1999 yamaha big bear 350 2wd grinding noise driver side????

[Colasonojon9]

Okay havnt been able to solve previouse post about carb because before i could my starter locked up, ended up having to remove guts of starter to be able to use pull start, too much resistance with guts still in starter. Finally got it to start after this and installing air box and it started good about the third time i pull started now there is a nasty grinding sound on driver side seems like behind clutch adjustment going to tear down tomorrow and take a look any ideas?

[davefrombc]

Likely  something  in the   gearing for the  starter.  That would  be  why it was  locking  up  with the  starter in place.

[Colasonojon9]

On 11/25/2017 at 10:11 AM, davefrombc said:

Likely  something  in the   gearing for the  starter.  That would  be  why it was  locking  up  with the  starter in place.

Okay i think this may have been partly human error on my part. I took the casing off the left side and one of the starter idler gears just fell out. I could be wrong but when i took the innerds of the starter out because the magnets inside the starter were swolen and causing the starter to clack and make alot of noise. I put the rest of the starter back in so it wouldnt leak oil. Without that piece inside starter would it be possible for one of the idler gears to fall out making said grinding noise i attatched photos and i dont see anything else that could be making that noise. I will be ordering a new starter tomorrow along with a new gasket for the cover, please let me know if im correct and headed in the right direction thanks

[davefrombc]

I don't  think  the idler  gear  could  fall  out  without the  cases  being split apart.  If   you  couldn't find anything else loose in there  that  could  have  fallen  down  and interfered  with rotor  and one  way  clutch  behind  it . I  don't  know where  the noise  would  have been  coming from..  As  I  said, I've never  had to tear one  apart,  so  I can  only  make semi-educated guesses  from  my  automotive experience.  Try  rotating  the  gear  train  that  makes  the  clutch  engage  to   start  the  engine  and  see if  you  notice  any   noise or roughness there ..  I  doubt  it  will  engage  the motor  and  lock up  to  start  since the  rotation speed would be  so  slow  and  I  think the  one way  clutch  would  need a  fairly  fast rotation to  engage.

[Colasonojon9]

On 11/26/2017 at 9:12 PM, davefrombc said:

I don't  think  the idler  gear  could  fall  out  without the  cases  being split apart.  If   you  couldn't find anything else loose in there  that  could  have  fallen  down  and interfered  with rotor  and one  way  clutch  behind  it . I  don't  know where  the noise  would  have been  coming from..  As  I  said, I've never  had to tear one  apart,  so  I can  only  make semi-educated guesses  from  my  automotive experience.  Try  rotating  the  gear  train  that  makes  the  clutch  engage  to   start  the  engine  and  see if  you  notice  any   noise or roughness there ..  I  doubt  it  will  engage  the motor  and  lock up  to  start  since the  rotation speed would be  so  slow  and  I  think the  one way  clutch  would  need a  fairly  fast rotation to  engage.

Ok so installed my starter works fine also after reassembling the grinding is gone but there is still a clack that has been there only hear when turning over and when engine stops i think i read where this is the one way bearing i have a short video of the sound its louder in person

 https://youtu.be/ePrM0Gm8TaM

[Colasonojon9]

Well i never 100% figured out the grinding after removing stator cover and replacing starter but i do know what the loud clack is its one way bearing i turn magneto by hand and seems to work correctly then i enguage starter and hear sound clack the magneto/flywheel lock both ways deffinately the bearing.

[Colasonojon9]

@davefrombc update: installed new starter clutch sound is gone. The starter clutch had a crack in it. I imagine thats why it was clacking during turnover. Just wanted to update in case this was helpful. Also changed pick-up coil and ignition coil. I have the primary/source coil but cant figure out how to remove the stator need to be able to flip stator over and tap the source out cant find any info anywhere. Do i need a special tool dont want to break stator windings. After assembly without changing source the bb only sparks once when you start to turn over wil spark once everytime if you wait a few sec inbetween engaging starter. Please help 

[Colasonojon9]

Atached is said crack in starter clutch