GY6 starter clutch ?? By rob63 (Read 6,041 times)

[rob63]

One of our Sym fleet bikes developed a knock/rattle from the engine. I`ve stripped the top end but found nothing obvious. Same goes for the transmission side of things.
So I popped the left crankcase side off to examine the starter clutch and oil pump. Again nothing was immediately obvious but on putting it all back together I noticed something odd about the starter clutch. With the washer and nut in place and tightened, I can move the gear towards me, so that it slides over the washer. I can`t say I`ve noticed this on any of our other GY6`s. I don`t think it`s normal as the gear would be flopping in and out onto the nut.
Anyone come across this before ?
Sorry about the hazy pics


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[Alleyoop]

It should NOT move in and out. Maybe the washer that goes first against the bearing is missing?
Alleyoop

Check it out in the pictures from RICH, scroll down and you will see him taking the starter clutch off and the washer.

www.scooterdoc.proboards.com/index.cgi?board=techtips&action=display&thread=6884&page=1

[rob63]

Cheers Alley, had a look at the link you provided and took it all apart again today.
It`s only the outer gear that`s moving in and out, the starter clutch and needle roller are held firmly in place by the washer and the castle nut.
Oddly I can`t see anything which would stop the lateral movement of the gear, if the washer was a larger diameter then it would foul on the outer gear when it was freewheeling.
I might strip a breaker bike we`ve got here to see if the same happens to the outer gear on that.

[Bashan]

That outer gear should not be moving laterally on the crank. I'm wondering if the case was holding it in position when in use? There must be something defective with the nut or threads.

[Alleyoop]

You got it the starter gear should not move in and out otherwise the Idler gear would not mesh to turn it to start the motor and or it could ruin the teeth.
Alleyoop

[rob63]

Jun 5, 2013 18:03:15 GMT -6 Bashan said:

That outer gear should not be moving laterally on the crank. I'm wondering if the case was holding it in position when in use? There must be something defective with the nut or threads.

Haven`t done much with this one today as I`ve been delivering other scoots. I have checked the nut and threads and they are fine. The washer only butts up against the roller bearing and in turn holds that and the starter clutch firmly on the crank. The washer can`t butt up tightly against the outer gear as that would make the outer gear move constantly with the crank, therefore making the idler and the starter motor move constantly as they are all in mesh.
Is it possible that under normal operation the friction of the starter clutch holds the outer gear in place ? I did notice that to place the outer gear into the starter clutch I had to rotate it in one direction which obviously provides the 'grip' to turn the crank when the starter motor is activated and alternately allows freewheel in the opposite direction once the starting phase is completed.
I`m just wondering if something is broken inside the clutch which has weakened the spring or friction tension to hold the outer gear in position. This might explain the rattling noise which I`m getting ?

[rob63]

Reckon I`ve found the problem causing the rattle and lateral movement of the outer gear. Took the three allen bolts out of the starter clutch and dismantled it, this is what I found inside

[Alleyoop]

Yes that is the weak point of the starter clutch the springs in there BUT The question IS WHERE ARE THEY?
Alleyoop

[rob63]

Jun 7, 2013 10:13:52 GMT -6 Alleyoop said:

Yes that is the weak point of the starter clutch the springs in there BUT The question IS WHERE ARE THEY?
Alleyoop

Indeed, there were some small bits of debris in the oil tray when I drained it, but I`ll be having a poke around in the engine with an extendable magnet next week in case anything larger pops up.

[grantlee1972]

Hey there, how did you resolve this issue? I have the same problem as described in your first post "With the washer and nut in place and tightened, I can move the gear towards me, so that it slides over the washer."

See my post and video here: scooterdoc.proboards.com/thread/10610/150ccgy6-starting-problems-starter-wrecked