GadiantonRob Posted February 22, 2014 Share Posted February 22, 2014 So, my bike started the infamous "crunch" noise upon start up late last riding season, and I finally got around to replacing what I suspected to be the starter clutch. Much to my great joy (or dismay) the starter clutch is fine and well and everything is in ship shape. Being the Sherlock that I am, I dove in and started searching for clues. And I stumbled upon this my dear Watsons... The gear reduction assembly had shavings in some areas, with worn cogs. Aha! I said, but I am wasn't done. I looked at the starter gear... I see a line in the gears, but they are not worn, and they pass the fingernail test. So is the problem a worn reduction assembly, or is something else worn causing it to wear? All other gears show no wear. Your hypothesis' please. Link to comment Share on other sites More sharing options...
Member Contributer vfr350 Posted February 23, 2014 Member Contributer Share Posted February 23, 2014 Is that a close up of a chunk of wire from a spring first pic? Like return spring on a worm? Havent looked at the diagram just a guess. Link to comment Share on other sites More sharing options...
motorman Posted February 23, 2014 Share Posted February 23, 2014 Looks like a lone needle from a needle bearing. Similar to what you find on a U joint for a car . Link to comment Share on other sites More sharing options...
GadiantonRob Posted February 23, 2014 Author Share Posted February 23, 2014 No, they are shavings from the worn cogs of the reduction gear, as stated in the post. There is no FOD in the case. Link to comment Share on other sites More sharing options...
Member Contributer BusyLittleShop Posted February 23, 2014 Member Contributer Share Posted February 23, 2014 I'd like to see a photo of the piece of metal all by itself... Link to comment Share on other sites More sharing options...
Member Contributer huntinggunns Posted February 23, 2014 Member Contributer Share Posted February 23, 2014 I'd like to see a photo of the piece of metal all by itself... I'm with BLS. Is the metal soft, meaning is it aluminum? You might have scraped the case on the gear when removing it and scraped off some material when pulling it. The gears would have chips missing from the teeth it that size of debris was coming from them. As far as the started clutch goes make sure to inspect it well. Those cracks are hard to see sometimes as they show up as hairline cracks. Also, the springs and rollers can cause that problem even if the drive housing is not cracked. Not too far from OKC to load it up and swing it by .......... Link to comment Share on other sites More sharing options...
The Phantom Posted February 23, 2014 Share Posted February 23, 2014 Not to doubt your investigative chops, Rob - but it's rare for this to be anything other than a cracked starter clutch housing. I have heard of people changing the brand/type of oil they use and having the dreaded crunch go away, though. To clarify - have you swapped in a new starter clutch housing and still have the problem? Or you just can't see any cracks in the original housing and are digging deeper? Link to comment Share on other sites More sharing options...
GadiantonRob Posted February 23, 2014 Author Share Posted February 23, 2014 Just peered over the starter clutch again with my magnifying glass and low and behold one of the three housings has quite a groove worn in by the roller. I'm guessing this roller is getting caught in the groove and is not moving fully. Can this be sanded out or is a new starter clutch in order? Sent from my fancy telly. Link to comment Share on other sites More sharing options...
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