Third time is a charm I guess.Since My build two years ago,I have only put 2.5 miles on my bike.I suffered a runaway engine on first start up and destroyed the original rotor.Second time,the starter clutch seized to the rotor,third and final time the starter clutch ring gear seized to the crankshaft.Now I can't get the starter clutch ring gear off the crankshaft.Anyone have any idears on how to pull the seized gear off the crankshaft without destroying the crank snout or bearings?
Rotor fell off in my hand when I removed the bolt.
(http://i205.photobucket.com/albums/bb17/ben_2_go/Motorcycle%20Stuff/starterclutchrotor.jpg)
Starter clutch ring gear is seized on the crankshaft.How do I remover this PITA?
(http://i205.photobucket.com/albums/bb17/ben_2_go/Motorcycle%20Stuff/ringgear.jpg)
Bumpy.
Starwalt,are ya still around?
After another look this morning,it appears that the rotor has spun on the crankshaft snout.I don't know if this happened when I tried to start the bike or when the starter clutch ring gear seized.I was riding across a fuel station parking lot when it seized.It locked the engine down and almost took me down.Luckily I grabbed a handful of clutch.
I am near about sure you have a boogered crank shaft in that part under the ring gear. I know cos I had a runaway starter on my virago and it ruined both the starter nose and the case hole. Aluminum against steel, the wear in aluminum was ~3X the wear in steel. However mine was grinding for several miles likely, cos @ 80 clicks you dont hear/feel it. Drop to 30 and it becomes very apparent.
Anyway I would try bolting a plate on the thing and rocking/hitting it etc.
However inspect the crank before you do that, you may be putting in a lot of effort trying to save a DOA motor cos thr crank is unserviceable.
Cool.
Buddha.
Since I couldn't get any help here.I decided to revert back to my auto mechanic ways.I grabbed my mid size gear puller,the wrench for it,and my dead blow hammer.I pulled the side cover off,and set up the puller.I gave it a few turns,and the ring gear started to deflect(bend).At this point, I usually give the puller a few wacks with the dead blow hammer.Before I could even reach over for the dead blow hammer,POW!It popped loose with a sound only a .32 cal could make.Scared the holy h377 out of me.I inspected everything really well.It looks bad, but there is no scoring on the crankshaft snout.Looks like everything is good to go for installing a new starter clutch assembly.
Gear puller set up.
(http://i205.photobucket.com/albums/bb17/ben_2_go/Motorcycle%20Stuff/100_0124.jpg)
(http://i205.photobucket.com/albums/bb17/ben_2_go/Motorcycle%20Stuff/100_0125.jpg)
(http://i205.photobucket.com/albums/bb17/ben_2_go/Motorcycle%20Stuff/100_0126.jpg)
Ring gear after it POPPED loose.
(http://i205.photobucket.com/albums/bb17/ben_2_go/Motorcycle%20Stuff/100_0127.jpg)
(http://i205.photobucket.com/albums/bb17/ben_2_go/Motorcycle%20Stuff/100_0128.jpg)
Aaaaaah ... suzuki isn't completely stupid I see ... thanks suzuki ...
See the proof is this statement you made - and the ring gear started to deflect(bend) - suzuki anticipated someone getting knackered like you and made it softer than the hardenend crank. Lucky you, and us.
Cool.
Buddha.
Difficult??......nah! that fell off :thumb:
This one took 150 tonnes 10 hours and about 1000DegC to get off :thumb:
(http://i52.tinypic.com/2yxryqh.jpg)
You do know there is a bronze bushing inside the ring gear hub with oil passages?This helps keep from destroying the crankshaft journal and crankshaft oil passage.
(http://i205.photobucket.com/albums/bb17/ben_2_go/Motorcycle%20Stuff/100_0130.jpg)
Quote from: ben2go on May 02, 2011, 11:07:33 AM
You do know there is a bronze bushing inside the ring gear hub with oil passages?This helps keep from destroying the crankshaft journal and crankshaft oil passage.
(http://i205.photobucket.com/albums/bb17/ben_2_go/Motorcycle%20Stuff/100_0130.jpg)
Yea but you had seized it all together so I thought it was galled to the crank ...
Yea bronze oil light bushing - I have one coated with something called oleophilic moly-teflon in my virago. Something like, oil gets to it, and it soaks it up and stays slippery when wet ... and it is always wet ... that's it.
Cool.
Buddha.
The bush has been starved of oil and picked up on the shaft, explains why it was stuck. You need to check the galleries and make sure the golden stuff can get in there, might have been down to prolonged use of the starter. Any light scoring can be polished out with very fine wet&dry but if you can see deep tramlines or smears on the bush or the journal or if it rattles around like a di** in a shirt-sleeve it will never be the same again........ game over.
If you can get hold of an accurate mic` and telescopes the rule of thumb for phozzy-bronze bushes is 1 thou` clearance per inch of length.... assuming zero ovality, best to try it in 4 places to get an average.
Gonna mic everything out tomorrow.Didn't have time today.I am planning on installing a new starter clutch assembly with a new ring gear.I think it was from a lot of starting.I was having issues with the carbs and battery.If I ever have starting issues again,I am going to lean my bike over, and let oil run up on the rotor and starting gear.I believe the clearance on the starter clutch ring gear is .0025-.0028.If it's too loose,the oil pressure will go down across the main and rod bearings.Oil is feed to the crankshaft from under and behind the transmission clutch.The last place the oil goes is to the starter clutch and ring gear.
Bumpity bump bump.
I await parts and I will be doing a write up on how to install a starter clutch when they arrive.I have some tips n tricks on how to make this go smooth as humanly possible.