Starter Clutch Question

[JaBey]

I was working on my buddies Vision the other day and noticed it had a knocking. Deduced it was probably the starter clutch. Once we got it apart to put longer bolts in it, we faced two interesting situations.

#1 - Someone has "repaired" it in the past. The holes have helicoils in them, which were just as loose as the original bolts themselves. It seems my options are to A)replace the helicoils with liberal loc-tite...which from what I have read here will only be temporary and will make the peening pointless. Or...B)Offset the starter clutch and drill new holes. HAS ANYONE FACED THIS PROBLEM? AND WHAT DID YOU DO?

#2 - The parts diagram of the starter clutch on yamaha.com shows a large washer (#9 90201-350F3-00) between the idler gear that rides in the starter clutch sprag, and the flywheel. However it was not present, and like I said, someone else has worked on it in the past. It was working fine without it, but I would think it wouldn't be there if it didn't have a purpose. ANY THOUGHTS ON LEAVING IT OUT? AND DOES ANYONE HAVE A SPARE THEY COULD SELL ME?

Thanks in advance guys!

[Rick G]

I might be able to comeup with the washer.

There are two sets of threaded holes one for the puller and  one set for the socket head bolts that hold it together. You cna use the other set of holes to hold it together and retap the set with the helicoils  (thats the way mine is ) the set for the puller can be  any thread  , so long as  the bolts used for pulling are able to pass through the puller.

[JaBey]

Well then...now I feel special:-) Because the bolt holes for the puller do NOT line up with the sprag clutch. But I think I have a solution. Since no one sells 9mm allen heads to fit the empty heli holes we are going to do this. We are going to loc-tite new helicoils in. Then we are going to loc-tite the new bolts in. We are going to peen the living hell out of them to try and get them to mushroom the helicoil. Then I'm going to MIG weld all 3 layers together from the stem and grind it flush. I don't know what the helicoils are made out of, so I may have limited results. But I figure as long as the weld holds the bolt, the helicoil has no where to go even if it does come loose or melt.

[Rick G]

Yours is special  because every vision I  have pulled the flywheel on any of my three  vibration damper pullers, will line  up with the  puller holes in the flywheel.  I think I would shop around  here and on ebay and pick up a servicable flywheel and replace it . If that thing detonates  at speed , he IS going to have a problem, Huston!   I bought one on eBay  for 10.00.  

[JaBey]

I sold a perfect one, sprag and all on Ebay 2 months ago:P
But it's not my bike and my buddy, like most of us here in Ohio this past year, is very cash strapped. So we are going to wing it. The motor only has about 7000 miles on it (my guess judging by compression and motor interior quality) so considering I built it for him out of a pile a parts he bought, it really runs like a top. If the flywheel is out of balance...he'll feel it. He's one of those paranoid types anyway who thinks there is a chance it might blow up if the nuetral light isn't functioning...haha:)

[Rick G]

I suspect that you have a different  name on eBay, I bought YOUR stater clutch LOL!  its a small world!