Buster Hymen
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- Mar 28, 2006
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I'm changing out a bad pick up coils, but you can use the steps below if you need to work on your starter clutch, flywheel, stator or slave clutch master also.
First put your VMax on a work stand or center stand. You can lean it to one side if you want to minimize the oil loss.
The flywheel/stator cover is on the left and the middle gear is to the right of it. Some oil will come out when you remove both covers so have a pan ready. Also oil will end up on your exhaust so you will probably want to put a cloth on that too.
Before you start, make sure you have both gaskets. Silicone *can* be used on the middle gear cover if you want but not on the stator cover due to clearance issues.
First, you have to remove the gear shift bracket and the footrest. The bracket is held on by 2 bolts as is the footrest.
Swing the shifter assembly out of your way. I mark the alignment of the shifter to the case so there is less adjustment time when I put it back on. Remove the bolt by the lower arrow and remove the assembly. It is on a spline so you may need to do some gentle prying.
With that hardware out of the way, you can start removing the covers. However, the bolts holding the covers are different lengths, so it is wise to create some type of template to keep track of the where the bolts go back in. Here is my high tech carbon fibre one made to look like cheap cardboard.:biglaugh:
Here is the middle gear cover removed. If you are replacing your slave clutch master, it can be seen to the left of the middle gear.
Middle gear cover. I lucked out and the gasket came off in 1 piece so I will reuse it.
The arrows show 2 of the most common oil leaks for the VMax. This is especially true if you have an older one that has cloth covered wire. The oil wicks along the cloth cover and drips under the bike. I have updated mine with the non cloth covered wire.
When taking off the stator cover, the wires for the stator and pick up coil are not long enough to let the cover sit on the ground. I use my dirtbike stand as a little work table and place it on that. It's also a good height to hold your beer! :biglaugh:
When removing the stator cover, you will feel resistance from the magnets as you pull it off. And as an added joy, parts will fall out!:damn angry: The parts will be part of the gear cluster for the starter. It may be 1 to 3 gears and up to 2 support posts for the gears that *may* fall out. The arrow points to one of the gears that has slid out of place (the support post is stuck in the cover).
Here's a close up to see the post hole in the back and the gear has slid down. The gear off the starter motor is to the left.
Here is the stator cover. The one support post with a gear is stuck in it and the arrow show the hole for the other post. When putting the cover back on, have both posts and all gears set up on the motor. You can see the gasket did not come off in 1 piece so I will replace it.
Here are the pick up coils. It is held in place with 4 screws (red arrows). as you can see, when I got in there, 1 of the screws is missing!! :bang head: I looked around for it in the motor casing but can't find it.:confused2: The green arrows show the metal tangs that you bend to hold the wire in place.
Pick up coils have been removed. When reinstalling, you can put a bit of silicone around where the grommet goes through the case, but that is all that is really necessary.
Meh... camera just died... reassembly is pretty straight forward. If you made a template for the bolts, it will be easier putting everything back in. I use a bit of anti seize on my bolts.
When I get the camera working, I show a final picture of how the starter gear assembly should look.
First put your VMax on a work stand or center stand. You can lean it to one side if you want to minimize the oil loss.
The flywheel/stator cover is on the left and the middle gear is to the right of it. Some oil will come out when you remove both covers so have a pan ready. Also oil will end up on your exhaust so you will probably want to put a cloth on that too.
Before you start, make sure you have both gaskets. Silicone *can* be used on the middle gear cover if you want but not on the stator cover due to clearance issues.
First, you have to remove the gear shift bracket and the footrest. The bracket is held on by 2 bolts as is the footrest.
Swing the shifter assembly out of your way. I mark the alignment of the shifter to the case so there is less adjustment time when I put it back on. Remove the bolt by the lower arrow and remove the assembly. It is on a spline so you may need to do some gentle prying.
With that hardware out of the way, you can start removing the covers. However, the bolts holding the covers are different lengths, so it is wise to create some type of template to keep track of the where the bolts go back in. Here is my high tech carbon fibre one made to look like cheap cardboard.:biglaugh:
Here is the middle gear cover removed. If you are replacing your slave clutch master, it can be seen to the left of the middle gear.
Middle gear cover. I lucked out and the gasket came off in 1 piece so I will reuse it.
The arrows show 2 of the most common oil leaks for the VMax. This is especially true if you have an older one that has cloth covered wire. The oil wicks along the cloth cover and drips under the bike. I have updated mine with the non cloth covered wire.
When taking off the stator cover, the wires for the stator and pick up coil are not long enough to let the cover sit on the ground. I use my dirtbike stand as a little work table and place it on that. It's also a good height to hold your beer! :biglaugh:
When removing the stator cover, you will feel resistance from the magnets as you pull it off. And as an added joy, parts will fall out!:damn angry: The parts will be part of the gear cluster for the starter. It may be 1 to 3 gears and up to 2 support posts for the gears that *may* fall out. The arrow points to one of the gears that has slid out of place (the support post is stuck in the cover).
Here's a close up to see the post hole in the back and the gear has slid down. The gear off the starter motor is to the left.
Here is the stator cover. The one support post with a gear is stuck in it and the arrow show the hole for the other post. When putting the cover back on, have both posts and all gears set up on the motor. You can see the gasket did not come off in 1 piece so I will replace it.
Here are the pick up coils. It is held in place with 4 screws (red arrows). as you can see, when I got in there, 1 of the screws is missing!! :bang head: I looked around for it in the motor casing but can't find it.:confused2: The green arrows show the metal tangs that you bend to hold the wire in place.
Pick up coils have been removed. When reinstalling, you can put a bit of silicone around where the grommet goes through the case, but that is all that is really necessary.
Meh... camera just died... reassembly is pretty straight forward. If you made a template for the bolts, it will be easier putting everything back in. I use a bit of anti seize on my bolts.
When I get the camera working, I show a final picture of how the starter gear assembly should look.
