Need help with starter clutch ...

LIMagna · December 21, 2013, 04:58:02 PM

Hello Gentlemen,

Today I tore into my Magna to replace the main clutch and address an issue that began this past Summer with the starter clutch. There really wasn't anything wrong with the main clutch but I figured since I would be cracking open the case, I might as well replace what was almost certainly the original clutch, now with nearly 30,000 miles on it. Anyway, the job went fairly smoothly, with the most time consuming part being the cleaning of the old gasket material from the case and cover. I had purchased new springs, caps and rollers for the starter clutch to hopefully rectify the screeching that would happen every now and then on starting a warm bike (never really happened when it was cold). However, upon disassembly of starter clutch I noticed what appeared to be cracks in the main body. There are three of them and they appear to be in exactly the same location, over holes that go through the body (not the holes that the springs go into though). Does anyone know whether this is normal or is my clutch shot?

Thanks in advance for any assistance. Oh, and a Merry Christmas to One & All!!

hootmon · December 21, 2013, 05:59:52 PM

I have a spare at home, i'll check If out when I get home...

LIMagna · December 21, 2013, 08:05:59 PM

Thanks Hoot! I appreciate it!!

TLRam1 · December 22, 2013, 12:39:59 AM

I will take a wild guess and say that does not look normal, good to have someone have a spare to check for you Charlie.

LIMagna · December 22, 2013, 06:52:46 AM

It didn't look right to me either Terry but seeing the same exact 'crack' (same shape/direction) in exactly the same location in three places on the disk, had me thinking that perhaps it's three pieces attached to a backing plate. I mean what are the odds that if it indeed did crack that it would crack exactly the same way three times. I know that this might be a weak spot in the disk but again, to crack exactly the same way ... seems like I had a better chance of winning the Mega

hootmon · December 22, 2013, 09:21:11 AM

Sorry for the delay... Christmas party and all last night!!

I have taken mine apart and it does NOT have the cracks...

If you would like my spare, it is yours...
At the time, I got a good price on a used one, so I put my new parts into the new piece, just because it had less miles than mine (now the spare)
So you will need to put your new parts into my spare... I don't see anything wrong with it....

Are you still in Coram???

LIMagna · December 22, 2013, 12:38:38 PM

Thanks for checking Harry. Yes, I'm still in Coram ... let me know how much you want for the part. I had already purchased new parts (springs, caps and rollers) because I thought that was the issue with mine. However, some things you just don't see until you've taken them apart.

hootmon · December 22, 2013, 07:59:30 PM

I'll try to get it off tomorrow in the mail... Not looking forward to visiting the post office so close to Xmas, but I will for you...

LIMagna · December 23, 2013, 06:40:48 AM

Hootmon, you're the best but please don't get in line for me. First off, I can wait ... it's cold up here so I probably won't be riding any time soon. Second, after giving this some thought I think I'll just pony up the extra Washington's in the hopes that the new part will last as long as the old one did. After all, for how many more years can we expect new parts for this machine to even be available. At that point these "spares" will be all that's left

Thanks again for confirming the diagnosis, I really appreciate the effort!!

Merry Christmas & Happy New Year to you and all my friends at MOOT!!

Ride Safe,

Charlie

hootmon · December 23, 2013, 07:17:40 AM

Quote from: LIMagna on December 23, 2013, 06:40:48 AM
After all, for how many more years can we expect new parts for this machine to even be available.

Unless they change their policy, I believe the answer is 2025... They usually support a vehicle 20 years beyond production.. So since the bike is virtually the same up until the 2005 model year, we should be good for another 10 years or so...

LIMagna · December 23, 2013, 08:44:21 AM

Wouldn't that be 2023 (2003 being the last year of the 3rd gen. Magna)? Still a ways out, I know. BTW, just ordered the part from Ron Ayers ... $127 to my door. Took advantage of their free shipping offer for orders over $89, which saved me $15. While I did find it for less at Partzilla.com, after shipping charges it would have been the same and given that I've never dealt with them before, I figured I'd stick with a company I've done business with many times in the past. If by some miracle of Christmas the part is in stock, perhaps it will even ship out today. Otherwise, I'll probably be waiting to the second week in January or so.

hootmon · December 23, 2013, 01:09:45 PM

Did the part come as a complete unit (rollers and springs, etc included) or just the holder piece???

LIMagna · December 23, 2013, 01:15:41 PM

The parts fiche does not indicate that it's a bundle of parts, just the "Clutch Outer" (part # 5):

http://www.ronayers.com/PULSE-GENERATOR-C190521.aspx

I had already purchased the springs, caps and rollers for a rebuild but never suspected that the main body would be cracked. Now I'll have all the parts that make up the starter clutch with the exception of the flange and bolts and those parts appear to be just fine.

hootmon · December 23, 2013, 01:20:14 PM

You are correct, just the one part...

LIMagna · January 04, 2014, 05:07:11 PM

Just wanted to close out this thread ... I got the new starter clutch body on Thursday ... not a crack to be found anywhere. Original Honda parts bag indicates that it's "Made in Japan" so I'm hopeful it lasts at least as long as the first one. I did have to pull the little roller pin out of the original and transfer it over and it was a bit of a challenge getting it out but short of that all went together without a hitch right up until I broke one of the clutch cover (not the starter clutch) bolts securing things. I was fortunately able to remove the stub with my fingers and managed to find another properly threaded bolt to use in its place temporarily (was a bit shorter). 9 ft-lbs isn't very much torque and although I was using a torque wrench it still managed to let me over-tighten this one bolt and snap it. I located the slightly shorter replacement at the top of the cover, filled her up with oil and she fired right up ... free of any unusual sounds. Since it's only in the middle 20's here today that was pretty much it for me. We're supposed to see low 40's tomorrow so hopefully, I'll get a chance to properly adjust the new main clutch.

Thanks for all the help guys!