OK....What's failed and what's the procedure? Bike started OK first thing........ Went to re-start it.........No go........connections AOK........ I can hear what sounds like the starter spniing without engaging...........but not that loud. I don't have a clue where to start on the SS engine. Any clues, please?
sounds like the starter sprag (one way bearing in flywheel hub) has lost its spring tension, common problem, put the bike in gear rock it bacwards a few times, the try to start, may hook up, if problem persists bearing will need examining. Bearing may not neccesarily be knackerd, posibly the spring omly, can be shortened & retensioned.
Just tried rocking it a bit, but maybe the battery is now a bit low.....will try again when I have charged it up. Thanks.
Well......It looks as though I have a job on my hands which is a worry because the skin is already torn in several places..... ....dammit, dammit, dammit. And bugger me, the bloody neutral warning light switch had packed up as well.......(might have got that working just about....the plunger was sticky for some unknown reason) F-me, I'm waspy today and likely to get waspier..........:Rage:
If it is the sprag don't worry too much. So long as you don't keep hammering it and damage the flywheel etc it can fixed for a tenner and about an hour's work if the bottom end is how I think on the SS.
I can't even start the bugger to hammer it! I guess I'm going to have to work out how to get at it...........been studying the manual and the parts diagram, but it looks a lot more than an hours work to me.....
Well I've just done my 996 twice! Drain oil, SS is air cooled so you've not even got coolant to worry about. Remove gear lever. Disconnect any wiring to the to/from the side casing. Electric screw driver to undo all the bolts. Cover off. Electric impact wrench to undo flywheel nut and behind it is the sprag. Pop that out. Fit new spring. Put it back together with new sealant. An hour. Give or take. This is where someone tells me the SS bottom end is totally different to a 996 and I've wasted someone else's time on here.
I know the 750 is a bit different to the 900, but I guess all much of a muchness..... Apparently it is possible to do it with the biked leaned over to the right so the oil is not lost, but seeing as I don't have an electric impact wrench, I would have to keep the bike upright, in gear, brakes on with the front wheel against a wall and a long bar on the nut.......at least I think that would work.... Also, it seems that the existing spring can be shortened by approx 12mm - 15mm ....... Alternatively, a new KTM starter sprag can be used on the 900, but is that the same as the 750....I don't know....
Al, alot of things can be done leaning it over on its side and rather than in gear on the brakes etc, i use a gear jammer, available on eBay. Or a small price of ally to jam it all up just enough to allow the nuts to be undone
Is it possible to get a new spring and which Loctite should I use? 601 seems to be discontinued.......I have 638, 648 and 641.....perhaps they are a bit too strong??
If you're near Brum you can borrow my tools. I used some red loctite we have at work, but I didn't use much as there was none on in the first place and it was still FT! Bought the elec impact gun for £70 only for this job. It's only the cost of an hour's garage labour but now I have the tool until I break it. I used the spring from a 50mm fork seal. Just wind the ends of the spring in a bit to stop it popping apart, like my first attempt did.
This December 2014 issue of Practical Sportsbikes has a step by step guide on how to replace the sprag on a 900ss Practical Sportsbikes December 2014 Kawasaki H2 Honda RC30 Ducati 916 GSX-R750 | eBay
I have an impact gun at work if you need my old friend, but what size is the nut? Think I've got upto 24mm.
Nowhere near Brum............but I now have tool which just cost me £68..........just need a 30mm impact socket (assuming it is the same size on a 750)........ I have a few 40mm and 41mm diameter fork seals, so I expect I will have to shorten the OEM spring instead. The OEM one screws together as far as I am aware (so as long as I don't cut off the tapered end!)......I can loctite the join with some 638.....(or heat resistant concrete)
Just bought an impact gun......need the socket (size unknown to me at this stage)............You could of course assist and collect your carbon tube for nought at the same time.......
The wife was on about me popping to B&Q to get a blind, might be able to combine the two. I haven't got a 30mm impact socket though, do have a 30 normal one.
Cover is off.........nut is undone..........didn't expect the nut and washer to be a one piece affair; IE flanged nut......... I expected a tab type washer, but there isn't one. Anyway, it looks as though the nut relied on some tough Loctite to keep it tight..........which has somehow got onto the shaft and keyway, so getting the flywheel off is going to be a pig.
