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While you still got it apart, check to see if the coupling that the pinion gear slides in an out of in the picture below is in backwards. For some reason I thought that the circlip in that coupling is offset.. I could be wrong but I'm just trying to go from memory.. And while you got it apart it's an easy thing to check..
OK I tried the starter without the back cover and this didn't make a difference. Unless I open the starter and see if there is an issue with the Bendix spline I've drawn a blank with that "adjustment".
In the photo you can see that the outer edge of the bore is clear but the edge of the large coupling (black) still protrudes a fraction.
I am at work but when I get home I will again double check the seal that you mention Yankee Dog.....its the only thing I don't seem to have photos of "before and after" when i put it in but I do remember checking multiple times on the internet before putting it in place in the Inner Primary but the comment you highlight of "there are springs on both sides of the seal" has me doubting myself now as I put it in spring side towards the outer primary.
I appreciate you're grasping at straws I am pulling my hair out!!!
Outer edge OK but inner coupling still protrudes.
Regards the solenoid contacts I have some new ones I found here but the Positive is much shorter than the original so I wasn't sure whether to change it or get the correct "longer" ones. The positive terminal replacement I have is shorter than original.
She'll be right, as they say here in the Antipodes, chuck the new one in.
Just double checking here, on the coupler, youve always referred to the direction as the short end & the long end, I dont know which end is short or long, you need to make sure the side with the counter bore, is facing out, away from the starter, towards the jack shaft.
Seems I dont remember the coupler sitting all the way to the step like that
.
I'm pretty sure this one is directional as well Make sure you have it in the right way.. #31.. but my mind is getting old and my memory is starting to suck..
It's that with the solenoid back plate on or off? That would be normal with the starter completely assembled..
Yes the solenoid plate is on, it is completely assembled so I am happy yo say the Bendix spline is OK and correct.
In terms of the couplings connections I have checked and double checked them and they are facing the right way. I've attached an image which shows the correct orientation and may be helpful for anyone else who comes along. When I refer to the "short" or "long" end hopefully this image will explain why I say that.
I will continue to try and refit everything again over the weekend (depending on rainfall!) but I have to say - if all the parts seem to be fitting "correctly" after I've checked multiple times and loosened and tightened the tranny etc. I may resort to my idea of placing a thin washer on the end in front of #43 which will essentially push #17 to the right (in the diagram) thereby allowing the clutch to turn without fear of hitting the Pinion gear teeth (#17).
I know its not a professional solution but I can't imagine it will break anything and I need to get the bike back on the road! I will trial it before closing the primary to make sure it does actually work.
Couplings orientation
Last edited by monchidog; Feb 28, 2025 at 03:42 AM.
Believe it or not I still havent solved the issue of the the clutch hub hitting the starter jackshaft drive. It has been raining non stop for 3 weeks so havent been able to work on her as only have her in a partially covered parking.
I found a day to try and refit the clutch and she is still touching. Basically she is pushed in too far back toward the inner primary. Now as you can see I have tried any number of adjustments but nothing changes.
I can only figure that either he main shaft splines are done or the splines on the clutch hib have been forced perhaps by my over tightening the clutch hub nut last time. It can only be one of these things!!
so Ive ordered a new clutch hub and will try it on the main shaft and see if it stay further away from the inner primary. If it does then excellent and Ill change it. If it doesnt then Ill throw the towel in and take it to an independent as I have run out of ideas. thanks all.
Last edited by monchidog; Mar 16, 2025 at 11:20 AM.
I can only figure that either he main shaft splines are done or the splines on the clutch hib have been forced perhaps by my over tightening the clutch hub nut last time. It can only be one of these things!!
Grab the clutch hub pull it outward and push it inward, does it move?
Last edited by Dan89FLSTC; Mar 16, 2025 at 03:30 PM.
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