Major Starter Clutch issue

[dragonz]

A couple of years ago, my starter clutch (one-way bearing) packed it in & at that stage I didn't know about the L&A option.
I spoke to the local yamaha dealer, Parts $500, & $100 labour to fit.
Thought that was ok (had no other option at that stage anyway) & got it done.
Since then through a combination of injury, sickness, & then just working too hard, have hardly ridden the bike!
Seriously I have only ridden about 35 hours since the starter one-way was replaced, & thats being generous!

2 weekends ago, got out for the first decent ride of the summer.
2nd decent ride of the day, & starter just goes wirr wirr, no cranky! NO GOOD!

Parked it up, & ordered new parts from L&A, went whole hog & got a new 52t gear just in case, don't want to have to do this again so figured I'd do it properly.

Started stripping the bike last night.
Got down to the stage of needing to remove the flywheel before I packed it in for the night.
Gave the 52T gear a spin, yup free-wheels in both directions, one-way must just have shit itself, but then I noticed the one-way was moving with the 52T gear!!!

Wriggled fingers round the back, & there are no capscrews in the holes of the one-way to hold it to the flywheel!

Now I'm terrified!!
Where have the screws gone???

How much grinding paste am I likely to find in the bottom of my crankcases??

What otherdamage have the screws done?
Were they even there to start with?

The Flywheel nut was only about 60lbf when I un-did it, so if the screws were there I figure they weren't done up tight or had no loctite.
I may find the ends broken off in the flywheel when I get it off, guess I will find out more tonight. 

The last few oil changes (i do it every 10 hours) have had pretty clean oil come out, & no ugly bits of busted steel in the filter.
Guess I'll be going over the engine with a fine tooth comb!!

I have never liked giving my bikes to a shop to work on, & now I like it even less!!

Will post pics & more info as I find it tonight

[Livingmylife93]

Sorry about your luck. 

Good luck getting it back together.

[Mad Dog]

It's not unheard of for those screws to just shear right off, that's why some places like ripper racing and alba will sell you a kit with better, hardened replacements.  You may find the ends/caps floating around your motor.

[dragonz]

It's not unheard of for those screws to just shear right off, that's why some places like ripper racing and alba will sell you a kit with better, hardened replacements.  You may find the ends/caps floating around your motor.

I'm kind of worried about that, capscrews aren't the softest, & gear-pumps for oil, & gearbox teeth & engagement dogs etc aren't generally improved by living on a diet of such things.

Guess tonight will "tell all"

Will be getting a really good magnetic probe to "plumb the depths with"
Hope any "fish" I catch haven't been too badly "mauled", or I will be very concerned about the rest of my motor & gearbox!

[dragonz]

All the capscrews were sheared off!
I got 4 of the heads from in the main oil gallery in the bottom of the motor.
I found a 5th in the clutch cover, but haven't found the 6th yet.
I need to tilt the motor in the frame to get the clutch cover off properly, but there is damage to the oil pump drive gear (burred teeth, but appear to all be there)
The capscrew heads I have found are mostly intact, some damage to all of them, & 1 is half chewed away.
Fair bit of metal filings floating round in there, so will have to give everything a very through clean.

The Flywheel is fucked!
5 of the 6 broken capscrews came out easily by hand, so no loctite on them.
Figure they must have been over-torqued, that helps explain the breakage.
The 6th I haven't been able to remove yet.
However, the major problem is the face where the one-way bolts up is damaged badly.
It is worn on the mating face & inside the shoulder where the one-way spigot mates up for alignment.
0.5mm clearance is excessive on this I think!

Will post some pics later.

I'm off to the bike shop to discuss the problem, don't know how much luck I will have, but hope to get them to replace the parts.
NO WAY WILL THEY BE DOING THE RE-ASSEMBLY ON THE MOTOR!!!
I have seen their workmanship first hand now!

I will be back with more later 

[fireman5166]

good luck. that sucks  :'(

[1badazz_700r]

Good luck. If they dont do something to help you in some way to make it right. You could always help there business by writing an article in the local paper,saying what a wonderful job the local atv shop did in repairing your quad . Sometimes you just have to seek alternate routes

[dragonz]

Well, found all of the capscrews last night, including 2 bits that had been sheared off of 2 of the heads (by what I don't know).
So feeling much happier about the whole thing
Used a long thin magnetic probe to "sweep" right through the crank-cases, & no other steel fragments were found.
However, I did find a small aluminium dowel pin that has been broken off from some point in the cases.
It is 3mm dia x 4mm long, so not s loaded part, maybe it was a locator for something during assembly??

So the casualty list so far:
The oil pump nylon gear is a bit damaged, needs replacing
The Flywheel is fucked, as it has worn where the one-way mates up
The oil pump???
a few gaskets

I'm concerned about the oil pump as it will have copped a bit of swarf & may have some wear in it, will have to strip it & check.
Would have done it last night, but just ran out of time to do it.

I think I will pull the motor out of the frame & wash the crankcases out with kerosene just to be sure there are no other fragments floating round, but I'm tempted NOT to split the cases, as I have now got all the capscrews out, & there is no other obvious damage.
The motor was running sweet when I shut it down, & was changing all gears etc, so unless I find something when I wash it out, I will probably leave it intact for now.

Keep promising pics, may put some up at lunch time

The local bike shop have said they will get me replacement parts at their cost price.
As the shop has changed hands, I think that is fair given the circumstances, but have yet to find out the price of such things as the oil pump & flywheel mind you!

[1badazz_700r]

glad to hear there helping you some hopefully everything goes smooth for you. as far as the locator pin. could be an allignment pin for mating the head to the cylinder,just a thought.My 700 has them so assume the 660 does to

[1badazz_700r]

There is a complete 660 motor part out in the parts section here. might help save money

[SKT]

Any updates with this one?

Curious how everything ended up...

[dragonz]

Hey there, guess I shoulda given everyone the final tie up on it.
As I said in my last post, Henderson Yamaha, my local shop, gave me all the parts needed at their cost price.
Pretty decent of them, as the shop had changed hands since the work had been done.
Washed the crank-cases out with large quantities of kero & a magnetic probe, & filtered all the kero to see what came out.
(Had already got all the fragments of the capscrews out, so wanted to be sure there was nothing else floating round in there)
Put the L&A one-way onto the new flywheel, loctited & torqued all the bolts correctly.
Re-assembled the motor, new oil & filter.
Checked valve clearances while working on it, & made some jetting adjustments
Ran for 10 min at idle/low revs to curculate the oil thru the motor to be sure anything still loose in there went into the filter.
Drained the oil, removed & cut open the filter, no new fragments of metal.
Re-filled with oil, new filter, been on 5-6 decent hard rides since.
Going like the clappers, no gear-change issues, no funny noises!

I'm fukin wrapt!
Still running a little rich, but time to clean air filter, so will give it a little more tweaking while I'm at it.

Thanks for the interest.

I would make a serious suggestion to anyone buying a 2nd hand rappy.
Pull the side covers off
Put a new clutch pack in (Hanson or GTYR)
Put an L&A starter clutch in, Torque everything EXACTLY, & use loctite on critical bolts (like the starter clutch/flywheel ones)
You will never need to go back in unless you blow it up, or want to build a bigger motor (wearing it out is just an excuse to build a bigger motor)