1150 starter not disengaging

[Carter Turk]

Added photos at end of thread. Trying to fire up the bike for the first time since June. Fresh oil, plugs, rings, piston, left end, starter clutch, used rotor....and the starter or starter clutch is staying engaged.

My Proto torque wrench only goes up to 800 in/lbs, so I heard the click and went further with a 1/2 drive socket. They say max is 126 ft/lbs

on the rotor nut. Which is what?-1512 inch/lbs. New thrust washer against the crank and new copper shim inside the starter clutch. Rather bummed, but I

wasn't expecting it to go smoothly for some reason. I did notice the larger starter clutch gear was turning one way like it's supposed to, but had a fair amount

of resistance. It's been pouring rain, but let up, so plan was go break-in the motor this afternoon. Not gonna happen now.

Any thoughts, advice appreciated, thanks.

[chef1366]

My guess is one of the springs popped out when you were fitting the rotor/clutch or the rotor is too far in on the crank taper.
Weird since the rotor had no wear at the taper and the crank end is new.
Did you use the dowel on the rotor? Did it seat all the way?
Are the bolts the correct length and not eating your stator?

[Carter Turk]

My guess is one of the springs popped out when you were fitting the rotor/clutch or the rotor is too far in on the crank taper.
Weird since the rotor had no wear at the taper and the crank end is new.
Did you use the dowel on the rotor? Did it seat all the way?
Are the bolts the correct length and not eating your stator?

Chef thanks for responding
All the above was done, however, when I just pulled the rotor off minutes ago, it appears the large starter gear was pressing firmly into the copper shim or whatever you call it in the SC. The dowel was too long at first, but I grinded it down, so that appeared to be seating properly. Actually, I told the mechanic it was riding high in that spot and he ground it down some more. Still not enough maybe???

The copper thrust washer that fits behind the larger starter clutch gear, appears "proud" of the the recess it fits into behind the gear which I think is correct.

It was relatively easy to remove the rotor, compared to previous recent attempts. I was worried that my partially stripped rotor puller was going to damage the

rotor I just bought from you. Eventhough it doesn't appear worn, I wonder if shimming the taper with floss or pop can might help matters?

[blowerbike]

main bearing then thrust washer then one piece needle bearing...correct?
you should not be having these problems.

[Carter Turk]

main bearing then trust washer then one piece needle bearing...correct?
you should not be having these problems.

Correct, that is the order.

[blowerbike]

so you can pull the idler pin and gear and the SC rotates smoothly one way and the other way it locks up tight as to turn the engine when engaged?

[rapidray]

Pull the rotor/starter clutch assembly back off to look at EVERYTHING before you hurt something that will cost you a LOT of money!! Call me if you need to.
Ray.

[blowerbike]

sharing is caring

[Rob S.]

main bearing then trust washer then one piece needle bearing...correct?
you should not be having these problems.

You can't trust those washers.

Sorry...

[blowerbike]

main bearing then thrust washer then one piece needle bearing...correct?
you should not be having these problems.

what you talkin bout willis?

[Rob S.]

what you talkin bout willis?

It's like I used to tell my students about calling it the "insertion point" instead of the "cursor" - you're revealing your age.

[Carter Turk]

so you can pull the idler pin and gear and the SC rotates smoothly one way and the other way it locks up tight as to turn the engine when engaged?

Yes... I care to share. Was almost just tempted to bump start it and do my break-in the hard way on a flat road.

[blowerbike]

if you choose that way then do it with the SC and rotor removed.
now tell me...
so you can pull the idler pin and gear and the SC rotates smoothly one way and the other way it locks up tight as to turn the engine when engaged?

[Carter Turk]

Is this a trick question? I thought I tried that when I pulled the rotor for inspection, although the rotor bolt was not on, so the rotor was spinning with the SC.

I'll try again in the AM.

[blowerbike]

very simple...
with your complete assembly installed...all but the idler gear..
will your large SC gear spin one way easily and smoothly and when spinning in the opposite direction does it engage and lock into place(will not turn).
try this several times just to confirm.
this can be checked off the bike but with your continuing problems...they need to be checked on the bike after it is impacted down.
what is causing the binding? that is the question.