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post #1 of 18 Old 02-28-2010, 05:05 AM Thread Starter
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Need a quick hand

Tonight earlier became my "doo-date".
Did the job, and it was very straightforward.
My problem, being stuck on reassembly, is:
Should the flywheel seat all the way down onto
the starter gear and washer?

I'm up to full torque, but there's 3/16" to 1/4" of space
before bottoming out.
Could the flywhel key have shifted?
Am I ok to put the cover on?

Argh,
CheapMark
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post #2 of 18 Old 02-28-2010, 05:09 AM Thread Starter
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The starter gear assembly is locked thru both gearsets and into the big starter gear too.
Shouldn't the skinny gearshaft on the starter itself be free until hitting the start button
or are they always meshing?


Hard to tell from the SM pics, and EM's instruction webpage.

Last edited by CheapBassTurd; 02-28-2010 at 05:16 AM.
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post #3 of 18 Old 02-28-2010, 05:38 AM Thread Starter
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As per EM's instructions, there is no left turnage of the starter gear.
It spins snugly but freely to the right with one finger.
The thing is probably done right, followed everything to the letter.
I pulled off the flywheel/rotor and the key is sitting perfect.

I understand now after the lite went on in my noggin' about the gears
always meshing. The starter gear doesn't spin while the engine is running.
I'm supposing all the other stuff should mesh constantly.

Hoping for a reply by someone in the know before buttoning it all back up.
Thanks again, fellas.
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post #4 of 18 Old 02-28-2010, 07:23 AM
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Are you saying the starter and flywheel gear aren't meshing laterally? If so, have a look here. http://www.klr650.net/forums/showthread.php?t=76444

Gray-haired riders donít get that way from pure luck.

Unknown
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post #5 of 18 Old 02-28-2010, 08:42 AM
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The Starter Gears are always engaged... the one way bearing (for lack of the proper word) will let the engine turn without turning the starter or gears while the engine is running. So you being able to turn it one way is OK.



Quote:
Anyway, it would appear that when some of the side cases are machined (mine is a Feb '08 build) the recess for the starter idler gear shaft is drilled a bit too deep into the side case.
Well that sucks.... 2 things to fix immediatly with the new side case design now...

- Joe

HighSpeed Hiker- DV o5'
Quote:
Originally Posted by larryboy
come awn... it's not far...it'll be fun..

sorry I can't....... I'm fishing today

Last edited by theotherbigjoe; 02-28-2010 at 08:48 AM.
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post #6 of 18 Old 02-28-2010, 11:15 AM Thread Starter
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OBJ, Flashdude,
They DO mesh. That is what was making me nervy.
(My first m/c engine split.)
On all my mopeds of the past there was a solenoid plunger thingie that made the starter
gear shoot out and engage the big gear. The one way gear bearing makes perfect sense now
and it's all good.

Thanks for the link, Flash. My cover does not look like that at all. It's clean.

I think I'll put 'er all back together after church and a run to Wally's for some Mobil 1.

As usual you guys rock,
CheapAndFeelingBetterAboutEngineTinkering.
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post #7 of 18 Old 02-28-2010, 11:41 AM
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dont know if this will help or not. it is what i used. good luck, post pics if you are still struggling. GL.

http://www.youtube.com/watch?v=26oSO...eature=related

02 klr - heated vest and grips, corbin dished, EM doo, petcock mod, MB PCV mod, stainless oil filter, bash plate, mayher hand guards, low mount fender, power socket, tall windscreen, jardine exhaust, jetted, studebaker shifter, magnetic plug, airbox mod, k&N, kenda knobbies, DIY pelicans, HID light
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post #8 of 18 Old 02-28-2010, 02:15 PM Thread Starter
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Thanks again!
Doc3,
I watched the video and I'm setup the same. I used the inner spring EM supplied,
and not the larger looped one outside of the inner cover. There wasn't one in the
doo kit. The narrator stated something right along that line tho. Only one spring
is needed on the eccentric. The tension spring and torsion spring both would be overkill.

I forgot to stop at WalMart after church. Hadda car fulla kids and it's easier to shop
alone anyway.

If I need both springs, PLEASE someone chime in in the next coupla hours.
Just in case I'll wait until after sledding with the young'uns to close it up and
add the oil.
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post #9 of 18 Old 02-28-2010, 03:16 PM
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Cheap -

You only need one spring, either the extension spring that goes to the left of the Doo, or the torsion spring that goes on the Doo.
Tom

Tom [email protected]

ďThe kid poured him another straight rye and I think he doctored it with water down behind the bar because when he came up with it he looked as guilty as if he'd kicked his grandmother.Ē -Philip Marlowe

ď'Why' and 'How' are words so important they cannot be too often used.Ē -Napoleon Bonaparte

Sting like a butterfly.
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post #10 of 18 Old 02-28-2010, 08:03 PM
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Cheap did you make everything fit? As Tom said, One Spring, your choice.

Tim

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2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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