[mbevo1]

Well -

One wimpy stroke on the kickstart after priming with several strokes using the decomp.  Turned the key on, started to move the kicker... and found I was a few degrees before TDC instead of after...  kicked back and jammed the sprague.

I was going to remove it before it failed as I've only used the e-start half a dozen times - now I gotta.

Seems the clutch assembly is jammed solid (inner and outer gears rotate together).  Problem is, the outer gear is jammed half a tooth off - and perfectly blocks the inner gear (the starter gear) on the crank sprocket. 

I'm thinking I need to put a good whack on the outer gear to break it loose, or, at least, make it line it up with the inner gear to be able to slide the crank sprocket off. 

Am I correct that the clockwise rotation of the crank when it kicked back is what jammed the sprague?  If correct, I think I need to whack the inner gear in a counter-clockwise direction to break it loose...

Starter gears and motor are staying off.  Gonna plug the starter hole with a JB weld patch.  Going to 18-tooth sprocket since I'll have the inner primary off.

Several days of rain forecast here... should be done by the time it dries out 

Mike and Stumpy in Michigan

[Rick Sperko]

I am considering dropping my starter and mechanism too. I would like to leave the inner primary in a way that I can re-add it if I ever sell the bike and JB weld seem a little permanent for that.

I will be very interested to hear how it goes.

-Rick

[REpozer]

Ace brought up the idea of making a "dummy plug", or "knock off plate" to seal the starter motor hole.

I was thinking about a piece of aluminum ( if its too thin will flex, too thick will not bolt up)

Anyway I use my E-start 30% of the time, usually with warm engine.

[mbevo1]

Gotcha, Rick...

I was gonna remove it when I got around to it and save it... don't think I'll buy another sprague just to keep  around, but I'll look and see if I can come up with a method to block the starter hole.  Shouldn't have any pressure on it - just need something to stop the oil splashing around (I think??).

Someone posted a pic of a rubber plug "he had laying around" to plug the hole.  I'll see if I can find it and see if he remembers where the plug came from.  

Mike and Stumpy in Michigan

[gunbunny]

When my sprag went I took out the starter motor and rode around for over a year with out blocking the hole ,it didn't seem to be a problem.

[mbevo1]

Duck tape?

Mike and Stumpy in Michigan

[mbevo1]

Had to chase the chipmunks out of my shed/garage yesterday... would hate to leave the hole open and have one call it home...

Mike and Stumpy in Michigan

[1Blackwolf1]

  WOnder if you could just hang the starter back in the hole.  It does have the bolts to mount it back to the engine.  Would also look a little cleaner than the tumor.  Just a thought.  Will.

[23hp]

On my AVL I finally got rid of my starter the other day after having got rid of the sprag a long time ago...

I had just planned to remove it and take a look at what was the best way to fill the hole but I finally cut a circle (with a pair of scissors) out of the lid of a thin metal biscuit tin and stuck it with a metal filler (JB weld type of thing).  All together took me about 5 mins and will do for now.  Have ridden lots since then and it holds up very well.

[Ice]

 I believe the local application of heat from a propane torch or cigar torch would soften J-B weld type epoxies enough to remove the cover plates if one were inclined to do so.

[mbevo1]

Well, I picked up a 1 13/16" rubber stopper from the hardware this morning.  I think it might be perfectly sized to close the offending orifice but be removable should I decide to reinstall the starter stuff (fat chance)...

Mike and Stumpy in Michigan

[Rick Sperko]

Now that I am living in a one-kick world, that looks very appealing to me.

-Rick

[rideOn]

my starter just failed so i tried something a little different. first, i gutted the starter. i have plenty of leftover radiator hose from replacing the intake hose. i cut a small piece to fit inside the small hole in the starter that was left. i had some two-part epoxy floating around, so i currently have a clamp on this configuration letting it set up Pluggint the starter hole and not the engine casing). i think putting the empty starter back on but leaving the wire off will make everything look normal without having all the vacant holes. to add a good starter back on the bike will simply require taking the dummy off and bolting up the new one.

[mbevo1]

I found a great bit to plug the starter hole at the Ace Hardware -

1 3/4" Automotive/Marine expansion plug - part number AMP 10258.  Cost about 6 bucks.  Large size version of a drain plug for a rowboat. 

Loctite on the nut, screwed it down.  Ain't gonna leak, and has a metal plate that covers the hole nicely.  I'll upload a pic this evening. 

Mike and Stumpy in Michigan

[mbevo1]

BTW -

I REALLY like how "pure" the motor sounds without all those extra whirly bits in there...

Really quiet when starting and stopping the motor, too... 

Mike and Stumpy in Michigan