Hey guys,
Over the past couple of months I've been experiencing a banging noise that fit the symptoms of this problem https://www.youtube.com/watch?v=QbneQjTWnqU (loose starter clutch bolts allowing the starter clutch assembly to bang about at lower revs). More recently, I've started experiencing slight power loss and a bad idle. The cam chain (which can make a similar noise if loose) appears tight to spec, and the guide is in good condition.
I recently opened the case and removed the starter clutch assembly, only to find that the starter clutch assembly bolts were in good condition and torqued to spec. I did, however, notice that the starter clutch ring gear (pictured in link below) had 2 or 3mm of freeplay allowing it to move up and down the crankshaft. This is odd, because the bolt holding the entire assembly onto the crankshaft was very tight. Could some kind of wear be allowing this to happen? Could this be creating the elusive banging noise below 2-3k revs? Could the movement be creating resistance and affecting my idle/power?
Any suggestions on how to remove the starter clutch ring gear freeplay or alternative diagnoses would be much appreciated!
Starter clutch ring gear is the big metal cog here: http://s205.photobucket.com/user/ben_2_go/media/Motorcycle%20Stuff/ringgear.jpg.html
Cheers,
Meuryn
The gear has an `oilite` type bush in its centre. I would be checking its condition. If its significantly worn it will allow increased float and lift and may even pick up on the crank causing drag.
(http://www.mooreinternational.co.uk/user/categories/thumbnails/OILITES-IMPERIAL.jpg)
The rotor assembly fits the crankshaft on a tapered journal and is held tight in place by the bolt in the end of the crank. The clutch inner member with starter gear on it is not clamped tight by the rotor and stops when starter stops and just sits there while the crankshaft spins inside it at speeds up to 11k rpm. Ample oil is fed thru the crankshaft into the clutch hub bearing surface. Near as I can recall the clutch hub/gear had about 1-2 mm lateral freeplay but very little radial play when I had it apart with 100k miles on my 02 GS. My knock was from the loose bolts holding the clutch to the back of the rotor. I don't recall my clutch inner member having an oilite bearing.
Also the 3 roller design leaves bite marks on the thing (not the crank, but the part that is the whatchamacallit for the clutch to bite on).
Mine was so bad, I had to replace that too. Lucky I had a used one off a seized motor lying around.
Cool.
Buddha.
Lets keep all this simple
See the gold coloured bush in the centre of the gear?
Check it for wear :thumb:
(http://i.ebayimg.com/00/s/MTIwMFgxNjAw/z/00AAAOSwiCRUbgTL/$_57.JPG)