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Board index Main Trail Technical Tips, Tricks & Maintenance "How To" Section
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Coragem
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Post subject: 98-99 Solid Starter gear to Starter Clutch Limiter (How To)
I have just finished the replacement from Solid Idle Gear (12611-32E00) to the Starter Clutch Limiter assembly.
Adventure Rider
I had posted this elsewhere on the forum and I had some trouble finding it, so i decided to re-post here and add a few pictures and explanations to help who
ever is considering a 98 or 99 model. Or someone who has one 98-99 model DR and didt do the starter gear replacement yet.
More information is always welcome, so please post down anything you guys feel that could be helpful to the thread.
You will need, 8 mm tool, new bracers for the cables, Oil, Oil Pan, maybe a new stator cover gasket so get yourself one before you start the job. and the parts
bellow.
1 - The two parts side by side, this picture i found on the web and was looking at for identifying the part in there. Starter Clutch Limiter on the left, solid idle
gear on the right.
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19/03/15 12:33
98-99 Solid Starter gear to Starter Clutch Limiter (How To) :...
http://drriders.com/topic10325.html
Page from the Clymer Manual illustrating the parts and showing the Starter Clutch limiter.
From the Clymer manual information and using the last picture i posted from the Starter side. You can already tell its the solid gear.
So if you can take a look from the starter side you can also tell which one is in the engine.
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19/03/15 12:33
98-99 Solid Starter gear to Starter Clutch Limiter (How To) :...
http://drriders.com/topic10325.html
4 - Remove the Cover, if doing it while changing the oil beware its going to be very hot, use some leather gloves or thick cotton cloves so you don't burn yourself
and drop the cover.
Watch for the Pin in the lower left of the cover and also note you will feel a resistance from the strong magnet as you pull it out.
Very Important, don't forget to disconnect the stator cables from the CDI and the bikes wiring because they are very short, I didn't disconnected them since i had
my old man to hold it for me
.
I did remove the tie holding them together near the frame. I installed it back the same way, if it leaks Ill replace the gasket.
Also there was a glob of dirt there i advise you clean before you close the cover again.
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19/03/15 12:33
98-99 Solid Starter gear to Starter Clutch Limiter (How To) :...
http://drriders.com/topic10325.html
5 - Several Shots of the Solid Gear and inside of the stator cover.
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98-99 Solid Starter gear to Starter Clutch Limiter (How To) :...
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19/03/15 12:33
98-99 Solid Starter gear to Starter Clutch Limiter (How To) :...
http://drriders.com/topic10325.html
Since the gasket was still in one piece, I Closed it with the same gasket.
Opening the case to check was very easy you only need a good 8mm socket or wrench. If you didn't check yours yet, do so.
By the way, the bike is 15 years old and has 32.311 miles on it with the solid gear. I've been using it daily for the last 2 years.
So don't assume yours is Ok just because you don't have any issues like I assumed.
I installed the torque limiter today, and followed the same procedures above to open the cover.
Took both gears out of the cover. the gear on the left shaft is going back in after the stater limiter is again on the cover. the solid gear is just a gear and a shaft.
just remove it.
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19/03/15 12:33
98-99 Solid Starter gear to Starter Clutch Limiter (How To) :...
http://drriders.com/topic10325.html
This time my old man was giving me a hand. being a professional Stator Cover stand. a very steady one by the way. he was holding the cover while I replaced the
gears, although i recommend you disconnect the cables from the wire harness and work with the cover on a workbench especially if replacing the gasket..
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19/03/15 12:33
98-99 Solid Starter gear to Starter Clutch Limiter (How To) :...
http://drriders.com/topic10325.html
My conclusion is that this is not a hard job to do and no reason to turn down a good deal on a 98 or 99 model, might even be a better deal just use it to bring the
price down!
The bike used to do a loud "CLANK" noise when I shut it off, and now it is silent on shutdown. Ill post a update on Friday if the new limiter really stopped the
"CLANK" noise on shutdown.
_________________
In Love: 1998 - DR 650 SE. Use: 100% On-road.
Now: IMS Tank, Iridium Plugs, Deluxe fuel screw, KTM needle, Scotts stainless steel oil filter, Zeta quick throttle tube, Sit & Fly seat cover, Ricor Shock (7.2
spring) and Marving Amacal Exhaust.
Soon: Ricor Intiminators.
Check: http://www.youtube.com/user/ViverComCoragem/videos
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mxrob
Post subject: Re: 98-99 Solid Starter gear to Starter Clutch Limiter (How
Bravo Coragem!
Member Servant
_________________
- mxrob -
Coragem
Adventure Rider
Post subject: Re: 98-99 Solid Starter gear to Starter Clutch Limiter (How
mxrob wrote:
Bravo Coragem!
Thank you for moving it to the correct section Rob. I hope it can be useful to someone in the future.
Im pretty happy with the job so far. Even though i opened the stator cover twice, the gasket is still working ok and not leaking at all.
Joined: Mon Jan 02, 2012
9:19 am
Posts: 668
Location: Rio de Janeiro, Brazil
Location: Rio de Janeiro, Brazil
_________________
In Love: 1998 - DR 650 SE. Use: 100% On-road.
Now: IMS Tank, Iridium Plugs, Deluxe fuel screw, KTM needle, Scotts stainless steel oil filter, Zeta quick throttle tube, Sit & Fly seat cover, Ricor Shock (7.2
spring) and Marving Amacal Exhaust.
Soon: Ricor Intiminators.
Check: http://www.youtube.com/user/ViverComCoragem/videos
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Board index Main Trail Technical Tips, Tricks & Maintenance "How To" Section
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19/03/15 12:33
98-99 Solid Starter gear to Starter Clutch Limiter (How To) :...
http://drriders.com/topic10325.html
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