Starter Clutch fix questions and answers

[scootertramp]

Okay I got  the bolts cut to size.  ground and dryed in to look at the fit. ARE THE BOLTS supposed to stick all the way through their holes and into the stator cavity?
They stick into the cavity two and a half threads. or so.
1/8 inch.Will it hit the Stator?
The original bolts were RECESSED..
So I can locktite them and peen the threads over.
Which HOLES do I install the piece through. The one directly over the keyway?
I forgot which it was, if ever knew..

[Lucky]

Yes they have to stick thru in order to peen them over. Locktie alone will not hold them.

No, they will not hit the stator.

there aparently are 2 different rotors, both have 6 holes, on most you can use either set of 3, on some, only 3 will line up, the other three are for the puller. if all 6 holes are the same distance from the center, it makes no differance which 3 you use. ?

clock position on the rotor makes no difference either. they are balanced units.

[glennw]

I have a question along these lines, about 6,000 miles ago I had a shop replace my starter clutch. I have been hearing the "rod knock" noise starting up again. Not having a flywheel puller (and after destoying a rental one the first time) I took it back to the same shop. When they took it apart the bolts had broken and/or loosened enough to destory the flywheel. The starter clutch looked just fine. What would cause this??
Thanks, Glenn

[glennw]

Guy's How do I get to Lucky's Web site, I can find it???
Glennw

[Walt_M.]

My first guess is that they did not use the longer bolts and could not or did not peen the ends, so they came loose and tore up your flywheel.

[glennw]

Hey the dummy (ME) found Lucky's web site. DUH...
Since I am handing over a replacment flywheel today to the shop I wanted to give them INSTUCTONS on how to do it right.

[scootertramp]

Excellent!
This is info thats going in my NOTE BOOK.
I have a shoe box full and its getting almost too full.

Thanks for your EXPERT help luckmeister.

I feel really stupid and helpless when I don't know which end is up. With all the help from everyone at this forum, up is up and down is down mostly.
Now for the starter  seal fixx.

[scootertramp]

Hey the dummy (ME) found Lucky's web site. DUH...
Since I am handing over a replacment flywheel today to the shop I wanted to give them INSTUCTONS on how to do it right.

INSTUCTONS? uh oh.. um, why'nt you let lucky e-mail 'em with that info?
ahahaha!

[scootertramp]

okay I got the bolts cut to size(took five tries so I'm glad I got extra. oy..)
loktite and tightened and peened over. it's easy if you notice where the threads go back into the hole. I used a board to peen em on. I wacked and tapped till I got a good line of peen right where the threads go back in.
i checked and adjusted those two shaft gear nuts. They good now.
I used a cap off a vitamin bottle wrapped in paper to help hold the rollers and springs in place when I installed them.
Flywheel is on and tightened' and torqued.
I'm ready to reinstall the stator as soon as I can rewind it. It seems easy so far. the tricky part is gonna be re-attaching it to the wires without breaking the very thin wires, If I break even one its all down the drain.
a hunnerd and fourty feet of rewinding: six feet per pole plus the distance between four poles. plus a few feet.
twelve dollar and fiddy cents worth of spray insul.
 a dollars worth of masking tape and the wire guy gave me all the little stuff I needed.
a new stator supposedly for  about twenty five dollars and some elbow grease.
we'll see if it works and how long it works.
We all know what happens when it goes.  ahahaha!

How do I change out the connectors..How do I get them off? I wish to keep from cutting them off.. and where would I go get new ones.  I tried getting them out but to no avail. help.