Spragre Clutch Repair

[gapl53]

Has anyone heard from "gemini641" and his spragre clutch repair.
Was the operation a success or is he still looking at a pile of parts.

[gemini641]

Hi, Guys...

Was out of town a couple of days.

Finally got all the parts and tools. Kevin was right, the right tool makes the job pretty easy. Now I can start a tool rental service!!

Got the inner chain cover off, installed the new Sprag clutch idler gear and driven gear, got the cover back on the Sprag clutch section with new gasket. Using Permatex Gasket Sealer sure makes it easy to line up the gasket.

Today I'll start reassembling the inner chain case and "stuff", install the starter motor, make some dynamic timing marks, and see if she starts. Then, hopefully, wrap it all up and hit the road.

Thanks for asking, Scooter...

Tom

[gapl53]

Glad to here it's going well.

When I was a young lad ,and complained to my father about not having the right tools to do the job. He would tell me that anyone could do it with the right tool. The challenge is to do it with the tools you have. No offence to my father, but it taught me to go and buy the right tools for the job. Makes life so much easier.

[justin_o_guy]

You shoulda hid his car keys.

[gapl53]

He was a lot bigger than I was!

[gemini641]

Oh, NO!!!! I can't believe this!

Got the new parts all back together. Double checked everything and finally, started the bike. She started right up and seemed to run well so I just let her idle for a while.

Then, believe it or not, I shut it down with the kill switch and as she was STOPPING, she backfired and took out 4 teeth in the ssame ES gear I had just replaced!!!! I can't swear on this board but I sure did in the shop.

So, now that I'm an "expert" at tearing down the entire inner chain case, I took it apart again, cleaned all the broken teeth and metal shavings out, and replaced the whole kaboodle WITHOUT ANY OF THE SPRAG CLUTCH GEARING INSIDE. Just put the starter motor back on to seal the unit.

Sitting here working up the courage to kickstart it, get it running, and adjust the timing as best I can. I may lose a knee in the process but I hope not. At least I can't trash another ES gear...there ain't none in there.

If I can get it to stop backfiring, I'll order another gear and install it and get my ES back.

What a %^&*$*&#$@ nightmare!!

Tom

[gapl53]

If you are afraid to kick because of the kick back, do a push start. I would probably try 3rd gear first and see how that works.

It's no fair to laugh unless you have experience with serious kick back, the type that breaks teeth off a metal gear. Then you can chuckle when you think of the time you thought you were going to die after being thrown from the bike while trying to kickstart the monster.

You don't need the engine running to adjust your timing. Check your manual for details.

[gemini641]

Thanks, Greg...

Great suggestion. I fianally got to the bottom of it and everything seems OK now. See my reply to "Kick start woes".

And thanks to you, too, Larry. As you can see, I got the timing marks on and dynamically timed it. Worked great just like you said.

And finally, big thanks  to Kevin, Tim, and Jim at CMW. They all pitched in big time.


Tom

[gapl53]

See it wasn't so hard after all.
When you had to do it the second time just consider that as practice.
Good job!