I did the whole one way thing and while replacing it we had a bit of trouble gettting the starter cover back on. Eventually we loosend up the whole starter and got the cover on. I rode for a day and every thing worked great. That night I went to start it up and the starter started freewheeling(again). I noticed some oil spray around the starter cover so I figured the gasket didn't seal or something. So I popped it off and the freeking shaft coming out of the start was busted off!! I also noticed that we did not replace the dowell in the upperright hole in the starter cover when reinstalling the starter cover. The bike started at least 10 times that day with no problems and no sounds like there was something wrong. I have a new starter on the way but don't want to jack this one up to so I ordered a new billet starter cover and I will most definitely be replacing the dowell.

Any thoughts about what might have happened?

 

When you replaced the one-way, did you replace the gear as well? Did you clean up all the metal shavings? A bad gear or debry might mess up your new bearing. If your starter shaft was bent/chewed up, it sounds like things didnt line up right. Are you using a L&A or stock bearing (junk)?

 

I used an L&A Designs one way. Also replaced the gear with a brand new factory one. We made sure there was no debris at all when putting it back together. When it broke the next day, the engine backfired so that may have had something to do with it. And like I said the starter had no problems all day long , in fact it worked better than it ever had.

When putting the thing back togethter We did struggle alot to get the damned starter cover back on though. Finally we loosend the mounts on the starter so we got a little wiggle room and it slid on. I don't know how we missed the dowell though, well yes I do, it was 1am and we were leaving for Glamis at 7am. Anyhow, all my parts to fix are on the way, just want to get it right this time, I hate working on bikes.

 

the same exact thing happened to me. i replaced the little flywheel key behind the flywheel because the motor backfired and sheared it off. well i guess upon reinstaling everything something didnt line up right or something because after about the 4th start of the day. the starter was freewheeling. i figured i broke another flywheel key. but starter shaft snapped completely off!! i bought another one and am getting ready to try for round two. you say you forgot to install the dowel? whats a dowel? i also had trouble getting cover on, but dont recall any spare parts. did you forget to put it in all the way or just didn't line up right. let me know if you have any luck because i also have to do it all over

 

I just ordered the starter online for $99. It's a rebuilt one with a 1 year warranty. I should get everything I need in a week or so. I also ordered a new billet starter cover. As for the "dowell", they call it a dowell but its more like a little metal sleeve that fits in the upper right hole on the starter cover, the bolt then slides through it and it joins the starter cover to the case. I lost mine I need to oreder one from yamaha I guess.

As far as what happened when we put it back together, we just couldn't get it to line up right. it seemed like the starter shaft was almost angled up just a little. I turned it a number of times and it didn't matter. No matter what, we couldn't get the starter cover to seat right. Especially with the freeking dowell, everything has to be near perfect for it to slide on right. I guess you just have to mess with it until it works. I'll have more time and patience this time since my next trip isn't until Presidents day weekend. I probably won't get the billet cover foe 5-7 business days so keep an eye out for this post. I will bump it when I get everything.

Also if any one has any tips, please let me know. You will save my wrenches and garage walls alot of damage! >=) My nighbors may appreciate it as well.

 

i think i will take the side cover off and put it back on again to make sure its right. il also check the dowel. i got to thinking maybe the higher compression piston is putting to much torque on the starter and snapping the shaft. is that a possibility if everything goes right il be firing up the new motor with the new starter on it sunday. so wish me luck. if the starter shaft snaps off again im going to take the starter motor off and through it through the yamaha dealers front window. il let you know how it goes.

 

Did you pay 300.00+ for the starter? Yamaha told me that and I about wet myself. Gotta love Ebay!

 

no. i didn,t give yamaha 300 dollars for a part that should be 100.00. ebay. 70.00. thank god for ebay

 

HELP ME PLEASE!

OK so I just got all of the parts to replace my starter. Starter, gaskets, Dowell, and even a new shiny billet starter cover. So I yank the header off and pull the old busted starter out. I slide the new starter in without securing it . Go around and slide the starter cover on and it slides on perfeclty( I did not secure it though). I remove the starter cover and go back to secure the starter. After tightening everything back down I go back to put the starter cover on and I have the same problem as I did when I did the one way. the shaft that sticks out of the start is now angled up slightly making it impossible to get the starter cover on I would esatimate maybe 1/16"-1/8" off. I don't understand this. The only thing I can think of doing is to build up where the starter mounts with washers, that seems kind of hokey though. Does anyone have a suggestion? Is there anyway I bent the part in the case cover that the starter slides through?

I am dying here and trying to get this thing ready for presidents day weekend at glamis!!

Thanks in advance for any advice.

 

have you taken a look at a repair manual and make sure youre doing everything like it says you should? take a look at raptortranny.com that might help out as well.