Topic: Starter problems - take 3 - now truely baffled

[City Boy]

Hi KB.I notice in your picture of the rotor bolt that the very end of the bolt is shiny.Has it been contacting something?    Rock On

[KB02]

Good question. I'm not sure. It's all stock components, though.

[wrenchmuch]

Iv'e read somewhere about this happening if the rotor and shaft tapers don't match properly ( shiny part ?) . The fix ( if I remember right ) is to put lapping compound on the end of the shaft and lap the rotor into the shaft . Clean the shaft and rotor and install the rotor . I had a quick look for the info by searching but I can't find it . Maybe try a PM to Hondaman on this .
Good luck
Mike

[City Boy]

Hi Kb.I would be checking to see if the bolt is bottoming out before rotor is tight.Good luck  and Rock On

[mystic_1]

You cannot skip torquing that bolt, since pressure against the taper is the only thing keeping the rotor in place.

I agree that the shiny part on the end of your bolt indicates that it's hitting something.  Inspect the inside of the hole in the crankshaft.

mystic_1

[kghost]

I personally believe part no. 6 in the diagram previously posted wears.

Thats the actual gear those three rollers act on.

[bistromath]

Only thing I can think of is the rotor was replaced by one with the wrong taper. If that's not the case, I don't know what could do that.

[scottly]

To check the fit of the taper, you might try painting the crank with a felt pen, then slide the rotor on and rotate it back and forth while pushing it onto the crank. Then look to see if the ink is evenly worn off.
If you do end up lapping it in, be aware that that rotor will now only match that crank. If the rotor itself is the problem, I would rather replace the rotor than cut the crank to a new taper.

[KB02]

There was a little bit of gunk in the end of the bolt hole. I cleaned that out the best I could. used a little lock tight on the bolt and let is sit for a day and a half. The issues seams to be resolved now. I was starting the bike last night until the battery was draining out (must be a a timing/ignition issue - just not running right), and the starter held up the whole time.

[beks82]

sorry to resuscitate an old post, but was having the same problem and read this post and had some questions.  do you think it possibly was the bolt itself that was causing the problems with the starter clutch not the starter clutch itself?  That would be a quick fix...