starter gear stripped...

Questions regarding the DR800

Re: starter gear stripped...

Postby BigBob » Fri Nov 01, 2019 7:44 pm

Oh dear!
User avatar
BigBob
Admin
Admin
 
Posts: 3930
Joined: Sat Jan 23, 2010 10:46 pm
Location: ESSEX

Re: starter gear stripped...

Postby bigguy » Mon Nov 04, 2019 4:46 pm

yep im in guatemala central america :clap:
any other bike use the same rotor holder?
maybe a dr650 if so i can ask the dealer here!

do i need to change the whole starter clutch assembly
or just one of the parts (middle) that is broken?

anyone have a pic of the rotor holder?
and what kind of extractor do i need to pull the rotor off?

thx!
User avatar
bigguy
Regular
Regular
 
Posts: 52
Images: 2
Joined: Tue Sep 09, 2014 4:33 am

Re: starter gear stripped...

Postby dave#22 » Mon Nov 04, 2019 6:11 pm

..............any other bike use the same rotor holder?
maybe a dr650 if so i can ask the dealer here!.........

Bob'll be able to advise on that...the thread on the rotor looks like m42x1.5.
I made my own rotor holder. It's a Y shape with m16 nuts welded on with two m16 screws machined down to 11.6 OD on the ends which align with the two opposing 11.9 ID holes in the rotor.
I have a spare used sprag clutch...it bolts on to the back of the rotor with allen screws.
It's quite small on it's own, so postage shouldn't be too prohibitive.
You'll need to check that the machined face that the clutch runs on is okay, if not, you'll need the big starter gear as well...also not too heavy...and I have a spare of that as well.
Good luck.
Dave.
dave#22
On Here A Lot
On Here A Lot
 
Posts: 315
Joined: Mon May 24, 2010 9:21 pm

Re: starter gear stripped...

Postby Hann » Mon Nov 04, 2019 8:58 pm

Some kind of strap wrench (chain/steel/leather???) may enable you to hold the rotor whilst undoing the rotor bolt.
I had a home-made one from another bike which fitted the DR but i snapped the steel strap when i did the bolt back up on reassembly, it`s that tight!

Image
Image

This is the rotor removal tool/puller;

Image

This is the type of job that can lead to unwise desicions being made in desperate attempts to get the job done, don`t be tempted to bodge it `cos it can go wrong, very wrong..
The rotor is very tightly fitted to the crank..
Hann
Regular
Regular
 
Posts: 45
Joined: Tue Jul 31, 2018 10:34 am

Re: starter gear stripped...

Postby BigBob » Tue Nov 05, 2019 10:47 am

I suggest you read the relevant part of the manual dealing with this, section 3-14. http://www.timguy.net/sites/drbiginfo/DrBIGmanuals/
You can get the tools here https://alpha-sports.com/tools/suzuki_tools.htm
If you use the wrong tools you will destroy part of your engine and it will be very expensive
The rotor can be very hard to remove and sometimes it`s best to just leave it under tension from the tool overnight and leave a cushion underneath, and in the morning you will find that it eventually fell off. Do not try and force anything or you can damage or break the crankshaft.
Adjust your balance chain while you have the cover off, and always use a new gasket.
User avatar
BigBob
Admin
Admin
 
Posts: 3930
Joined: Sat Jan 23, 2010 10:46 pm
Location: ESSEX

Re: starter gear stripped...

Postby dave#22 » Tue Nov 05, 2019 4:53 pm

Here's the tool I made for holding the rotor..... :tup:

https://photos.app.goo.gl/KQvkLsg1TTPWHRMv6

....photo taken from the back of the rotor, showing the sprag clutch.
Dave.
dave#22
On Here A Lot
On Here A Lot
 
Posts: 315
Joined: Mon May 24, 2010 9:21 pm

Re: starter gear stripped...

Postby GrahamW » Wed Nov 06, 2019 9:56 am

I didn't have a rotor holder when I tightened the rotor bolt back up so I wrapped a round bar (old plug spanner I think) in a bit of cloth and put it through the small end and used that to hold everything.
GrahamW
On Here A Lot
On Here A Lot
 
Posts: 404
Joined: Thu Oct 26, 2017 10:10 am
Location: Littlehampton West Sussex

Previous

Return to DR800

Who is online

Users browsing this forum: No registered users and 1 guest

cron

x