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How To: Starter Clutch Renovation / Rotor Removal

Discussion in 'The Garage' started by zaphoid18, Jun 2, 2012.

  1. xschris

    xschris XS400 Guru Top Contributor

    Just remove all the parts that are associated with it from the write up above. Then either find the factory block off kit that was used in the 77 xs360 2-D the 78 xs400 2-E or the 79 xs400 2-F, or use a freeze plug to cover the hole for the starter shaft. I think it's a 1 5/8" there are threads on starter delete. :)
  2. JacebF

    JacebF XS400 New Member

    Does anyone know the part number for the cover gasket?? Not the little round one but the bigger/oblong one? Just did the starter clutch rebuild and mine had no gasket when I took it apart, would really like to locate one.

    Thanks in advance!
  3. xschris

    xschris XS400 Guru Top Contributor

    1L9-15461-10-00 It would be better to buy a entire gasket kit then to get just the one. Cheaper that way in the long run. Check ebay for kits.
    JacebF likes this.
  4. Myke Nytemare

    Myke Nytemare XS400 Enthusiast

    Anyone have ideas on what to jam into the rotor to stop it from moving when trying to use the extractor tool?

    I am going through all the screwdrivers that are thin enough to actually get into the rotor!

    Attached Files:

  5. xschris

    xschris XS400 Guru Top Contributor

    Bike in gear with the back tire on the ground and you should't have to hold the flywheel. Or you could use an impact gun or a strap wrench.

  6. Myke Nytemare

    Myke Nytemare XS400 Enthusiast

    @xschris a revelation!!!!!!!!! Been working with the bike on the center stand so long, didn't even occur to me..letting frustration of having a non-running bike get to me ;-) ! Thanks!
  7. Myke Nytemare

    Myke Nytemare XS400 Enthusiast

    I guess I had a moment.... The starter clutch seems to move Jo matter if the bike is on the ground or in gear :(

    I think I'll just reinstall the cover and leave it on the bike... Too much effort to remove the unused piece.
  8. Jfalconer

    Jfalconer XS400 New Member

    This is a great write up, I used it before doing mine. helped me get everything in order before I actually did it.

    I unfortunately am still suffering from a slipping starter clutch. I replaced all the springs and rollers, I did not replace the piece between the spring and roller though (that hollow cap like thing) because they appeared to be in good shape and do not seem crucial aside from protecting the spring from damage. The clutch barely engaged before and it is almost identical to how it was before I replaced these parts. I received the motor in an entire motorcycle that didn't have a title, was in pretty bad shape aesthetically but the speedo read 5,000ish miles. The oil inside it was very clean, it was just clear that it had been left outside but the engine remained sealed enough. The one problem is that whoever owned it originally snapped off the internal mounts for the kickstarter, so there is NO way to start it other than the electric and bumping (which is embarrassing).

    I dont know what to do other than take it apart again and polish the starter gear, but im not sure that more smooth would help.... Any suggestions are appreciated and welcomed. I don't want to go through another riding season having to bump my bike to get it going half the time...

  9. xschris

    xschris XS400 Guru Top Contributor

    Impact gun.
  10. Face

    Face XS400 Member

    Can I use the rotor from a points ignition engine on an electronic ignition engine?
  11. xschris

    xschris XS400 Guru Top Contributor

  12. Petew

    Petew XS400 True Believer Top Contributor

    This came at a great time for me, thank you for a great, explicit,write upon these repairs. I can breathe a little easier!
  13. I know this an old post but I'm trying to do the same thing. How difficult should it be to spin the removal tool once it's hand tight? Mine doesn't seem to want to pull the clutch off and short of using WD-40 in out of ideas. Thanks for any help from anyone still seeing anything on this thread
  14. Petew

    Petew XS400 True Believer Top Contributor

    Mine was quite hard to move once I got it snugged down, so much so that I was concerned that I might screw something up. I asked a similar question to yours, waited a bit, and decided to move forward. I put a short length of pipe over my ratchet handle for lack of proper breaker bar. I applied some muscle and it cracked. I thought the worst, that I had snapped or stripped the bolt. Upon investigation the assembly slipped easily off the rotor. I would warn you to remove it slowly so as to maintain the small pieces and springs. I was "lucky" and corrosion had mine gummed into place. I was able to clean and reinstall mine and it works beautifully. So often that " go ahead and try again" thought process has resolved things that I thought were dead ends. Good luck with your project!
  15. Thanks I really appreciate you getting helping me with this project so far. I'll have to grab a cheater bar from family. I'm hoping the starter clutch rebuild will solve my electric starter issues. Here's to hoping!
  16. Any tips or tricks on getting the starter clutch back on with that woodruff key Kinda being a pain at this point haha
  17. Petew

    Petew XS400 True Believer Top Contributor

    slow and steady is all I can say. You might try rotating the motor so it is in an easier position to work with. In the past I have used a very small dab of grease to a component to maintain its position if the key is falling out.
  18. It's not falling out its just that I can't get the starter clutch to slide onto it and engage the gear
  19. Petew

    Petew XS400 True Believer Top Contributor

    just keep at it, try steadying the clutch while you are doing it
  20. I really want to thank you for help with this. I really appreciate it.

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