
JAN's REQUEST FOR
ADVICE
From: "Jan Nell" <j.nell@ru.ac.za>
To: "'Hans Knop " <mail@awol.co.za>
Cc: <a.winter@ru.ac.za>
Sent: Wednesday, July 02,
2008 4:02 PM
Subject: start problem
Hi Hans
I am hoping for some advice on my bike.
Had some problems with MR Max from the beginning. The starter motor
turns but not the engine, accompanied by the sound of a tin bucket of
bolts being shaken.
I have now installed a new battery, cleaned the water and rust out of
the fuel tank, stripped and cleaned carbs, cleaned all electrical
connections, stripped and checked the starter motor, opened the
starter clutch.
Here things started getting interesting, the gears that go between
the
starter splines and the driven gear were incorrectly assembled, in
other words they were put in in the wrong order. Just the friction of
the gears running next to each other was starting the bike, sometimes.
So it had seemed like I had it licked, it started perfectly for a
while. However it has started to do the same thing, not start,
starter spins but wont turn engine.
So back to pulling things apart, first checked the starter motor, all
in order there. Opened starter clutch again(keeping in mind that I
have not pulled the alternator out).Everything looked all right, but
on closer inspection found that the driven gear can move backwards and
forwards about half a centimetre, it appears as if when under load it
slips past the gear that drives it, is this possible?
I did all the usual stuff like new
plugs, oil,driveshaft oil,fork oil,air filter,oil filter,stripped
and cleaned brake callipers,and anything else that looked dodgy.
I also noticed that my clutch is dragging and that is probably
aggravating the situation. I will bleed that tomorrow. Would
appreciate any input I can get, I am at wits end with it.
Max thanks
Jan Nell
REPLY #1
----- Original Message -----
From:
billy.owen@murrob.com
To:
j.nell@ru.ac.za
Cc:
mail@awol.co.za
Sent:
Thursday, July 10, 2008
1:51 PM
Jan,
The drive gear cannot move that amount of play let me explain I had
the same fault on my V Max you need to take the cover off completely
then you will see you got three gears one is on the starter motor the
other one is the idling gear and then you got your main gear. What
happened with mine the starter clutch start to came loose on the
flywheel it is hold down with three allen cap screws at the back of
the flywheel (caught it in time otherwise it would have damage the
crank case so take note) but you need to remove the flywheel, you need
to loosen the crank bolt and then have a puller made that you can
remove the flywheel because it is on a taper shaft and there is a key
as well watch out not to lose the key. If you have taken it off check
the clutch you got three rollers and springs they usually get worn,
this is when the starter start doing what you have said, I have
ordered a starter clutch and a new main gear assembled and torque
everything again and wow it sounds again like a bike no more horrible
sounds or when you have stopped and want to start you cannot and
believe me the max is a bit heavy to push start. The cost was about
R1400-00 and I need to wait three weeks for them to import it for me.
Yours in Safety and Health
Billy Owen
REPLY #2
----- Original Message -----
From:
JJ and Mariana
To:
Hans
Cc:
j.nell@ru.ac.za
Sent:
Thursday, July 10, 2008
1:09 PM
Subject: Starter problems
Hans,
Last year, whilst returning from the
rally, we (me and Willem) filled up at Standerton, for the last time.
My Max battled to start (also with this tinny noise), but was okay
when getting home. It was then okay for another week, and then
collapsed. Starter motor running, but no engagement.
I removed the alternator cover as I
found some weird pieces of metal at the bottom of the cover. I removed
the alternator “flywheel”. Behind that are 3 capscrew that hold the
starter clutch assy in place. These capscrew came out, the housing
came apart and was ripped the apart in the gears. Luckily for you,
that haven’t happened yet. As soon as the starter motor cranks the
clutch, is forces the 3 rollers to clamp the crankshaft and turns the
motor. In your case, the movement of the clutch are caused by the
loose capscrews.
I purchase a new assembly and apply
Loctite to the capscrew’s threads on assembly.
Make urgent work of it!!!
Regards
JJ
REPLY #3
From:
Murchie, Ian (P)
Sent:
10
July 2008 16:59
To:
'j.nell@ru.ac.za'
Subject:
starter
hi there
My name is Ian and I had the same problem that you are experiencing.
I found after stripping mine for the 3rd time that the springs pushing
out the little cup gets weak and the cup goes to far up the hole and
sometimes sticks. I got hold of the Yamaha suppliers in Durban and
bought the kit. This comprises of the 4 rollers ,4 springs and 4 cups,
this did the trick at a cost of R196 for the lot. My cover the one
that sits over the whole clutch housing was loose so I drilled 3 small
holes and tapped them to keep this in place If this shifts then it is
possible that the rollers my fall out. What ever you do change those 3
components first as to ride it like that will cause serious damage,
was very lucky I did it when I did.And yes its a bitch to get the
bloody flywheel of , on my last attemp the thing nearly went through
the wall.You can phone me on 082-8076132 if you need to ask any
questions.
Cheers
Ian
JAN SAYS.........
01
----- Original Message -----
FROM:
Jan
Nell
To:
billy.owen@murrob.com
Cc:
'Hans
Knop Bamminger'
Sent:
Saturday, July 12, 2008 9:51 PM
Subject:
RE:
Hi Billy
Thanks for the response,I pulled the
alternator rotor,and sure enough ,the whole clutch assembly was
loose.By the look of those three bolts I would say I bought the bike
with that loose!.After replacing the 3 allen cap screws, locktighting
them in place,I re-assembled.Unfortunately everything is so worn that
the driven gear is not locking up.My parts have been
ordered(R1049-55),and its going to be a long 3 to 4 week wait since
there aren’t any in the country!
I hope that there is no other damage to
the engine,I guess I will find out one way or the other !
Thanks again
Jan Nell
02
----- Original Message -----
FROM:
Jan
Nell
To:
Ian.Murchie@za.nampak.com
Cc:
'Hans Knop Bamminger'
Sent:
Saturday, July 12, 2008 9:51 PM
Subject:
RE: starter
Hi Ian
Thanks for the e-mail.I did finally
pull that alternator rotor,and yes,it came off with a crack that left
me shaking!
The entire clutch assembly was
loose,the 3 allen head bolts were so chewed up that it’s a miracle
that it ever started! I have ordered an entirely new clutch sub
assembly and driven gear from X-treme Yamaha in PE .(R1049-55)So now
its patience until parts come from Nippon. JHB is out of stock!
MAXIMUM thanks
Jan Nell
03
----- Original Message -----
FROM:
Jan
Nell
To:
'JJ &
Mariana'
Cc:
'Hans
Knop Bamminger'
Sent:
Saturday, July 12, 2008 9:51 PM
Subject:
RE: Starter problems
Hi JJ
Those cap screws were loose,and nicely
chewed up! Unfortunately I got the bike with everything ratting around
in there and did not know any better.The new gear and clutch sub
assembly are on order,and hopefully that will be that!
Thanks for the advice
Jan Nell |