a bang when turning over today twice

[callykeys]

need some help guys please. yesterday i fitted new clutch lever (broke switch oooops) bypassed so i slackened the clutch cable right off then put back to exact point after new lever. i ran bike after and was fine as wanted to test new exhaust.

this morning went to start i could hear arking so i presummed the link to bypass the clutch lever switch was not making pure contact. the starter was clicking. it tried to start at one point sluggish then a bang very metalic, happened twice.

this afternoon stripped bike both sides and found a broken spring that pulls the clutch lever down its inside the sprocket cover so i believe that the bang was the pin that pushed the clutch being half engaged. could this be the problem?

with no plugs in turn over with spanner get compression and motor turns freely tried starter motor with cases off turns engine freely tomoz was going to examine the clutch basket etc to see if turns freely in gear.....

advice please my mechanical knowledge isnt great but have basics

ray

[callykeys]

clutch return spring it is called, so what can happen if this breaks ? the clutch push rod seems fine

[callykeys]

suzuki pointed me towards the starter clutch, need to pull it off in the morning after i have borrowed the swing arm bolt......... one of the magnets was loose and damaged a bit this must have been from  the bang that suzuki say they think was the starter clutch i will know tomorrow when i have it off. cant see any second hand magnetos in uk so no choice but get new..... stator looks fine

just hope the bike runs again after sorting the starter clutch and replacing magneto

[The Buddha]

Clang sound on the left side when cranking ... yes, in the starter clutch. Fix it now, before you get goats. I got it that way ... I ignored it for a year though.
The clutch cable and push rod mechanism is a garbage design. I hate it.
Cool.
Buddha.

[callykeys]

thank you for your response, had starter clutch out seems fine, only the springs were worn ordered new ones, whilst in the suzuki/yamaha shop yesterday was speaking to the mechanic i took the magneto and starter clutch with me he said also looked fine no scoring and was turning nice. i told him the day before the issue i could feel a slight grind when in 1st gear and to eliminate a gearbox issue i was going to put the bike back together and put on paddock stand and try each gear by turning the wheel to listen for noise.
the wheel would not turn in 1st .

i put back in neutral placed a booster on battery and the starter turned for less than a second then stopped and just clicking. so im guessing its the engine out and get it split in half. also very hard to select into 1st. so dont think i really have an option now. totally gutted as this is my first big bike and chose this over the er5 due to er5 regulator issues....

[callykeys]

also forgot to mention   after took off the paddock stand and rolling forward in neutral pulled clutch all way in put in first but wasnt rolling forward even with lever pulled right in?   surely the clutch should be disengaging

also due to heavy handedness i only have 5 bolts and springs in the clutch as broke one yesterday and have new one on order il take the other bolt out when i get the new replacement one.....

oil is old and black wanted to get the bike starting again before doing the service (as the previous owner was 67 and a lorry driver, cant say wether he used 10/40 car or bike)

[The Buddha]

thank you for your response, had starter clutch out seems fine, only the springs were worn ordered new ones,

You cant eyeball this and say its fine.

You also are buying springs only WTF  ... get the pins and rollers as well, its all of $25 ... if this blows and you get goats you will be really sorry.
And metallic bang from the left @ startup = all 9 components are on their last legs. What you're doing is like putting a tube in a tire that is worn 90%. Not worth the cost savings vs the life you'd get out of it.

Cool.
Buddha.

[callykeys]

yes agreed i will order the set and replace