[Lambertbb187]

I'm going to sound like an idiot here. The bike was running perfect before...

I had to take the clutch cover off and get it replaced. Dropped the oil, took the cover off but whilst I was taking it off the starter gear and rod came out slightly.

Got the new cover, lined everything up again. Fired the cover on. Put the oil in. Tried to start it and nothing.

Sounded like the starter works but as if something wasn't lined up right. But from what I can see from right at the back to the front all gears are lined up correctly.

Crank still turned freely.

Any ideas ?

 

[ti-6-4]

I'm going to sound like an idiot here. The bike was running perfect before...

I had to take the clutch cover off and get it replaced. Dropped the oil, took the cover off but whilst I was taking it off the starter gear and rod came out slightly.

Got the new cover, lined everything up again. Fired the cover on. Put the oil in. Tried to start it and nothing.

Sounded like the starter works but as if something wasn't lined up right. But from what I can see from right at the back to the front all gears are lined up correctly.

Crank still turned freely.

Any ideas ?

Could be the perspective of your photo but the top gear doesn’t look engaged.

 

[Lambertbb187]

I had it sitting better after that photo. And everything lined up with the casing and slid on fine as well. I'm going to take the gears off completely and try and see if there's something out of whack. Just praying nothings damaged after trying to start it. Didn't sound like anything grinded away and weren't any shavings in the oil but just not sure what's going on.

I'll give an updated soon

 

[ti-6-4]

Check that the thrust washers and bushings (1, 2 & 4) are all in place. I would like to think that those on the opposite ends of the shafts are retained by snap rings. Maybe they are still in the old cover.

Service Manual linked above has more detail

 

[ti-6-4]

Did you ever resolve this issue?

 

[Lambertbb187]

Yes I did. And I feel like a right dick 😂 I put an extra washer on the starter shaft that should've been on the engager shaft. So when I took it off I seen it was scored. Bassically the starter shaft was too tight to the casing once the casing was on and struggled to turn freely.



So people, if you're going to do things yourself, take photos, take notes, whatever, don't make my mistake

 

[ti-6-4]

I’ve done my share of dumb things. Good advice with the photos.

Glad you got it sorted.