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Major Starter Clutch Failure...what caused it?

2.8K views 6 replies 2 participants last post by  BGoodwin22  
#1 ·
As the title states, starter clutch on my Gen3 came apart yesterday. Just got it back together and was doing some checks before taking it to the dyno. Had started it up a several times to check for leaks, bleed coolant system, adjust CCT, etc. After installing the chain, plastics and some other things I went to fire it up to put it on the truck. Started to turn over and then there was a loud clunk. Tried it again with the same result. Third time I tried bumping it, it just sounded like the starter was spinning and not engaging with anything. Pulled the side covers off to find this...

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The starter clutch case had several cracks allowing the one way clutch to spin without turning the motor over. Anyone have any idea what would cause this besides it just being a POS part? :dontknow: Talked to the local wrench/machinist and he said he had never encountered it on any newer jap bikes and it just looked like a material failure. Didn't know if it could have been due to something like the cam chain being too tight or bolt being overtightened, but I'm 99% sure neither of those was the case. Motor still turns over fine by hand so that makes me feel a little better.
 
#2 ·
"just got it back together"...?

What does the inside of the clutch assembly look like?....if a foreign piece got in there it could have bound up and made this crack from the inside pressure forces.
 
#5 ·
Disassembled the starter clutch, couldn't find any foreign material. The "spring" type piece that goes around the clutch was broke, but i dont know if that let go before or after the case cracked and spread.
 
#7 ·
Yea wasn't too expensive and its easy to get to. And since im gonna be waiting for parts for a few more days I pulled the valve cover off to make sure nothing happened with the cams or valvetrain. Everything looks good there so im going to put it back together and hope for the best.