Bolt size

[gamorg02]

Vaseline? Hm, might work but I dont recall of ever doing this.

Once a guy came to me talking about a leak he couldt fix. He was torquing
the bolts tighter and tighter so finaly he broke 2 of them. I bealive it was the clutch cover. After removing broken bolts, i've checked that cover with clearance meter placing it on a good pice of glass - more then 1mm in some spots - that much could not be fixed. He told me did a DD upgrade some time in the past and reused the gasket.

Besides giving him another cover(trown the old one into scrap bucket) i also showed to him how to make a gasket by yourself.

+/- 10% of torque is ok. More then 20% can brake the bolt.

I use vaseline so the gasket could potentially be re-used. Ill wet it down next time. 10% is def my max I agree. Already have one helicoil on the clutch cover (that was to spec too)

U think the covers get warped? Or does the factory not care? It seems they don't leak until someone takes them off then can't seal them again.

 

[satariel666]

No, from the factory they are straight and under 0,1mm - hers the reason you need a gasket.
I use to ride a moped called SIMSON years ago and the engine was assembled without any gaskets - only sealant. But it was a 50cc small engine...here its diffrent.

I bealive they start to leak mainly becouse the improper torquing sequence.

 

[RaWarrior]

I'd heard of the vaseline trick, though I thought it was just to make disassembly later easier....don't have to pry and work at the covers to get them off, and I had to do when I originally removed my stator and gear covers(fairly sure they hadn't been off since it was made in '97).

The bike didn't leak a drop of oil until I took the covers off....but even with a fresh gasket and thoroughly cleaning the surface, it leaked when I put it back together, and it took me months of trial/error (I had the cover on and off probably a dozen times) before I finally solved the leak by just pressing the covers to a big disc sander. I tried double gaskets, gasket+a variety of sealants, sealants only, ect. Nothing worked, or not for very long.

I tightened the cover bolts using a 3/8 drive ratchet, gripping the ratchet at the head and tightening as much as I could that way....that's always been my trick for tightening "sensitive" bolts.

 

[Miles Long]

Prussian Blue contact check works very well to determine if parts are mated well. It comes in a tube, has the consistency of toothpaste, does not harden. Not to be confused with machinist's layout dye, that drys, and is used primarily for scribing.
To use, a thin layer is dabbed on one surface only( in this case, the engine mating surface) then the cover would be put in place, of course without the gasket. Only a light tightening of the bolts would be required, much less than the final assembly torque.
The cover is then removed. the areas making contact will have bluing on them. these areas are then lightly filed off, bluing is again re-applied/smoothed out on the engine, and the process is repeated, until 100% contact is achieved between the mating parts.
This process is not intended to insure absolute flatness of either part- but to provide a gap-free mating surface.

 

[CustomMax]

Ok, finally got to take it all back apart and the dowels are not bound up but I did notice I can turn the shaft from the starter with little to no resistance either way and once all back together you can feel it in the starter. Damn! Is this a common occurrence when those bolts come loose? I guess it didn't help when I'd keep touching the start button quickly to see if it would engage when the bolts were loose. It would first start to catch then spin free but I'd let off right away so as not to have it grind. Also noticed a few shavings on the magnet drain plug. Should I be concerned with that or whats the next step to be sure there's not more in there? Any help appreciated, Ed

 

[RaWarrior]

I'm not quite sure I follow you. What do you mean "feel it in the starter"? Like feel it grabbing, slipping, grabbing, slipping? Press the button, motor cranks momentarily, then it lets go and you get a nasty sound?

Do you mean there's no resistance when turning the gears either way by hand? Should turn freely one way and instantly lock against the engine when reversed. If there's play both ways the starter clutch is shot.

If you're positive there are no cracks or damage to the clutch ring, you might try replacing the springs and pucks in it. The "bag of rocks" is one of the pucks wildly chattering around, either from it not being pressed against the gear wheel lip(missing or weak spring) or the clutch ring being loose and allowing the whole thing to shift(thus not pressing it against the lip). Also inspect the gear wheel lip that slips inside the clutch for scrapes or damage.

Good news is the flywheel will be total cake to remove now. Probably won't even have to hit it.

 

[CustomMax]

It's when I spin the starter shaft with the other gears and pins off. The starter has little to no resistance either direction the flywheel spins one way freely but stops the other way and no bag of rocks sound since I tightened the starter clutch bolts. But I'm pretty sure its the starter.

 

[[email protected]]

Check out this page for some starter clutch help.
http://www.iowaz.info/cycle/vmaxstarterclutch.htm

 

[CustomMax]

WTF!!! Pulled the starter trying to find the obnoxious sound when I hit the start button. And the starter is fine, even took it to a rebuild shop and they tested the shit outta it. So back to pulling the stator cover AGAIN, pulled the flywheel, AGAIN. Checked everything, now I am noticing when I put the rear starter gear on behind the starter clutch and after lining up the keyway I slide it all back on the crank and tighten the center bolt ( anyone know the torque specs for the big bolt?) anyway noticing the rear starter gear will still move about an eighth inch away from the flywheel and THAT'S where the sound seems to be coming from like it's somehow partially missing the gears from the starter. It doesn't show a washer but seems like one should go behind the starter gear or am I not getting the flywheel on all the way? What the hell am I doing wrong or missing? I just can't figure this out. Any ideas?