Starter issues

[Urban_Legend]

Thanks Randy. OK hopefully 3rd time lucky. Oils and oil filter purchased. Will change it out tonight. Finger crossed for a result soon.

Mark

[RPM - Robert]

Mark,

    We actually just got the roller style rebuild springs and detents in. We have been working with a company for a while to get the springs and detents to be able to rebuild the starter clutch, or you can also completely do away with the old roller style that came standard in the FJ and upgrade to the sprag style they use in the XJR which will prevent the springs loosing tension in the future and eliminate all the associated problems. I have listed them below, the complete rebuild kit comes with everything you will need to split the case and either rebuild or upgrade the starter clutch and it gives you an option for either.

Complete Starter Clutch Rebuild Kit
FJ1100/1200 Starter Clutch Spring Kit
Sprag Starter Clutch

[Urban_Legend]

Thank you Robert. I am still hoping that Randy's solution will work, and I won't have to split the case, but glad I have options.

Mark

[Urban_Legend]

I put 400 km on the bike yesterday. Unfortunately the starting issue dowsn't seem to be resolving itself. Just need to save up some dollars and do the fix properly.

I will keep you all posted.

Mark

[racerrad8]

I put 400 km on the bike yesterday. Unfortunately the starting issue dowsn't seem to be resolving itself. Just need to save up some dollars and do the fix properly.

I will keep you all posted.

Mark

Mark, while you're saving up for repairs, keep putting the miles on it with the lighter viscosity oil and transmission fluid.

You put 250 US miles on it, keep going for at least 750 more.

It takes time for the detergent in the ATF to breakdown a contaminated engine.

Keep it up, if the starter clutch can be cleaned up it will take some more miles.

Randy - RPM

[Urban_Legend]

Well my starting issues have finally got the better of me. I went for a ride with a mate last weekend, and the bike performed beautifully. So happy with how the "new" 1200 motor is running, except for the starting. However. I have been unable to start the bike for the last 3 days. This is an issue as the bike is my main for of transport. So Randy/Robert, expected an order for the start clutch kit in the next few hours. Unfortunately I can't afford to go up to the XJR version.

Nark

[Bones]

This is where a removable Kickstarter would come in handy, like the XS1100 had for an emergency. These old  tanks weigh a ton when trying to push start.

[Urban_Legend]

Here's a short vid  of what is happening
https://youtu.be/SHY9hhP9jpg

[Urban_Legend]

Today I got the motor puller out......again 
Drained the oil first and checked it out. There were some very fine metal bits and the oil still had good color. My Starter clutch rebuild kit should arrive from RPM in the next few days. Not sure how I will go splitting the cases. Is there anything to watch out for?

Mark

[Urban_Legend]

The book says that to split the cases you must first remove the clutch. Done that. Had a good helper in the shed today too.

[racerrad8]

The metal bits will not be from the starer clutch, they are most likely from the transmission. Post up a couple of photos of the findings so I can see them

Make sure, double & triple check you have all of the bolts out of the case before trying to separate. There are a couple down in "holes" that get debris on the top of the bolt and hides them.

There is one bolt hidden by the oil pump and not able to be removed until you remove the pump.

There are 37 bolts holding the cases together, count them before you try separating the cases.

Once you get it apart, then you can access the start clutch.

Keep up the good work & updates.

Randy - RPM

[Urban_Legend]

Randy

Once all of the bolts are out and the couple of bearing keepers removed that span across the two halves of the case, should it come apart neatly into the 2 halves, or are there bits that may fall out. Is there a definit top half (crank, pistions) and bottom half ( Gear Box)

Which bit did you want photos of? The filings or the gears and crank?
I had good advice from Noel ( Ribbett) about putting all of the crank bolt into a piece of card board and number them.

Thank you for your help. Its just a bugger when the motor was running it was really strong....its just getting it running that is the issue.

Ta
Mark

[racerrad8]

Nothing should fall out. Usually the transmission will stay in the upper case.

Photos of the filings.

Randy - RPM

[Urban_Legend]

Randy
I had poured the oil into a container for disposal. I have strained it though and old pair of my girlfriends stockings (yes I asked her first) and the particles were so fine that it don't capture them.
Only noticed then as a very faint sparkles in the oil pan when I went in the sun to pour into the container. Any foreign bits you see in the photo is grass that made its way into the oil pan
Mark

[Urban_Legend]

On the upside. I now have the motor off the ground onto a metal trestle table for the tear down.