disengaged when it was supposed to.

 

I might be a little on the slow side but I'm one heck of a parts changer. Thank all of you for the help.

Chris

[Snaggletooth]

Well it's clear that you''re not afraid to dive into the motor to get things done.

 

If you've been reading the threads on the clutch upgrade I'm sure you caught the fact that the rotor can a bear to remove if it hasn't been off the crank before. If you don't have a good quality harmonic balancer puller check with your local auto parts stores for a loaner program. A 1/2 impact gun is handy too. Electric or air.

 

Was it a coincidence that this failed right after you did the stator? More than likely. It has probably been going bad for a long time and picked that moment to give it up. Like when I did the clutch upgrade with the full disk and new pressure plate springs on the OTHER side of the bike. Within minutes of closing that up the starter burned up. Or installing an digital voltmeter in the dash and the next day having the R/R fail. It goes with the mentality of "When it rains it pours", or "One thing after another". I always say I'm not rebuilding an old bike, I'm building a new one. A lot of truth in that. LOL

 

Oh and a reminder......

 

The idea of swapping out the rotor assembly (with engage clutch intact) from the other motor is a good one. As stated, a cheap test. If it is solid it you may be in good shape. Just remember NEVER to try to start the bike without the side cover installed. Seems like a good idea but those idler gears need support on both sides and if they jump out of line they can take pieces of engine case with them. It's only a few extra minutes to slide the cover on and bolt it down to try the starter. Sounds like you have had some practice with that anyway. LOL!

 

Keep us posted on what you find.

 

 

Mike

Edited November 20, 2010 by Snaggletooth