Starter Sprag Clutch issues
 

I started having a problem with my starter clutch recently. engine is a 163FML 2007 SunL atv.

My atv would not start after i shut it off the other day. the starter just spun. i push started it and drove home.

after cool down, the starter would still just spin. didnt turn the engine over.

I pulled the flywheel cover to see what the problem was. I noticed that the starter clutch(sprag clutch) was spinning freely in both directions.... it only supposed to go one way.

i used my impact wrench to remove the flywheel bolt. when i did, i noticed that the sprag clutch was now working perfectly! yay! i thought maybe something got stuck in it and the impact got it loose.

i put the quad back together and drove it the next day. the starter was working great. after getting home and shutting the atv off, i tried to restart it. the starter just spun.... i removed only the flywheel nut cover and used my impact on the bolt for 1 second. then it worked like it should again and the starter engaged.


has anyone experienced this issue? how hard is it to replace the flywheel and or start sprag clutch?

below are pictures and videos
the initial problem

https://www.youtube.com/watch?v=LZFY...nfSLYvv0PvKlpw

after i impacted the flywheel bolt it was normal

https://www.youtube.com/watch?v=jXg2...nfSLYvv0PvKlpw


http://i536.photobucket.com/albums/f...ps6d557fb9.jpg
http://i536.photobucket.com/albums/f...ps8ceea142.jpg
http://i536.photobucket.com/albums/f...ps2090ebae.jpg
http://i536.photobucket.com/albums/f...ps1ff72f45.jpg


This bolt was very tight. I used my impact to loosen it and remove it. Then re-installed . I did not remove the Flywheel http://i536.photobucket.com/albums/f...psa4737ac4.jpg

Universal "9" http://item.taobao.com/item.htm?id=38702236969
How to install :
http://gd1.alicdn.com/imgextra/i1/83...!839374980.jpg
1. Apply thread locker as picture (too much WILL had difficulties when un-bolt !!!)
2. As pic but NOT stone tight yet because flywheel hole maybe bigger than normal (un-balance)
3. Re-install rotor / Check movement are OK.
4. Tighten the bolts. Re-check everthing is OK.

Thanks for the input, HB.

I've never seen that specific symptom, but it makes sense that the one-way clutch bolts backing out is the cause. Loctite to the rescue!

Starter clutch ALWAYS need thread locker. A guy ended up as http://www.mychinamoto.com/forums/showthread.php?7142 when changing parts.

Typical "CG" family uses http://item.taobao.com/item.htm?id=15493827363
3-in-1 / 2-in-1 / holder ... http://shop35604947.taobao.com/category-674194625.htm
---
Non-std solution when special tool (puller) don't work. http://translate.google.com/translat...t_258826_1.htm :ohno: 3 jaw + mallet

Are you saying that a lack of threadlocker can shear the woodruff key?

That one looks like it will do. Can you measure your flywheel to be sure?

I recommend some lube on the threads before use. The tool steel isn't the best, and it can strip easily.

BTW, if yours is the model with RH threads in the flywheel, a metric bolt of the correct size will pop the flywheel off.

Thanks I'll remember that.

I ended up going with these 2 tools.

http://pages.ebay.com/link/?nav=item...336233&alt=web

I drove the atv for about 4 hours today on some trails and around my land. I had the problem intermittently. When it gave me the problem, I popped off the 4 some cover screws and just impacted the Flywheel bolt for a second. Then it would start right up. I'm excited to get the tool in so I can get my quad ready to take hunting.

That's a fair price for two tools.

flywheel clutch
 

On the back of your flywheel... there are rollers.. if these rollers get stuck they will not fly outward t o catch the shaft to turn it... remove the flywheel... with your tool.. and check the rollers for flat spots.. this is the problem.. make sure they look good.. this is how the motor turns over when the starter turns it... as the starter gear is what causes the motor to turn to start.. and then stop turning when the motor is running and you release the starting motor from trying to start the motor.. there is no bendix like a car starter to kick in & out

Thank you for the great reply! As soon as I get my tools in the mail. I'll take lots of pictures of the procedure