Starter clutch replacement?

[sxyryan]

I finally sorted out the carb problems with my 225DX, and had it running pretty strong, other than a little bit of smoke from the rings.

Took her out last Sunday, and put her through the paces. I love this bike in the tight twisty stuff. I came home and went to park it, and it stalled (unusual) and made a strange noise. I hopped off, pulled the rope, and it would barely turn over. After a bit of swearing because I thought the oil pump went or something along those lines, I tore into her and found when I removed the starter motor, the engine turned free once again.

I tore the thing apart, aiming for the starter clutch. I got in there, and find two of the allen heads busted off, one still intact. check out the damage in the following pictures. Everything else seems damage free, but I plan on looked through it all again just to be safe.

Should I replace the clutch? Or the just the screws? The previous owner was the last one in the motor, having replaced the stock one with a used donor motor after a seal or bearing went in the stock motor (I can't remember what he said). The clutches and stator and similar bits were transplanted in the motor swap. I assume these bolts were not tightened to spec and the manual mentions loctight, and there is no evidence of anything on the threads. The third bolt wasn't broken but you can see the damage to parts of the thread.

Here is a picture, with more in the album link following the image. I can take more if anyone needs some.


http://s202.photobucket.com/user/sxy...Yamaha%20225DX

Thoughts?

[Ghostv2]

That is the same exact thing that happened to my brothers, same exact model and year. Except i didnt tear into the motor, i sent it to my neighbor to get rebuilt. Smoked like a cuban cigar, among other little things.

[atc007]

This is kind of a Yamaha thing, 225,YFZ,Warrior,Raptor,a lot of problems in that area. Take the one way and apart and measure the specs on everything. Replace what is worn,loc tite the new bolts on assembly and all should be well again.

[sxyryan]

Well, everything seems within spec, so I ordered some new bolts and some loctite. At least Now I know why my electric start never worked. I never looked into it as this thing is stupid easy to pull start.

Interesting you mention it as a Yamaha thing, I had a Warrior that made some similar sounds (though not nearly as bad) right before I got rid of it. Live and learn I suppose.

Anyway. Fingers crossed!

[Dirtcrasher]

"Well, everything seems within spec".

Use a micrometer and inside telescopic gauges to make sure it's in spec.

Any machine shop would be glad to help for short or no money.....