Pickup on Starter idler gear ?

[DanShapotsky]

hi there

..anyone seen this before ? - rebuilt my engine and all was looking peachy till just after it fired up - then the starter idler gear siezed fast to its pin.. .took a great deal of effort and a two leg puller to liberate it - I've no idea why this happened .. everything was spotless and a double check was made at every stage, so i was perdy confident that things were gonna be ok... just wondered if anyone has seen such a thing before, or could suggest what might have been the cause...

I'm going to try to dress it up and see what happens when i have another go - could it have been heat due to lack of lubricant ? - it's all i can think of although it seems highly unlikely cos it had maybe turned a couple of dozen times on the starter when it locked... confused!

Cheers

Dano :cool:

[Derek]

Dano,

I'm not going to try to guess why that happened but it's good to hear that you've got the crankcase disaster sorted out. Did you get them welded or buy a set of used cases?

[DanShapotsky]

Hi Derek

..yeah - got them welded by a mates mate - as of right now the lump is sitting on the table in the sitting room, the ring gear is sorted and running freely, I've just whacked the belts back on, and am not too far off sticking it all back in the frame (which is currently in the porch :roll: ) and going for fire up #2 :D

..I'll keep ya posted - not that today is anything to go by (it's absolutely wild up here) - maybe we'll still get the odd day in before the snow eh ?

Cheers

Dano :cool:

[Edited on 28-10-2004 by DanShapotsky]

[Derek]

Afraid you won't be seeing me out this year now. They've started laying down the salt this week (mind you all this wet will have washed it away again) and my bike is tucked up in the garage and is currently up for sale. Any offers?...

[DanShapotsky]

hmm...

did it again! - cleaned up the idle gear and pin, which only took some light emery paper and a bit of time, which surprised me given that it managed to lock the whole thing down and took my bravest puller effort in a long while to liberate...

... put it together.. spinning freely by hand with the flywheel off, and the starter in place, located fine with the flywheel.. turned over by hand with a socket on the rotor nut no probs at all.. put the casing back on, in with the oil and went for a start... turned over no problem with the plugs out and in .. kill switch off.. couple of turns and the instant it started it locked and died again !!

I thought it might have been something to do with the sprag clutch but that appears to be working as it should too.. there's a force at play here but I'm damned if i can work out what.. the starter appears fine, the idle gear appears fine, the flywheel appears fine, but as soon as she fires it siezes -hard... scratchin me head till it hurts here folks.. any clues or experiences would be a major boost :puzzled:

cheers

Dano :(

[DanShapotsky]

Hi again

..as u were gents.. solved it ! - turns out I'd got a shim from the crankshaft end float measurement exercise mixed up with the one for the back of the sprag/flywheel assembly.. we're talkin a couple o points of a mil on the micrometer here but it just goes to show how critical such things are...

..the sprag was locking up under torque and transferring the load to the idle gear and causing the bind up... s'pose it goes to show that possibly these things should be left to them that know.. on the other hand I'm perdy chuffed that i worked it out and sorted things without any major failings whatever :D :D

..second kick after the new rebuild an off she went... sweet as a nut hehehe... the fact that I had her parked in the sun lounge at the time and filled the house with the obvious fumes didnt seem to bother the family too much :bouncy:

so far so good :D

Dano