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Odd starter clutch failure
mbrood posted a topic in Venture and Venture Royale Tech Talk ('83 - '93)
Well, I tore into the starter clutch. It would "bang and grind" every once in a while and since it's a good time of year, I figured what the heck. Once I got it off, I looked down at the pillow, laid there to 'catch" the flying rotor (thanks guys.. that's a marvelous money saving trick!) and I saw three dowels, two spings and two spring cups... TWO??? The bronze (or???) housing that the springs and dowels fit into had ONE spring cup still in it... slightly recessed... so IT was NOT doing it's job. So I tried to tease it out by gently pushing it in (VERY slight movement)... after an hour I was able to get it flush with the edge. After another hour I was able to get it to wiggle out about 1/3rd. I finally got it out and saw that the sides looked ok... (IT'S on the left). http://www.bergall.org/temp/venture/starter/starter%20clutch2.jpg So I blew out the recessed hole it sat in with WD40 and tried slipping in one of the other spring and cups and it slid in and bounced up and down just fine. I started really looking at the three spring cups. ONE had the open end just pristine but TWO had edge damage and the one that had hung up actually had a nick (or future chip?) that was hanging out... the outer diameter of the three is .248 and the open end at the nick spot was .252! Must have been just enough to snag and disable a third of the clutch! (The "offending" cup is still on the right.) http://www.bergall.org/temp/venture/starter/starter%20clutch3.jpg The parts fiche shows an odd part in the bottom of that recess, no part number though. SOMETHING is causing the edge to chip and this just is NOT a good thing. Either the spring cup has too much slop in the hole (sure doesn't feel like it or that .004 "nick" would still fit?)) or the cups are bottoming into something and chipping. Nonetheless, it's enough that it caused the cup to seize. The idle gear #2, that has the race attached that the dowels drive against, had a distinctive "dance mark" pattern where the dowels had driven in so that's an easy solution to repair... http://www.bergall.org/temp/venture/starter/starter%20clutch1.jpg I figure, once the bike starts, centrifugal force throws the dowels back against the springs and the cups are driven deep into the hole and maybe THAT is what leads to the chipping...? Any ideas? The bike only has about 46,000 miles. Here's a breakdown of needed parts from two web sites and my local Yamaha shop... and the shop wonders why I won't buy from them??? Flatout Zanotti North County Yamaha Bolt (3 needed) 91316-08014-00 .99 .80 2.48 Gear Idler #2 26H-15517-00-00 29.86 28.64 46.67 Whole Starter Clutch 11H-15580-00-00 74.54 73.68 109.24 Dowle Pin (3) 93615-12088-00 1.64 1.57 2.55 Spring Cap (3) 341-15583-05-00 4.76 4.57 7.44 Spring (3) 90501-04623-00 1.59 1.52 2.46 Left engine case gasket 3JP-15451-00-00 5.10 4.89 7.97 Rear case gasket 3JP-15461-00-00 1.80 1.73 2.97