Starter Clutch Repair

On my 89, I completed pulling the Rotor and Starter Engage Clutch Assembly today.

--- Here Is what I found ----

---- One of the three mounting bolts, was--- loose---- and backed out about 1/2 turn!!!!! It appeared to have not had any Loctite applied at the Factory.

---- The other two mounting bolts were Tight, they -- Obviously--- had Loctite applied at the Factory Installation.

-----One of the small springs was bent, another had damage on the end, and the third appeared to be OK

----- One of the spring caps, had lots of wear on the open end, and tip. Other two, not bad.

----- The about 1/2 Inch thick material that makes up the Center of the " Starter Engage Unit " ( which appears to be Brass, its copper color, but much harder then copper) Has a Crack completely through it !!

Another photo of Cracked engage Unit.

Also the ElectriX After market Stator. ( For anybody who may be interested, note the larger diameter wire, than they used on the Stock Stator units )

Another comment, on pulling the Rotor, It did not move Until it finally came off. It Flew Off. After applying heat for about 30 seconds, on the 4th try, of heating and Tapping with hammer, it flew off, went about 2 feet.

( I used an Automobile harmonic balancer puller, you will need to buy 3, 8mm bolts, 3 1/2 inch long, fine thread ( 1.25 pitch ) ( High Strength Steel bolts ) for the rotor pulling job. Also a butane soldering torch will come in handy ( map gas, whatever you have for heat )

I did not find any Damage on the 72 tooth Gear, behind the Rotor.

-----I'm adding a close up view, of the three Mounting Bolts, so you can see the " Staking method " used by the Factory, as called for in the Service Manual. One bolt was loose so, obviously they did not Do It Right.

Note: In the photo below, see the 8mm 1.25 thread pitch " Tap " I used to clean out the threads in the bolt holes. This is the best way to remove the Old Loctite there, before reassembly, be sure to clean threads with solvent, before reinstalling the " NEW " bolts that you are going to order , when you order your New " Starter Clutch Engage Unit "

-----Also adding Photo close up of the springs + weights that fit into the assembly. ( Note: the Crack in the Brass material )

-----Also Photo of Starter, and Gear Drive to the 72 tooth sprocket.

----- Also view of Entire Engage Unit as to how it fits to the flywheel ( rotor )

-----------My, Entire Engage Unit, needs to be Replaced. ---------

-------The Unit has 57,300 miles on it.------

------- The first time I heard the noise was around 20K.

-------- I have Done All the Other Fixes as discussed on this web site:

This is the first time I have pulled the Rotor Off. It took me about 4 hours, but I'm retired, and I don't work fast for anybody anymore !!! ( that includes the wife !!! )

Still waiting for the New Parts to get here. ( Going to be 50 F tomorrow !! well I guess I will just have to ride the Busa until I get this job done , Darn !!! )