damn it man

[mrlogix]

Well my truck died Thursday (dead, thrown rod), and the starter on the bike died Saturday. The bendix is not working. The starter spins but is not engaging the flywheel. Looking in the manual, it seems that the starter is always engaged with the flywheel by design? Kind of hard on brushes isn't it if this is true? If that is the design, then the key or pin or whatever is the rotational locking means of the starter gear on the shaft is gone, done, kaput.I'll try to dis-assemble tonight. This sucks, no transportation until I get the bike up or another vehicle. Weather forecast calls for rain most of next week.

 

[Matteson]

Can you roll it down the hill and dump the clutch?

 

[Cosworth]

No bendix on these starters the engagement device is the sprag clutch... it's bolted behind the starter rotor. You'll need a good impact and 32mm socket or the crank locking tool. Mines loaned out right now or I'd send it to you.

 

[Matteson]

Ya hopefully my parts all come in tomorrow. I have the bench all ready to go with everything laid out for surgery. So you should have your tool back by the end of the week Craig.

 

[mrlogix]

Matteson- had to bump start it to get home. Down hill with passenger on back, 4th gear before traction could overcome compression ratio.

Cos- f*ck, f*ck, f*ck. Sprag clutch? really? so now I have trash in the bottom of engine? %#@!

 

[Cosworth]

Unless something else went bad in the starter motor itself but its most likely the sprag clutch... Pulling the sprag side cover is pretty easy but will drain some oil so either drain the engine or be ready with a catch pan. You can pull the starter from the other side and inspect its teeth but its not likely.

As far as trash they are known to make a metallic paste like substance when they start going bad so yea it'd be a good idea if not mandatory to go ahead and pull the filter and the pump screen at the bottom and inspect for debris.

Hope it doesnt take much to get her back up and running.

http://www.badweatherbikers.com/buell/messages/290431/743317.html?1404613987

 

[Matteson]

You might have trash. Has it been loud and metallic sounding when you started it and it didnt fire? Or metallic clank when you shut it off? Mine became hard to start and I knew something wasnt right. Pulled cover off and ya it was shredding itself. Really fine metal though. A lot of it was stuck on the rotor because it's magnetic. I drained the oil and looked at the filter and there was a few small chunks. If it went all over too late now. New flywheel, sprag, housing, nut, gasket, loctite 272, filter and oil-$600 plus. $65 to rent tool, and I don't know about the rental for the torque wrench yet. Unexpected and not happy about it. 31,000 miles .Fyi, I bought new housing and flywheel because they were scratched. Lets hope it's just your sprag and new castle had the cheapest I could find $189.

 

[Cosworth]

When I reassembled mine I my highest torque wrench was 250 so I torqued it to 250 and then took a breakover and went some more. Put 1500 miles since then and no issues. Good luck finding a wrench good to 400ft lbs.

Good info on the sprag matteson, thats downright cheap for a new sprag.

In all I hope buell figured this issue out on the new 1190's...

 

[Matteson]

Ya ill rent the 250 put the bar on it too. That was the plan. It appears the spring that wraps around the sprag bearings had bound up somehow and was not allowing the sprag to do it's job.

 

[Cosworth]

Ducatis have issues with their similar spray clutches. And they were actually taking springs from lip seals and using those with some success to keep the sprag engaging correctly.

 

[mrlogix]

Matteson- where did you find the replacement parts? Searched fleabay with no results.

 

[Matteson]

new castle harley.

 

[mrlogix]

okay, looking at the sprag clutch design, is it a Rotax design? Do the Duc's and Aprillia use the same design? Anyone know if their version is more reliable?

 

[Cosworth]

They are similar for sure but I don't know if they are exact.

 

[Matteson]

I wouldn't say they are unreliable. I mean mine went out at 30,000 miles. Not bad. The duc guys use a spring from an skf seal that is beefier. They tape the sprag then cut out the center just enough to remove the spring while holding the bearings in. Then install the better one.
I almost bought one for a ktm that was only 55 bucks. Then when it didn't fit return it.

 

[mrlogix]

is there an oil passage in the cases that positively oils the sprag assembly, or is it splash lubed by the spinning crank and oil windage off the gears? Anyone?

 

[Matteson]

It's just like any other high performance motor. A mist or light spray is all that's used. Too much and it creates friction or drag and you lose the ability to make horsepower. My buddies old guzzis are like chevy big blocks running 30 or 40 psi of oil pressure and not producing many ponies
I will say that when I bought my 1125 the po had let the oil get a little too low for my taste and was too old. So maintaining good clean oil and the proper level will do wonders. The motor can perform as intended with a light spray.