2007 Yamaha Kodiak 450 starter Idle gear/one way bearing help please

[Charlesawest936]

Hello QuadCrazy guys and gals. Iv got a 2007 Kodiak 450 that's iv been trying to get running again after having to split the case so I could change a few of the transmission gears since the previous owner over did it and broke teeth off of 3 different gears. Anyways iv got the motor put back together and put back on the frame and I keep having problems with the one way bearing on the starter Idle gear locking up and causing the starter to spin with the motor. Now I am able to pull the rotor/flywheel off and then I have to pry the one way bearing off of the idle gear after this happens. But I am able to reset the bearing and put the starter gear on and I then put the keyway on it then I slide the rotor with the one way bearing bolted to it on as far as I can and I lock down the rotor by holding it and tightening it down. At this point all is great I'm able to rotate the crank by hand counter clockwise and the starter and idle gear are free like it's supposed to be and if I reach back behind the rotor and spin the idle gear counter clockwise it engages and spins the crank like it's supposed to. But after hitting it with the starter a couple times it locks up again. I'm pulling my hair out with this damn thing. Before I split the case to fix the transmission it didn't have any starter related issues. Also the starter Idle gear hub where the one way bearing rides doesn't look bad or anything same as the bearing it looks fine as well. Any ideas before I have to order a new bearing and idle gear? Oh also if I put it together and only use the pull rope of course it doesn't lock up, only does it after a few times of the starter being used.

[Mech]

Weird one !

 

The only thing I can think of is that the pawls are standing up too vertically when they lock, and get jammed up. Perhaps the pawl are worn on their ends, or the outer or inner race is the wrong diameter.   Bad manufacturing or wear.

I suppose you've checked the end-float clearance ? Not that that should cause those symptoms alone.

[Charlesawest936]

I remember after pulling it apart the 3rd time I used a digital mic to measure the starter Idle gear hub and made sure that it was perfectly round and not out of shape or anything else I can't remember the exact measurement right now but I know the mic didn't change change but maybe a decimal point anywhere on the hub otherwise I would've wanted to change it. Well iv got the motor back together right now and it starts up just fine and I can kill it and every once in awhile the pull rope will rotate the starter with it but if I start it with the button I sometimes get lucky and it frees up so that the next time I try pulling the rope it's free and works as it should but keeps repeating itself so I'm going to just have to try getting another bearing and idle gear and see what it does 

[Tbquadservice]

Maybe the flywheel isn't seating all the way on to the starter gear. I usually take a large deep well socket and slide it over the end of the crankshaft and smack it a few times with a big hammer before I put the stator cover on.

[Bish]

I had a similar problem with a kick-starter on a yz 125. I glued the outer crank case on and it would get stuck. I found that I had to buy a gasket instead of gluing it on. It didn't have enough clearance without the gasket. I found that if I lossened the outer crank case when It was glued it would free up and work fine, that's how I would test it.

I'm not sure if this will help you but I figured the information can't hurt.

[Charlesawest936]

No it definitely won't hurt any ideas right now are good lol. I honestly haven't messed with the pull rope lately iv just been starting it with the electric start although I am concerned about that 1 way bearing being engaged the whole time the bike is running and it eventually messing something up 

[Bish]

Did you put a gasket on the outer casing or just glue it? If you just glued it I would get a gasket and the thickness might give more clearance so the gear doesn't get jammed out