evil 650
XS650 Enthusiast
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Because there were problems, Yamaha redesigned the spring clip. I'm thinking they changed the diameter of the wire that the clip is made from, and as a result it does not fit into the original location. By placing it off to the side the newer design clip can do its job better.What happens if you replace that clip thing in the old position where it looks like ought go to rather than in the new position that looks like a mistake?
Hmmmmm....I have to admit that I've never been inside the clutch cover, but there are several videos on it and it doesn't look bad.
I'll bet it is just a bit of gummy old oil on the shaft holding that #4 gear from engaging. Once you get in there and give it a squirt of WD or something like that, it will probably work just fine. I certainly doubt that anything is worn. If it worked before you put the bike away - it should still be ok now.
Hey: here's a thought. Can you kick start the bike? Once it's running and warmed up - the oil should thin-out and perhaps that Darn old gear will function again without a teardown.
Pete
Spockwerks;
Read all of this thread and all of your questions will be answered:
http://www.xs650.com/threads/starter-gear-fix.18060/
Like I said before, the starter system is a well designed system, but the wish bone clip or drag clip does lose its proper tension as the years go by. It seems to need about 6 lbs of drag, as well explained in the linked thread.
I keep fearing that my drag clip will weaken and my starter will stop engaging, but so far mine has worked flawlessly.
As the drag clip gets weaker, the starter will start grinding occasionally instead of engaging. The clip slows the #4 gear's rotation so it can properly and easily engage with the gear on the crank. If the clip is weak and not slowing the gear down enough, it just grinds against the side of the crank gear instead of meshing into it. I've re-tensioned my drag clip twice now in the 10 years or so I've had my bike. I figure it's kinda going to be something that I need to do every 5 or 6 years.
For your problem, you mention no grinding. That could indicate that the #4 gear assembly isn't getting spun at all. I would start at the beginning of the starter spin delivery path, under that cover that sits below the countershaft sprocket. There's a couple little gears in there that tie the starter motor to the cross shaft through the motor. That transfers the "spin" over to the #4 gear assembly and to the crank. Maybe you left those gears out?