Need help reinstalling stator cover (starter gear) GS1100ES

[Guest]

I am finally reinstalling my stator cover with the fresh stator, but I'm somewhat confused I guess...

I know that the stainless pin will go through the reduction gear, and that the cover holds the pin in place, but the gear is just free-floating there, and doesn't seem to be easy to line it up and get it to stay before putting the cover back on.
Should I just trust that things will line up, or am I at risk of grinding some perfectly good gears when I hit the starter?

I'm just a bit reluctant to go forward.

Any suggestions or encouragement welcome.

[Steve]

There should be FOUR items you need to keep track of in there.
1. The "stainless" pin (I don't think it's stainless)
2. The idler gear
3&4. Two thin washers that should go on either side of the gear.

If you put the pin (with the gear and washers) in the engine, the cover will slide right over it. If it's not lined up, you will know it, because the cover will not mate up with the engine block. If you get the cover to mate up with the block, you will have no problem with gear grinding.

.

[fastfrank]

I really appreciate the help - just didn't feel right, not having that gear stay in place.

I do seem to have all the pieces here, so I'm encouraged that they'll line up, including the nice shiny pin that probably isn't stainless :-)

I also have the pin in the other side of the cover, which is actually pretty well stuck there.

I may put some gasket goo around the rubber wire grommet before I actually get it on there... don't see any other places that might leak.

Thanks!

[fastfrank]

Amazingly, I'm still struggling with reinstalling the stator cover... (although I've been mostly distracted working on other bikes) - even after getting my boys to help me about 3 times, I still can't get everything to line up and let me get the cover down completely. And keeping the gasket lined up on this one is just demonic. I'm almost at the point where I'm ready to call for the shop's trailer.

[tom203]

Put a little oil on gasket and stick it to crankcase....this will hold it in place. Line things up and the magnetic pull of rotor on stator will suck it on. Please note that a few cover screws are different lengths....hopefully you noted their positions during removal.

[Cwoods]

I just pulled the stator cover on my 1100e for the first time, reinstalled temporarily so I could scrub it while waiting for my flywheel puller to arrive and just again removed it today after my puller arrived.
Are you putting the pin/gear/as her shims in the case and then sliding the cover on or are you trying to install the cover with those 4 pieces installed on the cover side? Since the dowel pin was attached to my cover when I removed it I tried to reinstall it that way and I found it impossible to do. Instead I pulled those 4 pieces and installed them in the engine case with a dab of grease holding the outside washer shim to the gear and slid the cover on while reaching in with a finger keeping the wire loom grommet in place. Doing it this way it gave me zero fits and easily found home.
Mabey that's how your already attempting it but after my experience with this new to me machine I feel theres a chance your attempting it the same way I initially did.

[fastfrank]

Thanks for all the ideas -

I'm generally putting all the starter gear parts inside before trying to line up the cover, but I've tried it both ways. I just can't seem to get the pins, including the one in those gears, lined up at the same time... it always seems that the pin through the gears gets a little crooked as I'm trying. My boys are usually pretty good at getting things to line up when I can't, but they're frustrated, too.

I had previously put some oil on the gasket (which then kept it from sticking with dabs of rubber cement, of course), but maybe I'll just try some heavier grease to keep it there.

I'll keep trying.

[Steve]

If that pin with the gear on it is going crooked, you have some serious issues going on there. That pin fits almost 1/2" deep into a hole in the side of the crankcase, and there is virtually NO slop there. It should be held very steady with NO movement.

.

[wymple]

I just used a few spots of super glue at various points around the gasket. Never had any problem.

[fastfrank]

If that pin with the gear on it is going crooked, you have some serious issues going on there. That pin fits almost 1/2" deep into a hole in the side of the crankcase, and there is virtually NO slop there. It should be held very steady with NO movement.

.

This helped me figure it out - the pin wasn't going into the hole in the crankcase... there was some gouge there for some reason, and it wouldn't start in - my eyes are getting pretty bad, so I didn't see that it was as deep as it was, and it should go in there all the way. A little more light helped. I tapped it in with a small peen hammer and it is now all back together. This has been driving me crazy and holding me up for a long time now.

Thanks for all the help, guys.