Starter Clutch Failure

[aviationfred]

Was the engine cold when the starter clutch failed?

I wouldn't say it was 'cold'. The engine was at normal operating temps when I stopped to pick up some groceries. Maybe 30 minutes in the store.

I would say the engine was cold when we got it on the lift and the starter clutch engaged on the 2nd attempt to start.


Fred

[FJmonkey]

I wouldn't say it was 'cold'. The engine was at normal operating temps when I stopped to pick up some groceries. Maybe 30 minutes in the store.

I would say the engine was cold when we got it on the lift and the starter clutch engaged on the 2nd attempt to start.


Fred

My 89 has starter clutch issues with cold and thicker oil. Just asking...

[aviationfred]

Today I got the cases split. One thing the Haynes manual does not tell you is, you have to remove the oil pump to have access to a lower case bolt. Something i also noticed is the the rollers in the rebuild kit are about 1/8 of an inch shorter in length versus the Old OEM rollers. Before anyone asks, I am NOT replacing the starter chain. This engine is very quiet running without the common starter chain rattle.



Fred

[aviationfred]

Starter clutch breakdown photos.

The first photo shows the new rollers, pins and springs on the right.

The last 2 photos shows the OEM roller (upper photo) and the Rebuild kit roller (lower photo).

Fred

[Pat Conlon]

That does not look right...Why the difference in lengths?
I wonder if it has anything to do with the fact that you have the last year 1995 model uses the long rollers and 1993 was the last year for imports into the US and they used short rollers?

[aviationfred]

That does not look right...Why the difference in lengths?
I wonder if it has anything to do with the fact that you have the last year 1995 model uses the long rollers and 1993 was the last year for imports into the US and they used short rollers?

I dont know. The Yamaha part number for the roller is the same from 1984 to 1993 according to Partzilla. I also looked up the part on the Motorcyclespareparts.eu website in Europe. Their listing for the FJ stops at the 93 model also. Same part number as Partzilla. To the best of my knowledge the US spec 93 FJ and the UK/European/Australian spec 95 FJ are the same with the exception a few minor wiring differences.


Fred

[RPM - Robert]

Fred. I sent those on accident. Those are for a different bike. The rebuilt kit is just the springs and the "cups" use your stock rollers. They don't go bad.

[aviationfred]

Fred. I sent those on accident. Those are for a different bike. The rebuilt kit is just the springs and the "cups" use your stock rollers. They don't go bad.

Thank you..... the starter clutch is back together and ready to install.


Fred

[aviationfred]

Today, the plan was to put the repaired starter clutch assembly in and close the engine. I decided to check the condition of the starter chain guide.... Definitely not looking good. Not a simple removal. I did have to remove the intake camshaft to get slack on the cam chain. Rotated the crankshaft to center all of the pistons. Pulled the crankshaft out about 1/8th of an inch and removed the guide. A new one is on order.



Fred

[aviationfred]

Having spoken to a few people, I have decided to do a complete refresh. New bearings, rings, chains and sliders.




Fred

[Millietant]

And...........a big bore kit......you've got plenty of time, it's winter !! 

[fj1289]

I see a cliff ahead ... !





And I'm right there with you - my simple "pull down the race engine for bearings, rings, and a valve job" has turned into a much bigger project too.

[aviationfred]

And...........a big bore kit......you've got plenty of time, it's winter !! 

You are correct, there is plenty of time. Unfortunately there is not plenty of funds. I would love to do another 1297cc engine, but this will stay at 1188cc for awhile longer.

On a high note, when I do put in go fast pistons, I will know that the lower part of the engine is fresh.


Fred

[Pat Conlon]

Fred, I think you are making the right call. I am surprised at the condition of the starter chain guide.
Good time to look at the starter chain oil jet .
http://www.fjowners.com/index.php?topic=19016.0

[aviationfred]

Fred, I think you are making the right call. I am surprised at the condition of the starter chain guide.
Good time to look at the starter chain oil jet .
http://www.fjowners.com/index.php?topic=19016.0

The upgraded version has already been ordered


Fred