One day you might push the start button only to hear a high speed whine, followed by a crunching clanking noise. This would most likely be caused by the starter clutch not engaging the starter to the engine.

The starter motor is connected to the engine using a one-way starter clutch mounted on the end of the crank inside the right engine cover. When the starter button is pushed, the starter turns an idler gear, that turns the engagement gear in the center of the starter clutch. Engagement rollers move into position and engage the center gear to the housing and rotate the crank to turn the engine. The starter clutch housing spins around the stationary center gear when the engine is running, so wear can occur over time.

Inspection of the springs, spring cups, rollers, and center gear would be required. If the springs are weak, collapsed, or broken, the roller(s) will not move into position and not engage. The spring cup ends are slightly rounded, and will sometimes wear a recess in the surface that contacts the roller. The rollers and roller contact surface on the center gear can also become flat-spotted or galled.

New stock springs measure approx. 1.575" (40mm) long and you can use this for comparison. If the springs are not broken you can try stretching them, but new springs would be recommended. Next inspect the rollers for flat-spots, galling, or out-of-round. If any of these are found, you should replace the rollers. The center gear roller engagement surface should be smooth with no signs of galling or peaks (wavy). If the surface is not smooth, the rollers may not engage because the roller can skip. The gear should be replaced. You should also check the housing for cracks, and if any are found the housing must be replaced.

Note: The use of stronger springs is not recommended. We have found accelerated wear on the spring cups and rollers when heavier pressure is used. We have also found that the s.s. spring material often used is more brittle and has been known to break.

Once your damaged parts are identified and replaced, clean and re-assemble the starter clutch assembly. Re-install the bolts with a drop of RED Loctite and torque to 22 ft.lbs.