starter works but engine won't turn over
#11
I also opened up the right side crankcase due to a crack on the top right side of the cover. as soon as I pop it open a piece falls out and I thought the stator boss had improper contact between the starter and the stator but I couldn't find out where the piece came from. The boss is cracked and all but just by making a quick visual inspection it seems like the cog will hold out for a while without many issues. That's not to say that I won't fix it but just that the piece that I found has no visible origin :/ and if it was the cause of my bike not starting then I gotta make sure it doesn't happen again
Next pull the idler gear itself. It sits in a boss in the engine case. If that's cracked, your engine is toast. This piece:
#12
#13
Post up a pic of what you find.
I've got 2 engines in my basement with broken idler gear bosses. There's just isn't an easy good permanent fix for this. Yes you can have it welded and re-machined, but to do it right is too much work and money.
The easiest and best (if you plan on keeping the bike and want it to be reliable) is to get a used motor (unfortunately). Last time I just went and found a used motor and had it swapped in and running a day later.
I've got 2 engines in my basement with broken idler gear bosses. There's just isn't an easy good permanent fix for this. Yes you can have it welded and re-machined, but to do it right is too much work and money.
The easiest and best (if you plan on keeping the bike and want it to be reliable) is to get a used motor (unfortunately). Last time I just went and found a used motor and had it swapped in and running a day later.
#14
#15
Like I said, I've seen people try to repair this before with limited success. Short of stripping the case and rewelding the boss, which is a lot of work and some money to find a good welder.
But, I just saw this the other day and it gave me an idea. Hayabusa's have the same problem and they came up with a ring that goes around the start boss. Like below. So you might be able to epoxy the broken piece back into place. Careful not to get epoxy inside the boss. Then you could epoxy the ring around the outside of the boss if it's the same size or slightly larger. That should give it plenty of strength. You could probably make your own ring out of some thick wall steel tube. Or you can buy a ring from ebay if you can figure out if it will work.
GSX1300 Engine Case Saver 1999 2007 Protector Idler Gear Starter Suzuki Racing | eBay
But, I just saw this the other day and it gave me an idea. Hayabusa's have the same problem and they came up with a ring that goes around the start boss. Like below. So you might be able to epoxy the broken piece back into place. Careful not to get epoxy inside the boss. Then you could epoxy the ring around the outside of the boss if it's the same size or slightly larger. That should give it plenty of strength. You could probably make your own ring out of some thick wall steel tube. Or you can buy a ring from ebay if you can figure out if it will work.
GSX1300 Engine Case Saver 1999 2007 Protector Idler Gear Starter Suzuki Racing | eBay
#16
man that would've been a good idea to try out from the beginning but unfortunately for me I've already started my idea:
I'm going to drill right through the engine (since there's really nothing on the other side except the starter (removable)) and tap it with a bolt that I'll modify to fit both the tap and the boss, image attached, and let that work as an axel within the boss.
I don't know if what I said makes any sense (my wife says only me and my bike understand me) but I'll be sure to write up a How To to better explain myself
I'm going to drill right through the engine (since there's really nothing on the other side except the starter (removable)) and tap it with a bolt that I'll modify to fit both the tap and the boss, image attached, and let that work as an axel within the boss.
I don't know if what I said makes any sense (my wife says only me and my bike understand me) but I'll be sure to write up a How To to better explain myself
Last edited by optytrex; 02-16-2015 at 08:51 AM.
#17
That is a problem I faced on my f2. There is a solution that works. Drill and tap the hole. Run an appropriate size bolt in there. You'll have to shave down the bolt diameter to fit the sleeve. There's quite a few that have had success in doing this. I will be following it myself as soon as I get back to working on mine. Here's the link I got the idea from
'92 Honda CBR600 F2 broken starter-boss repair: http://youtu.be/qR_vFDHzvMI
'92 Honda CBR600 F2 broken starter-boss repair: http://youtu.be/qR_vFDHzvMI
#18
That is a problem I faced on my f2. There is a solution that works. Drill and tap the hole. Run an appropriate size bolt in there. You'll have to shave down the bolt diameter to fit the sleeve. There's quite a few that have had success in doing this. I will be following it myself as soon as I get back to working on mine. Here's the link I got the idea from
'92 Honda CBR600 F2 broken starter-boss repair: '92 Honda CBR600 F2 broken starter-boss repair - YouTube
'92 Honda CBR600 F2 broken starter-boss repair: '92 Honda CBR600 F2 broken starter-boss repair - YouTube
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