Starter Clutch Overhaul |
OVERVIEW A very common problem with Visions is that over a period of time the starter clutch bolts work loose. The solution to the problem is to replace the bolts with slightly longer ones, apply loctite, and torque to specs. The bolts must be long enough to protrude 2 threads out of the front of the flywheel, and are peened over. If the bolts are not peened, the problem will re-occure. The first symptoms are a severe sounding clacking or knocking sound deep within the engine. The noise has been compared to a crank bearing or wrist pin going south, but is actualy much less severe. The knocking generaly occures between idle up to about 2500 rpm, and will fade at higher rpm's. Damage associated with loose bolts seems limited to a cracked housing or rollers with flat spots. The housing can be welded and ground smooth. Note that the inside of the housing is coated and should not be disturbed. The rollers can be replaced. OVERHAUL PROCEDURES REMOVING THE FLYWHEEL 1) Drain the engine oil and disconnect the battery negitive cable. Remove left side engine cover, note the position of the bolts. Remove the center retaining bolt. Remove the idler gear by pulling the shaft out. 2) Attach a suitable flywheel/ balancer puller. (avalable from Sears #947626 for about $20 bucks, you might want to replace the 3 bolts included with the puller for stronger grade bolts) 3) Note that the tapped holes in the flywheel are open-ended, and if the bolts are inserted too far, they will press on the starter clutch and can cause damage to the clutch. The bolts should be inserted finger tight, use a wrench only if the threads are excessivly tight, but be sure not to let the bolts extend beyond the edge of the flywheel. 4) If the right side case cover is off, wedge a rag in between the running gear teeth to prevent the flywheel from turning, alternate methods such as a chain wrench around the flywheel may be used, but as always, use caution. The keyways used in these engines are reported not to be all that strong and will sheer with enough pressure. 5) Place a rag under the flywheel, when it comes off it will most likley pop off, scattering clutch springs, rollers and caps. 6) Now comes the SCARY part, removing the flywheel. the prefered method is to use an impact gun on the pressure bolt in the center of the puller. (pointed end against the crankshaft) If you do not have an impact gun avalable, mount the socket on a long breaker bar, and after taking a few turns on the center bolt, smack the end of the bolt with a good sized hammer or small sledge. repeat this procedure as often as needed, short turn & smack, short turn & smack. Eventualy the flywheel will pop off. Use patience, this can be a very slow procedure. STARTER CLUTCH INSPECTION & REPLACEMENT Remove the 3 allen head bolts securing the starter clutch to the back of the flywheel. These are the bolts you are going to replace. Bring them to your local hardware store and get bolts M8 x 1.25, with an 8 to 12 hardness rating. You want to get bolts that stick out about 2 threads out of the flywheel when installed. Coat the threads with loctite and torque to 20Nm (14ft.lbs) Peen the 2 threads sticking out of the flywheel, making the repair permanant. Inspect the starter clutch, springs, rollers and caps for damage, repair or replace as needed. TIP: If you need to cut or grind bolts to the proper length, install the proper size nut first so that after you cut the bolt, you can remove the nut, cleaning up the threads Reverse the above procedure to install, observing all torque specifications.. |
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Starter & Clutch component
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