Clunk on start - oh dear!

[pinholenz]

Recently I rebuilt the starter motor, put in a new oil seal and checked the peining (peening to our US cousins) on the flywheel. All good and tight.

Went for a run on the weekend and on the cold start had a horrible metallic clunk while it turned over. Retried, started OK. Same thing just now. Groan. Starter clutch?

[Tiger]

... Starter clutch?

That is were I would start (excuse the pun!!) ...  ;)

Remove the flywheel and starter clutch...visually inspect the starter clutch for damage.

If all is good, reinstall using 3 new soc' head cap screws and RED loc-tite/thread locker and peen/stake the ends.

Also, remove the gear behind the starter clutch and check that the 46mm nut is tight!!!

                  8) ....... TIGER .......  8)

[QBS]

Sometimes my '83 makes a similar sound on starting from cold, especially with a weak battery charge.  How strong was/is your battery charge?  My starter clutch was reattached 29 years and 65k miles ago.  Hasn't been off since then.

[pinholenz]

Now my stator and R/R is good, the battery is very strong. Sigh!

[fret not]

If the little springs that push the caps against the rollers get worn out or broken the starter clutch will just spin.  Just another place to look for the malfunction.  In any case it looks like you will be removing the flywheel to inspect the starter clutch, and the big nut on the balancer shaft.

[pinholenz]

No clunk for the last couple of days, good starting. 
What sort of damage will I do if I keep riding until it becomes a problem?
Thanks.

[Tiger]

No clunk for the last couple of days, good starting. 
What sort of damage will I do if I keep riding until it becomes a problem? Thanks.

IF it is a loose starter clutch it will eventually fracture if left to its own devices :o That, in its self is bad enough...however, finding another one can sometimes be a real PITA!!!

Remove the left side engine cover, flywheel and starter clutch...visually inspect the starter clutch for damage.

Replace or reinstall using 3 new soc' head cap screws and RED loc-tite/thread locker and peen/stake the ends.

NOTE: Make sure that the new soc' head cap screws and flywheel threads are cleaned of any oil, etc before using thread lockers. Use something like brake and parts cleaner, etc..

Do not forget to remove the gear behind the starter clutch and check that the 46mm nut is tight!!!

A couple of hours of your time could will save you some future heart ache!!!

                            8) ....... TIGER .......  8)

[jasonm.]

Starter clutch...you must use 12.9 grade allen bolts...anything else will loosen or shear. Typically are black. Did you bench test your starter before installation?  How long since your starter rebuild? Did you bench test it? A set of jumper cables while clamped in a vise,will clear that possibility and is a simple.

[pinholenz]

Thanks all. Yes I bench tested the starter before the reinstall about a month ago. Needed to make sure those gears were aligned OK. All good.

Haven't had the big clunk for a week now. I hope that I can run it for the rest of our summer before pulling it off the road at the end of April for its winter layover and tinkering. Meanwhile I am enjoying the ride.

I am having trouble visualising the flywheel, starter clutch, 46mm bolt setup etc. I am sure that the removal and reassembly has been better documented on this forum than in Haynes. Can anyone link me to a suitable post? Thanks

[Tiger]

This will help you (and others) ... 8)

http://ridersofvision.net/rovforum/index.php?topic=10678.msg96858#msg96858


                     8) ....... TIGER .......  8)

[pinholenz]

Brilliant Tiger. EXACTLY what I needed. Sounds so simple once all the specialist tools have been collected together. I have also noted the engineering grade of Allen key screw (12.9) from jasnm's post  that must be sourced from an specialist supply shop before reinstalling the starter clutch.

Now, can we make your post a sticky so that it hangs around a bit more prominently?. Every XZ owner needs this.

[kiwibum]

Pinhole. For a security fee and postage I have a 46mm crows foot spanner that fits a 1/2" ratchet you may borrow if you like. Security refunded on return of the tool. I bought it specially for the job of tightening this nut. On the three bikes I've checked this nut was slightly loose. And on all the XZ bikes I've had the starter clutch screws were loose, so yours will need to be done at some stage.

Steve
Rotorua

[pinholenz]

Thanks Steve (kiwibum) very grateful for the use of your 46 mm spanner. Looking forward to keeping in touch. Hoping to get out to do the Coromandel Loop before I break the bike down again. What a brilliant summer its been!