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I've put 1900 miles on the Kat, since I did a rebuild and one track day. The rebuild included, boring, new pistons, new starter clutch, new left end taper, cam chain and used rotor. The bike started intermittently, last time at The Ridge Motor Sports Park, It would not start in the morning. Then the rest of the day it started everytime I tried.
I haven't ridden the bike in almost a month and finally had a moment to have a look. Looked fine with the cover off, gear spun one way, locked the other.
When I pulled the rotor, and the starter clutch gear off, a bolt fell into my hand. It was the one closest to the dowel pin. All the rollers were shagged and the gear surface was scored. The rollers had lost 1-2mm in diameter already. I have an extra set of rollers, pins and springs, so I thought I'll try some wet/dry sandpaper on the gear surface and see if that'll do anything. I retapped all the threads, cleaned all threads, male and female, applied red locktite, and started reassembing. When snugging the bolts down one kept spinning, the one closest to the dowel pin.
I then talked to a local motorcycle mechanic, who did the cylinder boring for me and asked for his expert opinion. He said I need a new rotor, but he had a glimmer of "just maybe" in his expression when I mentioned heli-coils, but then said, I wouldn't recommend it, I said longer bolt with nut? no, will damage the stator, 10mm bolts? no, have to trim down the head of the bolt to fit in the recess.
I figured, what the hell, I'm going to try a heli-coil anyway, If it doesn't work, I'll have to source a new rotor and SC again. Haven't tried starting it yet, I'll let you know what kind of noises I hear, hopefully just the bike starting up. I lagged and didn't take any pictures.
I haven't ridden the bike in almost a month and finally had a moment to have a look. Looked fine with the cover off, gear spun one way, locked the other.
When I pulled the rotor, and the starter clutch gear off, a bolt fell into my hand. It was the one closest to the dowel pin. All the rollers were shagged and the gear surface was scored. The rollers had lost 1-2mm in diameter already. I have an extra set of rollers, pins and springs, so I thought I'll try some wet/dry sandpaper on the gear surface and see if that'll do anything. I retapped all the threads, cleaned all threads, male and female, applied red locktite, and started reassembing. When snugging the bolts down one kept spinning, the one closest to the dowel pin.
I then talked to a local motorcycle mechanic, who did the cylinder boring for me and asked for his expert opinion. He said I need a new rotor, but he had a glimmer of "just maybe" in his expression when I mentioned heli-coils, but then said, I wouldn't recommend it, I said longer bolt with nut? no, will damage the stator, 10mm bolts? no, have to trim down the head of the bolt to fit in the recess.
I figured, what the hell, I'm going to try a heli-coil anyway, If it doesn't work, I'll have to source a new rotor and SC again. Haven't tried starting it yet, I'll let you know what kind of noises I hear, hopefully just the bike starting up. I lagged and didn't take any pictures.
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