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Dreaded starter clutch replacement

Discussion in 'XJ Technical Chat' started by Jetfixer, Jul 10, 2021.

  1. Jetfixer

    Jetfixer Well-Known Member

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    A quick note anyone needing to do this here is a list of things you will need:
    1. Pan gasket for oil sump.
    2. Clutch cover gasket.
    3. Shift cover gasket.
    4. Red and blue lock tight.
    5. Starter clutch spring and roller kit.
    6. Optional a new starter clutch ...I put new in .
    7. My chain guides were in good shape but if it is breaking up you will need new guides.
    8. If you do guides you will need to pull head so you will need head gasket and guide gasket.
    9. Recommend Yamabond sealant .
    10. Of course oil and two oil filters....after running engine run for short period , drain engine and change filter . The reason is any swarf in the engine will be washed out in the oil.
    Fill with fresh oil.
    11. Optional if removed valve cover gasket might need replaced.
    12. New intake gaskets.
    13. After engine is reinstalled you will need new exhaust gaskets .

    I'm sure I left something out but these were some of the things I found.

    Cheers
     
    RuhRohRaggie069 likes this.
  2. lostboy

    lostboy Well-Known Member

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    14. patience
     
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  3. Franz

    Franz Well-Known Member

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    Four torx bolts for middle drive gear.
     
  4. Jetfixer

    Jetfixer Well-Known Member

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    I should have added somethings for this task.
    1. Several large zip lock freezer bags.
    2. Sharpie marker for labeling .
    3. A couple of cardboard boxes ...draw out with sharpie the pattern of the case to keep the location of the bolts , I marked them with the size of bolts for location.
    4. Recommend , I have a set of 3/8 inch drive Allen wrenches as well a set of Torx these are real handy .
    5. Of course 10, 12 mm wrenches as well as sockets in this size as well. A 30mm socket for the clutch nut . A 19mm wrench is my preferred for the left crank shaft nut. ( a crescent wrench can be used).
    6. 2 torque wrenches inch pounds ( in/lbs) and foot pounds (ft/lbs).
    7. Degreaser / cleaner .

    Well I hope I have helped anyone having to do this
     

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  5. Jetfixer

    Jetfixer Well-Known Member

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    Went to put rotor back in housing , engine would not turn with crank bolt:mad: took it back out the torx screws were dragging on the back of the rotor , took them back out tapped plate no help screws were not flush . Broke out my aircraft sheetmetal tools ...had to blow dust off ( been in managment since 2010) took out a countersink opened the fastener holes on the plate , the screws are now flush and remounted rotor and ...engine turns over with no dragging.
     
  6. Jetfixer

    Jetfixer Well-Known Member

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    Put shift lever cover on , poured oil down cylinders left spark plugs out. Poured oil in and put starter in ...and it cranks .!!!! Sounds good to boot . Still have to put stator and cover back on , might pull engine out of the bike and this engine back in .
     
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  7. Jetfixer

    Jetfixer Well-Known Member

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    I started removing the engine out of my seca ,down to mount bolts and wiring hope I can get it out in morning maybe.
     
  8. Jetfixer

    Jetfixer Well-Known Member

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    Removed engine , reinstalling repaired engine had a bunch of problems getting it back in . Finally got it in place , got left side mounts in but had to call it a night . This has taken me 9 days if I could have worked without interruptions could have done much faster . Trying to decide if I'm going to fix the engine I just pulled right away or not.
     
  9. Jetfixer

    Jetfixer Well-Known Member

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    Oh joy when I got engine in I did not look at the drive shaft boot ...it was wedged between the drive flange , had to take out mount bolts and raise engine slightly ...but got it. Got electrics hooked up ,engine cranks over very well , down to exhaust and installing carbs .
     
    Last edited: Jul 26, 2021
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  10. Simmy

    Simmy Well-Known Member

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    You can do your spare motor in your sleep now. :)
     
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  11. Simmy

    Simmy Well-Known Member

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    starter motor O-ring
     
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  12. Jetfixer

    Jetfixer Well-Known Member

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    Now I'm mad ...put carbs on but have not put exhaust on , tried to start ...no joy have a weak spark ..think it is in the timing plate since I had it off , gave up for night .
     
  13. cds1984

    cds1984 Active Member

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    One thing I learnt from one of the overhauls I did was, to put the complete thing together, wait for the carb bowls to be full and have the battery fully charged before hitting that starter button.
    My 'learning' was from ending up with a flat battery, fouled plugs and being really pissed off.
    Clean those plugs, fill those bowls, charge that battery, put on the exhaust, enable the enrichment circuit and take a deep breath.
    It'll all be fine! (the power of positivity surely must work!)
     
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  14. Franz

    Franz Well-Known Member

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    Timing plate is fixed so it may be one of the connections from the pickups. Is your battery fully charged? Be something simple stopping it from running, usually is.
     
  15. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    The spark is a weak spark to begin with, so you may just be looking at a normal spark
     
  16. Jetfixer

    Jetfixer Well-Known Member

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    Epic fail ...trying to check everything I could think of was riding the Johnny Cash bike and had a shazam moment . Did a compression check and it was 0 yes zero on all four cylinders :eek: pull valve cover and I think I rotated crank without cam tensioner in and think valve timing is off ...I have a cheap borescope did not see any sign of valve contact with piston ..at least I hope not , so tomorrow going to check how far these are off . Live and learn if I have to will pull down the engine I just removed and for the starter clutch failed and do the deed on it ...but will know to not rotate crank .
     
  17. Franz

    Franz Well-Known Member

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    When you rotated crank you would have felt resistance if piston hit valves. Hopefully when you put tensioner back in the timing will be correct. Did you rotate the engine by hand before doing the compression check?
     
    Last edited: Jul 28, 2021
  18. Jetfixer

    Jetfixer Well-Known Member

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    Checked oh joy cams are 180 degrees out ....will have to have to reindex.
     
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  19. Jetfixer

    Jetfixer Well-Known Member

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    Re indexed intake cam , turned engine over and was smooth, did a quick compression check all around 100psi a little low but this engine has sat for close to 2 years . Have to put it all back together, this went easier than I thought it would . I was afraid I bent a valve , but so far the compression check was good . Take my advise if you do the starter clutch replacement...DO NOT turn the crank and check timing marks on the camshaft ...don't ask me how I know about this lol.
     
  20. Jetfixer

    Jetfixer Well-Known Member

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    She runs , still need to put exhaust system on .
     

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