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Post by rctaudio on May 29, 2015 10:26:51 GMT -6
Hey all. My starter just started spinning freely. I think the clutch is messed up, but I cant get it open to see it. I've removed all 9 bolts around the cover, the left foot peg and the spring clip thingie. I read in the haynes manual that the cover might be held in place by the magnets on the strator, but when I try and pull it off it feels like something is still holding it on. I'm wondering if I've missed a bolt somewhere, OR if the starter is somehow holding it in place. any tips?
Thanks
-Patrick
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Post by Blaine on May 29, 2015 15:27:53 GMT -6
Hey all. My starter just started spinning freely. I think the clutch is messed up, but I cant get it open to see it. I've removed all 9 bolts around the cover, the left foot peg and the spring clip thingie. I read in the haynes manual that the cover might be held in place by the magnets on the strator, but when I try and pull it off it feels like something is still holding it on. I'm wondering if I've missed a bolt somewhere, OR if the starter is somehow holding it in place. any tips? Thanks -Patrick If memory serves me correct there are 10 bolts. If I'm wrong & you got them all the force of the magnets takes a good pull to overcome.The starter does not hold the cover in any way.  |
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Post by eaglerider on May 29, 2015 15:44:17 GMT -6
You have missed a bolt.....look again...on the bottom, likely. Hey, don't feel bad, first time I pulled mine, I missed one, too!!!  |
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Post by rctaudio on May 29, 2015 21:14:02 GMT -6
Yeah thats what I kept reading but I've only found 9. I've triple checked and there is only 9 bolts and the shaft that goes to the shifter. I took the shifter pedal off and the retaining clip for it. It still feels like there is a bolt missing somewhere on the bottom.
Are the only bolts for it on the face of the cover? There are 2 or 3 bolts on the bottom of the cover going direct up, would one of those be the missing bolt?
Thanks
-Patrick
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Post by Blaine on May 29, 2015 21:20:31 GMT -6
Yeah thats what I kept reading but I've only found 9. I've triple checked and there is only 9 bolts and the shaft that goes to the shifter. I took the shifter pedal off and the retaining clip for it. It still feels like there is a bolt missing somewhere on the bottom. Are the only bolts for it on the face of the cover? There are 2 or 3 bolts on the bottom of the cover going direct up, would one of those be the missing bolt? Thanks -Patrick All the bolts are on the cover.I checked a couple of diagrams....Looks like 9 is the total. |
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Post by rctaudio on May 29, 2015 23:07:01 GMT -6
It is definitely stuck on there still do I need to remove the peg that the shifter bolts on to? What could still be holding it on? Is it possible that the sprocket came off the started and somehow jammed the cover from opening?
Any other ideas?
Thanks,
-Patrick
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Post by Blaine on May 30, 2015 5:05:35 GMT -6
It is definitely stuck on there still do I need to remove the peg that the shifter bolts on to? What could still be holding it on? Is it possible that the sprocket came off the started and somehow jammed the cover from opening? Any other ideas? Thanks, -Patrick No it slides off over the shifter peg.If someone had it apart before they may have used a sealer on the cover instead of a gasket.You can try to get a putty knife to get it started.Just be sure not to gouge the soft surfaces. |
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Post by rctaudio on May 31, 2015 16:10:14 GMT -6
Thank you for the putty knife idea, that is all it was. I now have the cover off and can see that the starter moter and chain is working correctly. I just want to double check before I start ordering parts.
The outside hub thing is the alternator rotor correct?
The starter clutch is on the backside of that rotor and if the starter clutch is working corretly it should engage and spin the motor and the alternator rotor correct?
Right now the starter, sprocket, and chain spin but the alternator rotor is stationary.
Should I order that special alternator rotor holder, or go down to sears and get one of those belt wrenches people talk about?
one last questions ( I hope:) ) can I use a starter clutch from the vulcan 500 and / or ninja 500? I know the motor a modified ninja motor, I just want to source the cheapest correct part to get my bike running again, I'm a poor college student so I've trying to save money with out sacrificing too much!!
Thanks again Blaine for the putty knife idea that was a lifesaver!!!!
-Patrick
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Post by Blaine on May 31, 2015 19:10:31 GMT -6
Thank you for the putty knife idea, that is all it was. I now have the cover off and can see that the starter moter and chain is working correctly. I just want to double check before I start ordering parts. The outside hub thing is the alternator rotor correct? The starter clutch is on the backside of that rotor and if the starter clutch is working corretly it should engage and spin the motor and the alternator rotor correct? Right now the starter, sprocket, and chain spin but the alternator rotor is stationary. Should I order that special alternator rotor holder, or go down to sears and get one of those belt wrenches people talk about? one last questions ( I hope:) ) can I use a starter clutch from the vulcan 500 and / or ninja 500? I know the motor a modified ninja motor, I just want to source the cheapest correct part to get my bike running again, I'm a poor college student so I've trying to save money with out sacrificing too much!! Thanks again Blaine for the putty knife idea that was a lifesaver!!!! -Patrick Correct on all your questions.Everything should turn.A strap wrench will work fine to hold the rotor. |
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Post by rctaudio on Jul 15, 2015 17:28:07 GMT -6
Work has been crazy, and I haven't had much time to work on the bike. I finally got it all apart, and I think the problem might be the starter clutch sprocket. Mine will pretty much freely spin in both directions, but it should only spin in one correct? It looks like the springs and rollers are good. I just want to confirm about the sprocket before sourcing another one out.
Thanks
--Patrick
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Post by Blaine on Jul 15, 2015 18:04:18 GMT -6
Hey all. My starter just started spinning freely. I think the clutch is messed up, but I cant get it open to see it. I've removed all 9 bolts around the cover, the left foot peg and the spring clip thingie. I read in the haynes manual that the cover might be held in place by the magnets on the strator, but when I try and pull it off it feels like something is still holding it on. I'm wondering if I've missed a bolt somewhere, OR if the starter is somehow holding it in place. any tips? Thanks -Patrick If memory serves me correct there are 10.Double check I could be wrong.There is a fair magnetic pull from the flywheel & needs a pry to get started.Just be careful of the mating surfaces & don't gouge them. |
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Post by rctaudio on Jul 15, 2015 18:24:53 GMT -6
Hey Blaine, I think you responded to an earlier post of mine  I already got that flywheel off, I'm looking at the sprocket and it is able to rotate both ways. From what I've read online, it should only spin one way? I think thats what I need to replace now. What do you think? thanks -Patrick |
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Post by lastamericanoutlaw on Jul 15, 2015 19:14:20 GMT -6
I'm having the same problem rite now.
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Post by lastamericanoutlaw on Jul 15, 2015 20:15:31 GMT -6
Where is the best place to find the starter clutch Assembly ?
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Post by Blaine on Jul 15, 2015 21:07:30 GMT -6
Hey Blaine, I think you responded to an earlier post of mine I already got that flywheel off, I'm looking at the sprocket and it is able to rotate both ways. From what I've read online, it should only spin one way? I think thats what I need to replace now. What do you think? thanks -Patrick You are correct...The rollers & pins from a Ninja or Vulcan 500 are the same. |
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Post by eaglerider on Jul 16, 2015 6:07:31 GMT -6
Ebay is a good source for the 454 parts. Remember, the starter clutch for the Vulcan and Ninja 500 are the same as the 454, and possibly easier to find.
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Post by lastamericanoutlaw on Jul 16, 2015 17:01:52 GMT -6
I was able to to find the parts at my local kaw dealer. For cheaper then I was able to find them on the web.. I kinda lucked out.
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Post by eaglerider on Jul 17, 2015 7:35:35 GMT -6
Great!! |
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Post by joe454 on Oct 3, 2015 6:45:30 GMT -6
Was there oil in side the cover?
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I already got that flywheel off, I'm looking at the sprocket and it is able to rotate both ways. From what I've read online, it should only spin one way? I think thats what I need to replace now. What do you think?