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Discussion Starter #1
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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Discussion Starter #2 (Edited)
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.
 

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Discussion Starter #3
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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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.



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...
 

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Discussion Starter #6
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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Discussion Starter #8
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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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
 

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Cheap did you make everything fit? As Tom said, One Spring, your choice.
 

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Discussion Starter #11
Yes, and thanks for the help everyone.
I'm test firing in the morning. Been busy w/ other stuff today, plus waiting
for a few posts on this thread to make sure I wasn't building a bomb inadvertently. LOL

After watching the youtube video again (last time was a while back),
everything is spot on and looking great. The inner cover looks great,
all the gears n' washers are in place, and the longer spring is installed under
the second cover. Wally was out of M-1 15-w50 so I picked the next
bestest thing on the block, Rotella 15w-40 fer diesels.

Cheers to the best non-porn site on the web:),
Cheeeeeeeeeeeeeeeap
 

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nice. now put yer ipod on, crank up to vol. 10 and start the bike. if you dont hear stairway to heaven you got a problem.
 

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Discussion Starter #13
Like clock parts!
Thanks fer asking. Now we can let this thread fade into the cyber abyss,
where readers can go back and say "whatta dork", but hopefully have a little
respect for a dude who was willing to try and to trust those who have been
there before him. The video instructions were literally excellent with every
step shown and explained all the while he did the work.

After the initial shock of all those shiny thingies that ride on thousandths of
an inch clearance and need to be perfect, all was good.

As a side note, did an oil change of course but didn't change the filter.
Just fer giggles, I soaked the filter in a coffee can o' gas and shook it around,
then slowly drained the gas into a bottle of fire-pit starter fluid (lol, FOOM!),
and the pearlescent shavings left in the bottom were quite alot for an engine
with 1244 on the odometer and has had two changes already. I hope it's
fully run-in now and ready to flog. (been flogging since 20 miles. ooops)
I normally run 5+thousand miles a year but my first summer on the bike was
cut 72 days short due to "legal responsibilities". Didn't know there was an
old warrant from '06. (My P.O. caught me drinking on probation and never
told me he was writing it up. Been living right under the law's noses, paying
support at the courthouse, etc. Nothing for 3 1/2 years until pulled over fer
speeding. Maybe this summer will be much freer and warmer. I plan to ride
the living crap outta this thing.

A big thank you to the guy who sent me the doo money, and Tom for loaning the tools!
You hooked me up when I was broke, not Cheap. Now I'm just Cheap again. LOLOL

I will "doo" the same for the next deserving dude or dudette who really wants to do this
and doesn't have the spare coinage. I do now and'll pay the favor forward.

This is what real bikers doo for each other. I hope to meet some of you this summer!
Specifically Paper first, as he's only a couple or few hours out. Then anyone with
a spare spot or couch fer my bedroll. I'll buy dinner. Been doing this since '02
with internet folk and not hadda problem yet. Same here if you are passing thru.
Save the cash for a room and enjoy mama's home cookin' and a couch.

I'm just that way.

Los Cheapos Muchos
 

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Nice man! I'm glad it is done. I would have advised, but I probably would have made things worse. I did my doo with a lot of help and it scared the crap out of me. I've become a little less wrench-shy since then.

Kudos for getting in there and doo-ing it. :)
 

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Cheap you ever make to south west mo i got a bunk for ya. congrats on the DOO.
 

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Discussion Starter #17
Map, thank you for the kind offer.
There ya go. Instant vacation destination. Not that I'm planning it.
Do a daytrip over, get some snooze, hang out n' ride fer a day, get some
snooze, daytrip home on any three day weekend.

It's doesn't get any more simple. I'm willing to travel or take a rider in
for a day or two. Makes for some great pics and threads afterwards.

Shred some dirt, backyard firepit n' cookout,etc............
 

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Discussion Starter #18
Test run went very well in yestersay's 50 degree weather!
I can hear the chain whirring now! It's not loud
or sounding problematic at all, it can be heard now is all.

The stock spring though installed and hooked on securely, had no tension.
I've never adjusted it.

Great day for a 36 mile run!.

Just got off my 12 hour shift so it's nap time even though it's beautiful out.
I'm too beat up to be alert.
I'm changing the front tire after supper,snoozing tonite,
and looking very much forward to tomorrow's predicted 59 degrees !!!!!!!!!!!!!
 
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