Changing A Starter Clutch For Beginners

1st get it confirmed that it is the clutch !

Mine was going clkclkclkclk. Select 1st gear, and mark gear change spline to match the gear shift bar and remove.

Then drain the oil, draw a sketch of the clutch cover on a piece of cardboard, and as you remove the cover studs,

push them into the appropriate position on the card. They won't get mixed up this way.

Remove side cover and cover up,( watch out for the cog falling off ), to undo the clutch retaining bolt, I used a socket and the

long bar, give it a whack with a rubber mallet , it took three goes and remove.
Now you need a puller!

I found one on e bay for £9.00  I had to grind down the drift part so it fitted the shaft ( mine was too big).

Fix it on using the three bolts & washers. Now get the wife ( very useful at times ) to stand on the brake pedal, and apply the

brake lever as well while you turn the puller. This stops the bike moving,watch out for the lot falling out!

Now remove the woodruff key ( that funny shaped thing in the groove!), use a small electric screwdriver, then

the idler gear, and the thrust washer ( don't you just love that).
My rollers were multi angled, and the idler gear was mullered  ( to coin a northern phrase !), along the edge.So a new idler gear at £31.19, new rollers

£7.21, new springs £2.94, new caps £8.80, gasket £10.23.
Total, with discount at Webbs, £51.38, not bad.

Don't forget the oil, if you can, move the shaft with the woodruff key to the top position ( it's easier to put back)

Replace the washer and idler gear,and the woodruff key ( I used a toffee hammer to get it in better)

Replace the caps on the springs, push one in the hole ( spring 1st ) hold with a small screw driver, and insert the roller, 3 times.
Now the awkward bit, line up the groove with the woodruff key, once I got it there, I gave it

a gentle whack with my trusty rubber mallet. Screw the bolt back on using the wife to do her brake dancing

trick. I suppose you should use a torque wrench, but I didn't have one ,so I tightened it up well !

Now put the small shaft and the cog which connects the starter motor to the starter clutch on 1st,

or you won't get the cover on. Gasket on ,cover on, studs in ( correct places due to diagram ),  oil up, job done,

and a fortune saved.
Colin.
P.S. Mine started 1st time, no throttle, but only lasted for 5 miles, as some

BASTARD "T" boned me and wrote my bike off, giving me a fractured foot and three cracked ribs.

Thanks to the following bike shops that helped and also offer 10% discount to members

Webbs of Lincoln, Portland Street, Lincoln

D & J Bike Spares, Portland Street Lincoln. 01522529435

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