Starting issues By mcgyvre (Read 1,238 times)

[Bashan]

That washer is too big. The clutch drive gear is supposed to fit over the retaining nut and washer. The drive gear should slip off without removing the nut. The nut and washer hold the clutch on, the outer case cover holds the drive gear on. Somebody installed the wrong washer on that mechanism. That trashed your gear alignment. I'm not sure what the heated engine does to make it work but it's wrong the way it is assembled. There are three bolts holding the clutch together as Alley said. Those holes on the drive gear are not supposed to be lined up with anything below. The crank and starter clutch actually spin beneath the drive gear when the engine is running. The drive gear only spins when the starter is engaged and it grabs the little tumblers in the clutch. Once the engine starts the drive gear is released.

Here you see the proper washer:

It fits UNDER the nut. Rich

[mcgyvre]

Hey Rich. I sure wish I wasn't too busy putting it back together to have read your post. Gotta take 'er apart again as I reinstalled that same washer. There is no way in H*LL I'm putting back together wrong after all I have been through this weekend!!! It did start and perform normally, but I have the correct washer and no fire will see that cylinder until I have it right. As I said early on in this thread, you guys have never let me down. There is all kinds of hinckey stuff going on with this bike. So many things point to it being new in 2011 while there are many others that point to it being 'refurbished'. I think I'd be totally lost without you guys. As a general note, and specifically for JCT, I meant nothing by the earlier post about the brake lever. I truly am grateful that someone takes the time to point out what may be obvious to some but not everyone. As I said earlier, Sometimes we can not see the forest for the trees, so it helps to be reminded of the simple things. I can't count how many times I have overlooked something simple and overanalyzed a problem when it was staring me in the face all along. Occam's Razor is a good thing to keep in mind at times like these. "when you have two competing theories that make exactly the same predictions, the simpler one is the better." So, I sincerely thank each and every one of you that took your time to read and respond. Also thanks to those that read and chose not to respond. I'm confident that if you had encountered this in your experience, you would have offered suggestions as well. If not, then I hope you gleaned something from my experience.

[mcgyvre]

Final note to Rich - the deal with it being warm is simple. It's dialed in so good right now that a bump will start it. As can be seen in my video, it almost invariably grabbed for a few revolutions when first engaged. When either the weather or the bike was warm, that quick engagement would be enough to get it started. It was not making any difference in the way the clutch was slipping, just how easily the bike started.

[Guitarman]

Oct 20, 2014 8:27:14 GMT -6 mcgyvre said:

Hey Rich. I sure wish I wasn't too busy putting it back together to have read your post. Gotta take 'er apart again as I reinstalled that same washer. There is no way in H*LL I'm putting back together wrong after all I have been through this weekend!!! It did start and perform normally, but I have the correct washer and no fire will see that cylinder until I have it right. As I said early on in this thread, you guys have never let me down. There is all kinds of hinckey stuff going on with this bike. So many things point to it being new in 2011 while there are many others that point to it being 'refurbished'. I think I'd be totally lost without you guys. As a general note, and specifically for JCT, I meant nothing by the earlier post about the brake lever. I truly am grateful that someone takes the time to point out what may be obvious to some but not everyone. As I said earlier, Sometimes we can not see the forest for the trees, so it helps to be reminded of the simple things. I can't count how many times I have overlooked something simple and overanalyzed a problem when it was staring me in the face all along. Occam's Razor is a good thing to keep in mind at times like these. "when you have two competing theories that make exactly the same predictions, the simpler one is the better." So, I sincerely thank each and every one of you that took your time to read and respond. Also thanks to those that read and chose not to respond. I'm confident that if you had encountered this in your experience, you would have offered suggestions as well. If not, then I hope you gleaned something from my experience.

And that Sir, is the entire reason for this forum.  Welcome to the club. 
We may now abuse you verbally. (Or at least in writing) LOL