well this electrical gremlin lead me to the stator/starter....and upon removing the stator cover, i noticed something loose -a gear that connects the starter output shaft to the flywheel.

this gear rides on a metal dowel that fits into two machined holes, a raised one in the stator cover and a raised one in the block. the stator cover's hole was sheared off, i figured i could just get a new stator cover and be done with it....

.....but when i pulled the starter, the gear got loose enough to remove....and that's when i noticed the hole in the block had sheared off too....and the gear had been chewing into the aluminum.

so. options? obviously there's no way to like....re-build that raised hole in the block is there?

on the upside, there will be parts in the classified section soon.

P.S. I've had this bike for maybe 3 months. this sucks.

-T

 

i had a thought - is it worth maybe having someone grind down the surface flat, then weld a new hollow piece on the block for the dowel to sit in?

-T

 

Have you considered buying a new engine case by chance? its TOTALLY fixable, depending on how dedicated you are. I'd hate to see another good bike be junked/parted out on account of a simple fix.

 

well thats the easy half of the fix. i can get a new stator cover/engine case for like 50 bucks.

it's the other side that's the issue, i'd need either a new engine block or a welded repair.

here are pictures, might help shed some light on the situation. sorry the close-up is blurry.

-T

[IMG]local://upfiles/29387/CD101CD23255430DB3F09AD3FC2E90BF.jpg[/IMG]

[IMG]local://upfiles/29387/AB5F85AE5A674BAE8A43B25C7BA2BF79.jpg[/IMG]

 

looks like there is light at the end of the tunnel.

i found a machine shop that specializes in aluminum cylinder heads that can build the hole back up. so she goes in on monday. just have to strip her down and take out the battery and drain her fluids so the shop can *gulp* lay her on her side to work on her. i'll post back when the repair's done, if it goes as planned.

and since shes already all taken apart....good time for a paint job! the rattle cans are already gettin warmed up.

-T

 

Awesome...sounds llike a plan!...shes down but not out![sm=happy046.gif]

 

SHE'S ALIVE........

got the holes built up with aluminum at a cylinder head repair place that specializes in aluminum welding.

so after a lot of struggling to reassemble, and cursing and grinding down the repair because the guy built up the stator cover holeso far that it was causing the starter gear to bind up, she cranked and cranked and finally fired up again. i was shaking, i was so excited.

of course, stupid me decided since she was gonna be apart for a while, now's a good time to prime and paint the plastics.....they're primed, but....now i actually have to finish the paint job. damn.

thanks for your help everyone!

-T

 

Good to hear you didnt end up parting her out, and now she once again lives.