Evil starter clutch! Any suggestions?
Oct 2, 2007 | 11:18 PM
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Trailblazer
Joined: Jul 2005
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Evil starter clutch! Any suggestions?
Hi,
This spring, my dad bought an '01 Suzuki kingquad 300 (ltf300) that blew it's cam chain (how an atv engine's cam chain blows up is beyond me), for cheap. We then picked up another engine for it, but it had a hole in the back of the center case. Got it cheap. So, I split the cases, replaced the broken case (a real chore with the rear diff in the case; I hate this engine). Put it all back together, got it running nice. Carb was a tad messed up, still needed to be cleaned properly. It backfired, and wouldn't run. Cam timing was way off. The flywheel key sheared. Fixed that, put it back together, it ran a little, then stopped running, and make a kind of clunking noise when being cranked with the starter. I thought I screwed up when I put the clutch side back together or something. Ended up being a starter clutch issue.
So, here's what's happening-
The starter clutch is locking up. It will not disengage. To remove the starter clutch from the flywheel, I have to pry the clutch free from the flywheel. I have a spare flywheel; the starter gear wouldn't fit in it. I managed to make it fit, but it was kind of stuck going either way, and made a pretty bad noise when I turned it the correct direction (this is on the bench). We did pry the gear from the clutch, previous to all the messing around on the bench, get the clutch working again, and put it back in. It started up, and the clutch locked up again. Anyway, I was messing around some more with it, and I cannot get the starter gear to fit in either starter clutch now. Actually, I have a spare gear, identical, and it doesn't fit, either. Both clutches are identical. As previously noted, when I finally managed to make the gear fit in the clutch, it would kind of work properly, but when turning it in the direction that it should spin free, it spun rough and made a grinding noise.
I highly doubt anyone has had this issue, but I think it's worth a shot to ask. I'm really sick of working on this thing; I'd much rather be working on a dirtbike (much simpler and easier to work on, IMO).
I appreciate any suggestions. If anyone has any clue as to what's going on, I'd appreciate your comments.
This spring, my dad bought an '01 Suzuki kingquad 300 (ltf300) that blew it's cam chain (how an atv engine's cam chain blows up is beyond me), for cheap. We then picked up another engine for it, but it had a hole in the back of the center case. Got it cheap. So, I split the cases, replaced the broken case (a real chore with the rear diff in the case; I hate this engine). Put it all back together, got it running nice. Carb was a tad messed up, still needed to be cleaned properly. It backfired, and wouldn't run. Cam timing was way off. The flywheel key sheared. Fixed that, put it back together, it ran a little, then stopped running, and make a kind of clunking noise when being cranked with the starter. I thought I screwed up when I put the clutch side back together or something. Ended up being a starter clutch issue.
So, here's what's happening-
The starter clutch is locking up. It will not disengage. To remove the starter clutch from the flywheel, I have to pry the clutch free from the flywheel. I have a spare flywheel; the starter gear wouldn't fit in it. I managed to make it fit, but it was kind of stuck going either way, and made a pretty bad noise when I turned it the correct direction (this is on the bench). We did pry the gear from the clutch, previous to all the messing around on the bench, get the clutch working again, and put it back in. It started up, and the clutch locked up again. Anyway, I was messing around some more with it, and I cannot get the starter gear to fit in either starter clutch now. Actually, I have a spare gear, identical, and it doesn't fit, either. Both clutches are identical. As previously noted, when I finally managed to make the gear fit in the clutch, it would kind of work properly, but when turning it in the direction that it should spin free, it spun rough and made a grinding noise.
I highly doubt anyone has had this issue, but I think it's worth a shot to ask. I'm really sick of working on this thing; I'd much rather be working on a dirtbike (much simpler and easier to work on, IMO).
I appreciate any suggestions. If anyone has any clue as to what's going on, I'd appreciate your comments.
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