FZS600 Replaced Starter Clutch Cover and now won't start...

[Nick H]

Hello,


I replaced the starter clutch cover and gasket today but now the bike won't turn over when I try to start it. I had a bit of a struggle getting the bearing out of the old cover and ended up cutting it out, but worried I might have damaged the bearing.


However, the bearing spins smoothly, and the gears turn when turned by hand. Just when I bolt the cover back on and try to start the bike it just clicks.


Is it possible the gears won't turn if the bearing isn't 100% flush with the cover? Any other ideas would be very much appreciated 


Thanks


Nick

[unfazed]

Did you disconnect the starter motor lead or something simple like that before doing the job?
If the bearing was fully home and cover went back on easily then all should be ok internally.
There is nothing really that can go wrong inside the cover, if the bearing was in crooked then the cover would have been difficult to put back on.
If it is just clicking then it sounds like the starter is not turning.
Remove the cover again and remove the top idler gear, with ignition on thumb the starter button momentarily, you should see the starter spinning at the top.
Spin the bearing in the cover to see if it is running freely.
Is the battery ok and fully charged?
Have you any pieces left over? 
 

[richfzs]

When you say it just clicks - where from?

Sounds a candidate for a dud battery that isn't able to hold the relay closed (which then makes the clicking sound as it oscillates between closed and open)

[Nick H]

Motor lead definitely not disconnected and no parts left out that should have gone back in.


Will try taking the cover off again and see if it spins


Battery is fully charged but will stick on the charger over night just in case and try it in the morning.


Click is coming from the starter motor


Thanks for your help, will keep you posted 

[Nick H]

*Update


Click is coming from the offside, under the seat next to the battery. One click when starter button is pressed and once when it's released

[unfazed]

That is the starter relay/solenoid click you hear if the battery is low.
Was it starting ok before you changed the cover?
Has the bike been idle for a while?

[Nick H]

Bike was starting fine before I changed the cover and is used everyday

[richfzs]

doesn't sound like a battery issue, if its closing on button press, and opening on button release. battery issue would see it cycling constantly.

summat else, but outside my ken I'm afraid!

[unfazed]

What richfzs is correct, it would be chattering with a dodgy battery but clicking if you have a dodgy connection. Your best bet is to do what I suggested in my first post, but check all the connections just to be sure before you take anything apart again. charging the battery will do harm, it just rules it out as an issue.
The bearing is for the end of the starter motor shaft to support it when spining the idler gear. When you take off the cover ensure everything is fitting cleanly and all the cogs are engaged. The cover should go back on without much force, just maybe a tap of the side of fist to seat it over all the shafts and dowels.and should be flat agains the crankcase before tightening the cover bolts. What you could check is if the bearing is in all the way and straight by measuring the depth all roud the cover edge and maybe check the old cover as as to how far in the bearing was and measure the depth the  bearing is in the new cover.
 

[popeye72]

not sure if this will help i get this fault intermitently, press the button and  just a single click, press a few more times and eventually she turns over, has happened every now and again for about ten months, im guessing its a loose connection somewhere, i checked everything i could, didnt find anything obvious but has not done this for two months now. long story short check all connections could just be dirt

[keno]

Had to replace my starter clutch housing when i had a crash 2 years ago.
Best way to get the bearing out is stick the casing in the oven for about 10-15 minutes then take it out and tap the back of the casing with a rubber mallet and bobs your auntie out it comes.
To put it into new casing put the casing in the oven cook it for a few minutes and put the cold bearing in without any hassle.But dont forget the casing will be HOT.

[oldmotherfoccer]

***From Deefer666***

Did you replace the gasket on that casing? It provides just enough clearance for the starter gear to turn. If you replace that casing minus the gasket the gear is pinched and therefore will not turn. The clicking is the starter relay giving way because the motor simply cannot turn.... Simples

[Deefer666]

Yeah what I said!

[His Dudeness]

Yeah what I said!

yeah take off the cover and if the bike starts with the cover off then the gasket is your problem. did you re use your old bearing? re-using old bearings is a mistake imo

[Nick H]

*UPDATE*


Took off the cover again and the gears were turning and bike was starting so had to be the pressure of the cover on something stopping it moving.


I managed to get the bearing in a bit more using Keno's oven trick and it solved the problem 


Thanks for all of your help! Much appreciated