79 XS400 Starter Clutch repair, but no go!

[delma]

I recently replaced my starter clutch, the original one was making the tell-tale grinding, rattling noise when hitting the start button and not grabbing the drive shaft.

Yet, after replacing with brand new springs, caps and pawls, purchased from Yambits here: https://yambits.co.uk/xs400-starter-clutch-repair-kit-p-11137.html, it didn't do a thing to remedy the problem. Went to try the new clutch, hit the start button and same issue; grinding, rattling and only the occasional grabbing of the shaft.

It seems when the sprocket, for the chain from the starter motor, is closer to the flywheel it grabs more often. But it moves slightly back and forth on the shaft between the guide.

Am I missing something? Could there be another issue here?

Thanks guys, any help is appreciated!

 

[BBS360]

The woodruff key is in there, right?
Last picture in this post: http://www.xs400.com/threads/how-to-starter-clutch-renovation-rotor-removal.7989/

 

[delma]

Yes, woodruff key is still in.

I’m actually sitting here now reinstalling the flywheel. I did a recheck of everything, made sure there was no obvious wear on the sprocket, etc. Just got the flywheel back on, after fighting the key, and about to torque it down again. All looks good from what I can tell.

 

[delma]

Thanks for the reply BBS! A quick update, after getting it back on it worked great for about 10 or 12 cranks, then back to its old tricks.

At this point, no clues. Thinking a new sprocket is in order.