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Message started by verslagen1 on 12/13/13 at 13:03:11

Title: Starter Torque Limiter Repair
Post by verslagen1 on 12/13/13 at 13:03:11

I have helped out a couple of times in putting these back together.
For those of you that face this daunting task, here's how to do it.

Here's the kit plus an extra washer that just came in the mail (hope you don't need that washer somewhere)

Look at the witness marks on each side of the gears and washers and you can reassemble w/out too much problem.

The small gear has a counterbore that the C clip on 1 end of the splined shaft has and it should nest almost completely in.

Then stack up washer-fiberdisk/gear/fiberdisk/gear/fiberdisk/gear/fiberdisk-washer/3xspring-washer/bushing on the splined shaft.

And that's the easy part.

Get a vise and 2 identical height sockets and a 3rd to fit on the end of the shaft like so...
See IMG_0168.JPG
I did this vertically so it can be done single handed and used a magnet to hold 1 socket in place while I positioned the other.
Leave enough room between the sockets and the shaft to install the retaining ring.

Now squeeze that puppy till the groove is visible and install the ring.
See IMG_0167.JPG

Unfortunately, the guy sent the wrong retaining ring along with an extra washer.
So I couldn't finish it off, but there you go... that's how to put the genie back in the bottle... if you have a cork.

What some guys will do for a laugh. ;D

Title: Re: Starter Torque Limiter Repair
Post by verslagen1 on 01/23/14 at 22:13:46

rings

both retaining rings are standard items.
you can get them from any of the retaining ring mfgr's

truarc 5100 or D1400
http://waldestruarc.com/clip_images/5100external.gif

truarc 5103 or M1800
http://waldestruarc.com/clip_images/5103external.gif

Title: Re: Starter Torque Limiter Repair
Post by slickiverson on 02/11/14 at 17:41:25

Should there be any washers that go between the unit and the crankcase/both ends of the shaft?

Title: Re: Starter Torque Limiter Repair
Post by verslagen1 on 02/11/14 at 17:54:16

637C79737B79667562637F7E100 wrote:

Should there be any washers that go between the unit and the crankcase/both ends of the shaft?

yes, there should be a washer on both ends of the torque limiter gear.

Title: Re: Starter Torque Limiter Repair
Post by kochic on 05/30/14 at 06:43:35

I know its an old post but i just received a starter clutch bought on ebay.
I dont know why but the guy messed with the snap rings, I need both of em to install it.
Is there a place online i can buy these two without aving to buy a box of 25?
Thanks,
Marc

Title: Re: Starter Torque Limiter Repair
Post by verslagen1 on 05/30/14 at 07:13:05

You might find them locally at a bearing house and you could try an auto store.

Title: Re: Starter Torque Limiter Repair
Post by S-P on 05/30/14 at 14:23:35

34303C37363C5F0 wrote:

Marc, I found some at Ace Hardware.

Title: Re: Starter Torque Limiter Repair
Post by kochic on 05/31/14 at 10:36:00

I will check monday at work, if I dont find any i will take a look at the canadian tire store.Hardware stores around my place stock only grade 2 bolts and nuts with very few metric bolts in 8.8
Thanks,
Marc

Title: Re: Starter Torque Limiter Repair
Post by Dave on 02/25/16 at 05:05:20

OK....I am going to be a troublemaker here.

I bought a torque limiter without the snap rings.....I have no idea why someone would think it is a good idea to take this thing apart? It is useless in pieces!

The D1400 and M1800 are a series of snap rings - but you also need to know the size to complete the part number.

Here are links to the chart....what size of ring do I need?

http://waldestruarc.com/pdfs/M1800.pdf
http://waldestruarc.com/pdfs/D1400.pdf

Title: Re: Starter Torque Limiter Repair
Post by verslagen1 on 02/25/16 at 07:25:05

1st thing to recognize is S and G are different.
I would measure G and get the ring accordingly.

Yes I wouldn't take it apart if I didn't have to.
But, sometimes it gets stuck in the case and if you couldn't wiggle it out...
But I'd also have the good sense to keep the rings together with all the parts.

Title: Re: Starter Torque Limiter Repair
Post by Dave on 02/25/16 at 08:14:31

I had a bit of trouble trying to measure "G"....my calipers are too fat to fully seat into the bottom of the groove.

I will give it another go tonight....now that I have the tables to compare the measurements with.

Title: Re: Starter Torque Limiter Repair
Post by verslagen1 on 02/25/16 at 08:24:11

If you're going to a bearing store for the rings, pretty sure they would have a blade mic to measure with.

I'll try to remember to locate the one I have and measure it too.

Title: Re: Starter Torque Limiter Repair
Post by Dave on 03/09/16 at 18:12:42

I wasn't able to figure out what I needed without taking a torque limiter apart that had the correct clips in place.

The end with the big washer needs a 14mm clip.'

The end of the shaft with the sprocket has a "keeper" made from 2 semi-circle pieces.

I found that the 2 piece ring can be matched with a 1/2" snap ring, and I was able to cut the ends off 2 clips and make the missing pieces (only one is shown in the photograph). I used a Dremel with a small cut off wheel to cut the ends off the ring, then a small stone wheel to smooth the cut ends.

http://i65.tinypic.com/2n84qc7.jpg

Title: Re: Starter Torque Limiter Repair
Post by och on 10/08/22 at 05:32:05

Hey guys, resurrecting this post. I am another victim, perhaps of my own stupidity. I don't know how the sprockets on my gear got out of alignment, so I couldn't install the idler gear. I tried to align the sprockets but they wouldn't budge, so I took the gear apart and now can't assemble it.

What is the proper way of aligning these sprockets, and is it common for them to get out of alignment?

The photos in this thread are gone, hoping you guys still have them and might be able to reupload. I suggest imgur, they seem to keep photos forever. Specifically looking for the photo with the vise trick. I understand it, but would be nice to get a visual.

Title: Re: Starter Torque Limiter Repair
Post by verslagen1 on 10/08/22 at 06:58:05

I reattached my pics, but I think your question refers to the other post about 4 speed upgrade.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1288911670/0

Title: Re: Starter Torque Limiter Repair
Post by och on 10/08/22 at 07:04:15

23302726393432303B64550 wrote:

I reattached my pics, but I think your question refers to the other post about 4 speed upgrade.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1288911670/0

Thank you so much, just like I thought with the sockets. I will reassemble it in my shop next week, provided I can find the snap ring locally - I bent the old one and I'm not sure if its reusable at this point.

My question is about this gear, it consists of 3 separate sprockets/gears, and they are all supposed to be aligned, but somehow one of them was misaligned, rotated half a tooth from the other ones, and so the idler pulley didnt line up because its the width of all three.

I'll snap some photos later.

Title: Re: Starter Torque Limiter Repair
Post by verslagen1 on 10/08/22 at 07:26:53

The gears can be rotated after assembly to align them.

Title: Re: Starter Torque Limiter Repair
Post by och on 10/08/22 at 07:32:26

6A796E6F707D7B79722D1C0 wrote:

The gears can be rotated after assembly to align them.

Here are the photos, the first photo shows how they are supposed to be all aligned, and in the second photo how they were out of alignment. I have no idea how they became misaligned, but when I opened the cover and the idler gear came out, I couldn't put it back in because the gears in the torque limiter gear were out of alignment. I tried to spin them by hand and with a screwdriver, unsuccessfully, and so the genius in me decided to take it apart.

http://https://i.imgur.com/sJd8I1t.jpg

http://https://i.imgur.com/IT90PvB.jpg

Title: Re: Starter Torque Limiter Repair
Post by och on 10/08/22 at 12:53:10

I was able to reassemble it without a vise, used two pairs of visegrips. Will need a vise to align the gears.

http://https://i.imgur.com/dkKut38.jpg

Title: Re: Starter Torque Limiter Repair
Post by och on 10/15/22 at 22:05:14

Another question, after I reassembled the gear and reassembled everything on my bike, there is a screeching noise when starting. I wonder if it is the torque limiting gear producing it. I cleaned all the clutch plates with carb cleaner so I could handle it, and perhaps the lack of oil between the plates causing the noise. I assume over time oil should penetrate between the clutch plates and the noise should go away?

https://www.youtube.com/watch?v=hk1_s2rXt6Y

Title: Re: Starter Torque Limiter Repair
Post by verslagen1 on 10/15/22 at 22:49:15

I have no idea.