Topic: Starter clutch out, kick starter grinding. Video inside!

[Tews19]

I had an hour this afternoon and tackled my 75 550 starter clutch. This time it took far less time then on the parts bike I picked up the other day. Well funny how previous owners will hide #$%*! I pulled the oil pan and literally the huge starter clutch part was in it. Luckily there is no further damage but the kick starter constantly rubs.  Is it possible to repair without splitting the cases?

Please watch the video! Any insight is greatly appreciated!

https://www.youtube.com/watch?v=EGc0AUubD2g&list=UU7fRFY6CGVmaMZJEEtJDbXg

[dave500]

I think its been assembled wrongly?bit hard to see?is the heavy return spring hooked up correctly?if the shaft is turned toward the kick to start direction(counter clockwise) itll start engaging that gear,try twisting the shaft in the release direction(clockwise)

[Tews19]

Can I take it apart with out splitting the cases? I think it's in correct . If you look closely. The arm part that sits on the engine seems cock eyed. 

[Bootsey]

One of the other members was having trouble with this when reassembling his the other day. That silver cast piece that should be retracted and not engaged wasn't orientated the right way and one of those flanges pushing it into contact. He said he rotated it, and that sorted it. Here are a couple of pics that might help you. Also, that shaft has a circlip on the inner end, which might allow you to pull it apart if need be. Hope it helps.

Wrong


Right

[Tews19]

Thanks Bootsey! The pics are not working though.

[dave500]

great shots bootsey!itll be a bloody fiddle trying to remove it with out splitting the cases!,that circlip on the end has to be fitted while holding spring tension away from it.

[Tews19]

great shots bootsey!itll be a bloody fiddle trying to remove it with out splitting the cases!,that circlip on the end has to be fitted while holding spring tension away from it.

Looks like I will use the spare engine to test taking it out while in the engine.

[Bootsey]

Can't take credit for all the pics, some are Mick"s handy work.
The pictures working for you Tews? I can msg them through to you if not.

[dave500]

that circlip is small,youll need bent cirlip pliers to snag on to it,dont over stretch it taking it off it has to go back on tight,if that clip lets go your rear wheel might lock up.

[Tews19]

One of the other members was having trouble with this when reassembling his the other day. That silver cast piece that should be retracted and not engaged wasn't orientated the right way and one of those flanges pushing it into contact. He said he rotated it, and that sorted it. Here are a couple of pics that might help you. Also, that shaft has a circlip on the inner end, which might allow you to pull it apart if need be. Hope it helps.

Wrong


Right

 

Bootsey do you have that link?

[Bootsey]

Replied to your PM. There isn't a link to a thread, there's just those pics from a few PM's. Maybe hit up Mick if you get stuck?

[Tews19]

After looking hard I notice the arm that catches the kick starter lip was bent down. Hence why there was no gap showing the smaller spring. I bent the arm back up. It catches the lip and now it functions. I will reassemble to see if the is corrected everything.