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Author Topic: Busted starter clutch and dead ignition.  (Read 1203 times)

esjones

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Busted starter clutch and dead ignition.
« on: April 30, 2008, 11:50:22 AM »
Just had a new '08 AVL classic come into our shop with a broken starter clutch and idler gear and no spark - 200 miles on the bike. After pulling apart saw that the factory had a long loop in the wiring harness going to the stator/trigger unit in the chaincase that had rubbed the primary chain and worn thru the insulation - throwing the spark timing all over the place (prime suspect killing the starter gears) and eventually cutting the cable.
This condition should be easy to check on new units by removing the top chaincase plug and ensuring the cable is routed correctly in the case away from the chain. The one I worked on had rubbed the chain just inside this plug area. Excess cable can be pulled thru the grommet and secured without removing the cover to keep it away from the chain.